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BUILDING A COPPER BOILER. If it is an existing design, see if the construction has appeared in one of the model magazines, or try to find others who have built it to learn if there any problems, and the best sequence for construction. If you cannot get any information, study the drawings and try to see which parts would be tricky to fit after other items were in place.
If you can buy a kit with the plates already formed, do so. The saving in the time that it takes to make the formers is worthwhile, and the extra cost is minimal.
All copper will need to be annealed before starting, and probably several times during forming. Keep everything as clean as possible, as it will have to be thoroughly cleaned before soldering.
The main parts of a (loco type) boiler are: barrel, plates, tubes, foundation ring, girder stays, stay bolts. In the absence of other instructions, start with the boiler barrel. If it is a parallel boiler, clean up the ends and make sure that they are square. For a taper boiler, start by making the barrel. A card template is useful to ensure that the everything is the right size before cutting metal. Then join the barrel, either with a coppersmith's joint, or with a lapped plate, finally squaring the ends as required.
Make the plate formers, remembering to allow for the plate thickness and bending allowances, and then form the plates Cut boiler tubes to length, and turn the ends down if required. Cut the material for the foundation ring, crown girders, etc. Make all the studs, and bushes for fittings.
Mark out positions of tubes, fastenings, bushes, except for those that have to be marked from another surface.
Then assemble. A typical order of assembly is: (1) Barrel, any extensions to the barrel, and outer firebox; (2) bushes on barrel and dome (see below); (3) Front & sides of inner firebox and tubes; (4) if the whole tube assembly is to go in as one unit, the front tubeplate; (5) then the tubes + firebox go into the barrel with the foundation ring front and sides; (6) Fit stays; (7) firebox backplate. NOTE, bushes on barrel may have to be fitted after assembly if they will foul other construction. Crown girders will usually be fitted at (3) and (5).
Cleanliness is essential to ensure satisfactory soldering. Pickle all parts regularly during the forming prior to construction to remove all oxidisation, using whatever pickle you prefer, and then clean with steel wool. When all silver soldering is complete, allow the boiler to cool and then place in a bath of dilute Sulphuric acid to remove any residual flux. Then wash in clean water, dry, and clean thoroughly, either with steel wool or Scotchbrite.
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