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Brass dome cover construction

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andrew winks28/01/2015 07:43:34
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117 forum posts
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Thought I'd share some very pleasing fabrication of a dome/safety valve cover for my 5" gauge Queensland Railways A-10. These are available as aluminium bronze castings but I thought it would be a rewarding exercise to machine and fabricate from solid brass round and phosphor bronze tube, both scrap "donations" to my workshop of ferrous supplies. Below, machining the top from solid brass round section.

dome blank machining.jpg

andrew winks28/01/2015 07:45:12
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117 forum posts
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step 2, rough out the top and fit to PB tube section.

dome- early.jpg

andrew winks28/01/2015 07:48:34
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117 forum posts
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Weld a former/spigot together to form a die to press the PB into shape. Anneal first. Simple press fabrication from angle, etc. 12 tonne bottle jack provides the encouragement..

flange forming.jpg

andrew winks28/01/2015 07:49:34
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117 forum posts
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looking OK, shape is appealing and even.

flange forming 2.jpg

andrew winks28/01/2015 07:50:09
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117 forum posts
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Check fit..

trial fit.jpg

andrew winks28/01/2015 07:51:39
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117 forum posts
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Final skim to size

dome- final skim.jpg

andrew winks28/01/2015 07:54:03
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Quite pleasing, close to prototype. Producing these parts is most fun one can have standing up!!

finished dome 1.jpg

Johnboy2528/01/2015 09:12:32
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260 forum posts
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Congrats... Nice piece of work. Certainly looks the part.

John

Jeff Dayman28/01/2015 10:29:18
2356 forum posts
47 photos

Great job Andrew, well done. Nice to see a good bit of presswork done in the home shop. JD

andrew winks28/01/2015 15:29:20
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117 forum posts
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Thanks! Used a similar method to produce the petticoat for the stack.

The engine is running on air, boiler was completed and hydrostatic tested in 2014 (I have a bunch of pics on the boiler construction that I will post one day soon) and hope to have first steam up before mid year. Bought the castings in '97 so about time I made some solid progress!

Andrew

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