New Steel Boiler for under £200

[S.D.L.Participant @s-d-l]

Posted by fizzy on 20/08/2012 22:01:55:

What about the boiler tests…100psi wp, test 250psi, if 6mm steel wont hold that i will eat my hat!

Within PED Pressure tests are a test of workmanship and materials not design. If there was no design calcls to an acceptable standard then the proof test could be up to 10 times working pressure.

Bost boilers I have seen have had a Tig root then stick weld with a tig cap on top on a lot of traction engine boilers. Is mig allowed without a root run first? as it should cheapen the cost of construction.

Steve Larner

[nigel jones 5Participant @nigeljones5]

Rest assured that rigerous calculations were made prior to final design, all fully documented and proven.

[S.D.L.Participant @s-d-l]

Posted by fizzy on 21/08/2012 16:06:22:

Rest assured that rigerous calculations were made prior to final design, all fully documented and proven.

Were you required to follow a particualr standard or just first principles?

Steve Larner

[nigel jones 5Participant @nigeljones5]

Used published formulae for model boilers

[S.D.L.Participant @s-d-l]

Posted by fizzy on 21/08/2012 18:35:06:

Used published formulae for model boilers

Looks good, hope all goes well with boiler inspector.

Steve

[nigel jones 5Participant @nigeljones5]

iTS FINALLY OVER!! I went into the workshop at 8 this morning abd came out nearly 12 hours later – 5 cups of water has kept me going all day! Ive silver soldered the tubes in today, but to be super sure of a good joint in the firebox I separated the firebox section of boiler from the main boiler tube, that way I could get at both sides of the joint. Managed to slightly burn a tube but nothing major. I then soldered the tubes into the end plate before weldint the lot back together – propper hot root run followed by a hot fill and cap run. I will need the joint testing and certifying but its a small price to pay considering I was quoted £2500 for a copper boiler with a two year waiting list. Ive had it up to 170psi with the odd weep around the bust plugs, just needs a bit of ptfe tape to sort. Going to get it to 200psi tomorrow, then weld cert and finally to the inspecter. Costs are: Plate £50, Tubes £60, silv solder £22, allow £20 for various gasses and wire, £60 for the weld test and cert and probably another £50 for 'stuff', and you can see It still cost under £300 all in. If I were to make another there would be so many things id do differently, ive learned a lot on this project.

[SpringbokParticipant @springbok]

I know that I was one of the people who said do not attempt it, I take it all back in spades

CONGRATULATIONS

Bob

[MICHAEL WILLIAMSParticipant @michaelwilliams41215]

Fizzy ,

I considered a 'cut and shut' on the boiler shell as a means of getting at tubes but with so many unknowns in the design already I was reluctant to add any more by suggesting this course of action . It will be interesting to see how this part of the build process stands up to scrutiny by boiler inspector .

Before doing any more pressure tests fill the boiler completely with clean water and set it to boil vigorously for several hours , venting to air and topping up as nescessary . The leaks around the tubes are blocked with hardened flux at present and this will withstand any pressure – possibly giving a false result for pressure test . It will be better to discover any of these flux plugged leaks now and deal with them rather than find them during some future steam up .

The building of this boiler has been an interesting experiment . If it gets past boiler inspection I will be interested to hear how it actually steams .

Regards ,

Michael Williams .

[julian atkinsParticipant @julianatkins58923]

michael, i guess im with you on this one, and whilst i admire 'fizzy's' unconventional approach, i reckon a 6mm inner firebox of steel on a medium sized 5"g loco boiler (where most of the heat is transferred to the water) is unfortunately going to be more than a shy steamer and therefore a complete waste of effort. i built a similar sized conventional all silver soldered copper boiler last year in 6 weeks for £220 in materials (copper and bronze) and say another £100-£200 in silver solder (cant say exactly the amount or value of the silver solder as i already had most of it in stock from many years ago). so not that different in cost to 'fizzy's' boiler.

cheers,

julian

[nigel jones 5Participant @nigeljones5]

I never said it would be a good steamer!!

[Sub MandrelParticipant @submandrel]

If australians can build all-steel briggs boilers that make plenty of steam , why shouldn't this one?

Neil

[SpringbokParticipant @springbok]

Look Everyone

Stop knocking Fizzy I think he is doing a fantastic job, I will not put this in caps "but could you do it" as my father would say "put your money where your mouth is" he taught me how to use a myford when I was 9 he new Curly but never would take me down there, Dad said he was a very strange person but very interesting. What he would say was saw this very interesting design Hmmm
and leave it that that.
Look Fizzy
Steam on and leave the armchair pundits behind
Bob

[nigel jones 5Participant @nigeljones5]

Pressure tests concluded – one spirt aside a tube, and a very odd weep on a stay weld. The tube squirt went away after reheating the lot and throwing another £20 of silver solder at it and a quick grind and reweld around the stay sorted that. Holds 250psi all day now. I will post some pictures of it finished so some of you can tell me how the boiler tube spacing is all wrong!!

[Sub MandrelParticipant @submandrel]

I don't like the colour,

Neil

[nigel jones 5Participant @nigeljones5]

its also avauilable in maroon!!!

[SpringbokParticipant @springbok]

Sorry Darling only in pink

Could not resist

[nigel jones 5Participant @nigeljones5]

I painted it for you…will be black eventually.

[nigel jones 5Participant @nigeljones5]

[nigel jones 5Participant @nigeljones5]

[nigel jones 5Participant @nigeljones5]

[nigel jones 5Participant @nigeljones5]

[Sub MandrelParticipant @submandrel]

I hate to tell you this Fizzy, but that blanking plate is far too small

Neil

[Carl Wilson 4Participant @carlwilson4]

Hello Fizzy,

Fantastic work. What is the spec of the steel you are using?

Thanks, Carl.

[Ady1Participant @ady1]

Looks great

How close to budget did you get?

Looks like less than 500 quid

Was it a cheapo welding set you used?

Would you make the plans available?

wtg

Edited By Ady1 on 02/12/2013 02:38:41

[Mr MooParticipant @mrmoo]

I hope it steams as good as it looks!! I don't blame you for having a go yourself, that 2 year wait boils my water as well. I don't think my MIG is upto scratch for this kinda work but I might know someone who is…..

ATB

Ben

[Author]

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