Station Road Steam STAFFORD User manual

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Stafford Kit Build assembly instructions
Feldbahn supplement
This supplement is to be referred to in conjunction with the standard Stafford assembly manual and
details main points of difference between Stafford and Feldbahn.
Fit lubricator link arm using using a M4 x 35 Cap head with a 17mm spacer and bolt to the top
threaded hole on the expansion link (10101), Finally secure using an M4 nyloc nut on the back side
of the expansion Link.

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Fit Lubricator to the mounting Bracket Using M4 x 10 Hex head bolts. Fit lubricator pipe to the union
and tighten.
Fasten the other end of the Lubricator link arm to the lubricator using a M4 x 10 Hex head bolt and
Nyloc nut, tighten till it nips up then back off half a turn.

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Fit the Left and the Right side rear decks to the chassis and bolt into place using M5 x 10 Hex head
bolts.
Wrap boiler lagging around the boiler and secure in place with masking tape.

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With the help of a friend lift the cab into place and bolt down using M6 x 10 Hex head bolts and
washers.
Fit works nameplates to the sides of the cab (holes pre-drilled). These are fixed into place using M3
x 12 Button head screws and nyloc nuts.

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Assemble the rear cab support using M4 x 10 Hex Head bolt and nuts. Assemble onto the engine and
bolt into place using M4 x 10 Hex Head bolts and nut at the top and M6 x 10 with washer on the
bottom, this is fixed from the underside of the footplate and screws into the support base plate.

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Place on the Boiler cladding starting with the bottom sheet first. This is place on from the top and
rolled around the boiler to sit at the bottom. The top sheet then goes on and overlaps the bottom
sheet ensuring that the holes line up with the boiler bushes.
The boiler cladding is then held into place with the boiler band and these are secured by using M4 x
30 Cap Head screws and a nyloc nut. Ensure that the tabs are face under the boiler barrel to hide out
of view.

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The rear boiler band is the next to be fitted, this is fitted over the boiler and slide back towards the
cab till it is flush with the boiler cladding. Access to the tabs is from the underside of the water tanks.
This can be tricky and help of an extra per of hands my by useful. Please note that the middle boiler
band doesn’t go on at this point, it is best to fit this after fitting the dummy sand and steam dome to
ensure that it is seated mid-way between the two.
Both the Sand and steam dome studs are fitted at this point, the longer one of the two is for the
steam dome and is fitted nearest the front of the engine. They are supplied with an M10 lock nut
and they simply screw into the bushes and lock the nut off to ensure a secure fixing.

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We recommend putting a layer of masking tape on the bottom of both the sand and steam domes as
this will prevent scratching to the paint work.
Before fitting the steam dome you will need to fit the dummy regulator and dummy Safety valves, all
of which are bolted up from the inside of the dome. For the dummy safety valves use M8 x 20 hex
head bolts and for the dummy regulator use a M6 x 20 hex head bolt.

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Screw the dummy regulator rod in to the regulator and lock off the nut.
To fit the dummy steam dome you we need to seat it over the mounting stud threading the dummy
regulator rod through the hole in the cab first before finally seating it onto the boiler barrel.
Finally secure down with a M10 lock nut.

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The dummy sand dome is then fitted on to the engine, this is secured by using the lid and the knob
to fasten the dome down. Once the lid is in place apply some 243 loctite to the threads on the knob
and secure into place.
8mm compression fitting are then fitted in to the sand dome ready for taking the pipe work.
The last of the three boiler bands can now be fitted. Ensure that the band if sat mid-way between
the sand and steam dome before the final tighten.

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Fit the pressure gauge bracket using M6 x 12 hex head bolts with turned down head (3mm thick).
Ensure that the head of the bolt is threaded throw the cab from the outside of the cab, this ensure
clearance on the water tank when we come to fit them.
Fit the pressure gauge to the bracket, the union nut acts as the locking bolt to secure it in to place,
the pressure gauge must have PTFE tape on it before fitting to ensure a good sealed join.
Fit the pressure gauge syphon to the fountain and the pressure gauge.

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Fit smokebox steam blower fitting through the smoke and lock into place with the nut.
Thread the steam blower pipe through the square hole in the spectacle plate and fit to the steam
valve on the fountain.

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Fit the other end of the steam blower pipe to the smokebox fitting.
Finally fit the blower pipe to the tail of the smokebox fitting inside the smokebox.

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Fit Tanks into there outer pockets. Use a peace of paper at the back of it when fitting as this will
prevent scratching the paint work.
Bolt the tanks in to place from the inside of the cab using two M6 x 12 hex head bolts and washers.
Fit the 3/8” BSP brass hose tails to the underside of the tanks use PTFE tape to seal. The hose tail
should be facing in towards the frame when fitted.

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Fit the 8mm compression fitting it to the tank, again us PTFE to seal.
Fit the water tank to water valve pipe work and tighten up the compression fitting.

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Fit the spectacles starting with the outer one first with two M4 x 10 hex heads ready in place top and
bottom. Then place in the glass follow by the inner spectacle (an extra per of hands maybe helpful at
this point). Fit the remaining bolts, don’t over tighten the bolts as this could course the glass to
crack.

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Fit the hand rails in place using M4 x 10 hex head bolts. Fit the bottom boss first lose then fit the
handle and the top boss and final bolt in to place. Repeat this on all four hand rails.
Fit on the reverser level assembly. This is easier to fit up in one peace (including the Vac Brake valve
pipework) as it save’s a lot of the fiddly fitting after.
Bolt it in to place with M6 x 10 Hex head bolts with washers.

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Bolt the reach rod to the reach rod lifting arm using a 20mm motion pin.
Connect the Vaccum gauge pipe work to the Vaccum Gauge.

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Connect the the steam pipe to the ejector.
To determine where the reverser sits the return crank needs to be set at approximately 45 degrees
(as shown in the above picture). Adjust the position of the reversing stand until the gap at the top
and bottom of the expansion link to die block is equal. Once this is equal top and bottom bolt the
reversing lever stand in its final place.

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To set the valve gear take off the valve chest cover plates and set the reverser to the first notch
forward. Roll the engine forwards and backwards adjusting the slide valve locking nuts until there is
an equal valve opening on both sides.