Boiler Build

[potty]

Thanks Derek

I didn't think anyone was following this not having got a lot of response.

OK went on the hunt to B&Q (great big hardware store) for some  Thermalite/Celcon blocks (Autoclaved Aerated Concrete (AAC)) picked up four half price 50p each as they were damaged, but for my use as a hearth that won't matter.



This afternoon I've made a lid for the tank



Still got to put a lock on it just to keep the contents safe away from animals and children

I spotted an oblong bucket at B&Q for keeping paint in for roller application  looked just the right size to fit in the tank and take the boiler.



The acid will be in the bucket and the tank will act as a second skin containing  accidental leaks and splashes.

Stew

[old man]

Hi Stew you dont know me but I have been following your build and because I know nothing about metalwork I learnt a lot .
Like my Dad use to say keep yer eyes open an yer gob shut So dont think no-one is watching your build I am.
                                           Old Man

[steamboatmodel]

"I didn't think anyone was following this not having got a lot of response."
We are watching, just didn't see anything that needed comment that Derek hadn't posted.
Regards,
Gerald.

[potty]

Thats OK Guys:-  I was getting a bit worried that the thread wasn't quite fitting into the interests of the Forum.

That good advice you're Dad gave Old Man 

Cheers

Stew

[steamboatmodel]

Check the views,
 246 Views
We are watching. keep posting.
Regards,
Gerald.

[Stuart Badger]

Hi Stew!

I've watched the boiler build from the start and am (excuse the pun) riveted! I think the reason you haven't had many responses is that we are all learning from your very clear posts - so we don't have to ask questions!

Keep at it - please.

All the best

stuart

[potty]

Thanks guys

Well yesterday was a case of best laid skeams and all that. I'd more or less got the afternoon free to get on with the boiler, but my daughter turned up with 2 month old grandson, now if theirs anything better than a grandson for keeping a grandad out of his shop please tell me  , so only manages to get a little done.

Cutting out the rad on the throat plate using jewelers saw and home made sawing table.



Throat plate having first fitting to boiler tube.



I annealed the boiler tube using a rough hearth pieced together with the thermalite blocks and the biggest  burner I've got for my torch just to try it out, the blocks worked well but the burner scared the crap out of me talk about a roaring flame, not too easy to control, I've got two torches so using the next size burner down with both torches will give me more control when it comes to soldering.

As you can see from the pic the acid bath worked will, I ended up using the acid salts only needed to make up 3 liters to cover boiler and adding about two tablespoons of salts gave me a Ph between 2 and 3 (if I'm reading the indicator paper correct)

Cheers

Stew

[Stuart Badger]

Potty
I understand Annealing and I vaugly remember pickling from years ago - but please refresh me on the purpose of 'Pickling' the boiler?
Is it just for preparation for hard soldering or does it serve some other purpose?

All the best

Stuart

[potty]

Stuart

Pickling cleans the scale off the boiler and gets the surface nice and clean for the soldering.

Copper as you know work hardens you have to anneal it to get it soft to do this you heat it up to a red colour for a minute or so then you can then let it cool down on its own, or you can quench it in water, the quenching doesn't do anything. After annealing it will be nice and soft I could bend the boiler tube just with my fingers, but its surprising just how quickly it hardens up.

Cheers

Stew

[derekwarner_decoy]

PD's....according to my mate "bogstandard", .... ...the pickling solution is also used POST silver soldering to soften the glass like flux residue  Mr Moore  ...Derek

[Stuart Badger]

What's the active acid?

Stuart

[potty]

Derek

Yes your correct I forgot about the post soldering benefits of Pickling.


Stuart

The stuff I'm using is this:-

http://www.chronos.ltd.uk/cgi-local/sh000001.pl?REFPAGE=http%3a%2f%2fwww%2echronos%2eltd%2euk%2f&WD=acid&PN=Dry_Acid_Pickling_Salts%2ehtml%23aACD100#aACD100

This is nasty stuff, you can mix it up to quite a high strength, a acid with a PH of 3 - 2 is strong, instead of this stuff I would recommend using citric acid you can buy it from the chemist as used for baking or home brew, it takes longer to work but its a lot safer and environmentally friendly .

Why are you using the nasty stuff you may ask?, well two reasons:-

First I bought it over 12 months ago before I found out about using citric acid so I'd got it.

Second I have experience and training in running metal finishing processes using Chromic, Phosphoric and Sulphuric acids.

I've taken and will take quite a few precautions with the stuff:-

I've built a double skin lockable container.
I've only mixed the minimum amount to get the job done.
I know when mixing you must add the acid to the water 
Correct Protective clothing Goggles Rubber gloves etc
I've got clean running water available.
I will use washing soda to nutralise it for disposal
I know to let the job cool before adding it to the acid:- acid can boil up inside tubes and spray out.

Cheers

Stew

[Stuart Badger]

Thanks Stew!

I do quite a bit of 'hard' soldering when producing brass and copper fittings. I hadn't thought of using Citric acid (of which I have VAST amounts as we have to descale our pipes avery month). I Also have access to Hydrochloric and Sulphuric - believe it or not available in supermarkets here for drain cleaning!!!!!

I'll stick to the Citric acid I think - thanks for the info.

All the best

Stuart

[potty]

Well yesterday was yet another case of "best laid skeams of mice and men all gang away". I could see the whole day in front of me in the shop, but I'd forgotten about the Boss, we'd booked seats for a Don McClane (of American Pie Fame) In Liverpool for the evening, but the Boss thought it would be a good idea to go early and have a wander around the shops visit the Tate modern art Gallery at the Albert Docks etc etc so strike one afternoon in the shop. Enjoyed the visit and concert though, and came across one interesting fact you guys across the pond will be interested in, theirs a very nice bronze statue at Albert Dock commemorating emigration donated to the city by the Mormon Church, it's plaque states that over 9 Million people emigrated from Europe to North America through the port of Liverpool:- just what % of the population are decended from those emigrants now  :scratch: the mind boggles.

Back on topic:-

The wings of the fire box rapper need to be extended to do this I will have to make a joint, this can be a simple lap joint but this will take up some water space or a joggled joint, I'm going to use a joggle joint. First thing make a joggling tool, now this isn't going to be a fancy tool just dog rough and functional.

Mill a bit of flat steel (garage door thanks Ralph) flat and put a groove up it 1/4" + plate thickness + a bit for luck.



Then with the plate well annealed and a 1/4" square bar squeeze the plate into the grooves.



This will bend it out a bit wack it back square with a bit of ally bar and a hammer.



And thats the joggled joint formed.



Cheers

Stew

[potty]

Now if you've got a nervous disposition look away now:- this is going to be cheap, nasty, and as rough as the proverbial Bears back side,

(If any of you guys have felt a Bears back side and lived to tell the tail I would love to know just how rough it is)   

But It'll do the job  :proj:

Making the brazing Hearth.

Fist off cut a boiler size hole in the base of a large ally oven tray:- the reason for the hole will become apparent in next weekish.



Then four bolts in each corner fastens it to the top of a work mate, and a bit of scrap ally sheet pop riveted to two sides makes the wind shield.




Now it was a great bit of advice that I got to use Thermalite block cut in half with an old saw for insulation. (You must keep them dry)
They cut like butter.  :thumbup:



And her we have it's all ready for the first soldering job and all for less than a ten squid, and build in an afternoon.



Stew