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SUPERHEATER FABRICATION

Reason for action:  Final fabrication of superheater elements into packs.
Drawing/Specs:  Original SAR drawing + 3D modelling by DTco
Material: 1 1/2" OD steel tubing, 300 linear metres
Purchase cost: $20,000.00
Progress: We have $5,860.00 left to fund! 

BOILER TUBES

Reason for action: Original tubes are at the end of service life
Drawing/Specs: 2 1/4" x 6M long seamless boiler tubing
Material: High quality pressure vessel grade steel manufactured in Germany
Purchase cost: $150.00 Per Tube (120 Tubes)
Progress: We have successfully funded 120 tubes! Thanks to all our generous donors!!

SUPERHEATER MATERIAL

Reason for action: Current superheater elements are old and wasted
Drawing/Specs: SAR original drawing
Material: 1 1/2" OD steel tubing, 300 linear metres
Purchase cost: $12,850.00
Progress: This component has been successfully funded! 

SUPERHEATER BENDING

Reason for action: Current superheater elements are old and wasted
Drawing/Specs: SAR original drawing
Material: 1 1/2" OD steel tubing, 300 linear metres
Purchase cost: $10,640.00
Progress: This component has been successfully funded! 

SMOKEBOX MATERIAL

Reason for action: Wastage beyond serviceability
Drawing/Specs: 520 class Smokebox Arrangement
Material: 10mm & 16mm mild steel rolled to a radius
Skills required: Plate rolling
Progress: This component has been successfully funded! 

BLAST PIPE

Reason for action: Original Blast Pipe cracked and wasted beyond repair
Drawing/Specs: Original 520 blast pipe drawing
Material: Mild steel
Skills required: Fabrication
Component cost: $4,790.00
Progress: This component has been successfully funded! 

FIRE GRATES

Reason for action: 12 Replacements needed
Drawing/Specs: 520/620 fire grates
Material: SG Iron
Skills required: Casting
Casting cost: $350.00 per grate
Progress: This component has been successfully funded! 

FLUE SAFE ENDING

Reason for action: Grit blasted second hand flues and existing flues need re-ending.
Drawing/Specs: Lengths extended to 6M by welding on one piece to pressure vessel spec.
Material: Existing seamless flue tubing
Skills required: Pressure vessel welding & radiographing
Fabrication/Testing cost: $220.00 per flue (18 Flues)
Progress: This component has been successfully funded!

GRIT BLASTING OF FLUES

Reason for action: Determine condition of 30 flues
Skills required: Grit Blasting
Component/Service cost: $120.00 per flue
Progress: This component has been successfully funded! 

GAMMA RAY TESTING OF BOILER

Reason for action: Certification requirement
Drawing/Specs: 520 class Boiler Arrangement
Skills required:
Component/Service cost: $3,000.00
Progress: This component has been successfully funded! 

CLOTHING GRIT BLAST

Reason for action:  This process will allow us to preserve 520’s clothing for a longer time period due to the quality of the paint, as well as providing the best possible surface for painting top coats.
Skills required: Grit Blasting & Coating
Purchase cost: $2,850.00
Progress: This component has been successfully funded! 

STEAM PIPE MACHINING

Reason for action: Main Internal Steam Pipe material requires machining
Drawing/Specs: S.A.R. 11-L-37
Material:
Purchase cost: $2,400
Progress: This component has been successfully funded! 

FLUE SWAGING

Reason for action: Final 12 flue tubes for 520 require swaging
Drawing/Specs: British Tube Mills drawing L40 - 1948
Material: 5.9m x 5.5" seamless tube
Purchase cost: $2,400
Progress: Once funded these tubes will be transported to SteamRail in Victoria for Swaging
This component has been successfully funded!

PRESSURE GAUGE RESTORATION

Reason for action:  Original pressure gauges are faulty
Purchase cost: $2,200.00
Progress: This component has been successfully funded! 

MAIN INTERNAL STEAM PIPE

Reason for action: Original Main Internal Steam Pipe heavily corroded internally.
Skills required:  Sourcing parts to required standard and machining.
Purchase cost: $1,700.00 (Parts & Machining)
Progress: This component has been successfully funded! 

 STEAM CHEST GRIT BLAST

Reason for action: To clean exterior of the steam chests for inspection and painting
Material: Garnet
Skills required: Professional hydro blaster
Service cost: $1,500.00
Progress: This component has been successfully funded! 

FOUNDATION RING RIVETS

Reason for action:  Rivets required to fasten three inner firebox corners to foundation ring 

Drawing/Specs:  40 rivets - 24x180mm rivets, 42mm snap head.
Material: GR 1020
Purchase cost: $1,200.00 ($30 per Rivet)
Progress: This component has been successfully funded!

SMOKEBOX RIVET SNAP

Reason for action: We need two Snaps to Rivet 520s Smokebox.
Drawing/Specs: SR Drawing
Material: 4141 Steel
Process: CNC Machining
Purchase cost: $900.00
Progress: This component has been successfully funded! 

RIVETS FOR NEW SMOKEBOX

Reason for action: Originals destroyed - 75 needed
Material: Forged mild steel
Skills required: Forging
Component/Service cost: $800.00
Progress: This component has been successfully funded! 

TENDER ELECTRICAL SYSTEM

Reason for action: Original electrical system corroded beyond use
Drawing/Specs: 520 class electrical systems
Material: New rigid steel conduit, classic style flexible steel conduit & LED conversion
Skills required: Electrical fitting
Consumables cost: $800.00
Progress: We have This component has been successfully funded! 

VALVE RING PATTERN

Reason for action: Spun cast hollow bullet no longer manufactured
Drawing/Specs: 520 class valve ring drawing
Material: Wood
Skills required: Pattern Making
Component cost: $620.00
Progress: This component has been successfully funded! 

BOILER PAINT

Reason for action:  The boiler is due to be grit blasted and will need a fresh coat of inorganic zinc paint.
Skills required: Painting
Purchase cost: $600.00
Progress: This component has been successfully funded! 

Internal Steam Pipe Machining

Reason for action: Post welding of cone ends, the regulator end of the main internal needs a skim on the tapered section.
Drawing/Specs:  Original SAR drawings
Material: Pressure vessel standard seamless pipe.
Purchase cost: $500.00
Progress: This component has been successfully funded! 

BLAST NOZZLE

Reason for action: Cracked and wasted
Drawing/Specs: 520/620 blast nozzle
Material: SG Iron
Skills required: Casting
Casting Cost: $500.00
Progress: This component has been successfully funded! 

FIREBOX INNER CORNERS

Reason for action: Current corners removed as new ones required.
Drawing/Specs: SAR original drawing
Material:
Purchase cost: $300.00
Progress: This component has been successfully funded! 

LENS RING MATERIAL

Reason for action: Original Lens ring wasted
Drawing/Specs:  Original SAR drawing 
Material: 275mm cast iron billet
Purchase cost: $200.00
Progress: This component has been successfully funded!

PLATE TO COVER OIL BURNER HOLES

Reason for action: Safety requirement
Material: 250 grade mild steel
Skills required: Profile cutting
Progress: This component has been successfully funded!