The Boiler and Burner
The boiler is quite straightforward, designed with the ASME code in mind. The shell is rated 2500 PSI busting pressure well above the code’s 3.5 times working pressure. The heads are SA-516 grade 70 and are 3/8 inch thick per the minimum allowed for boilers less then 42 inches in diameter. The welding is PW-16.1 (a)The welded assembly was stress relived after welding. After tubing it hydro at 1000 PSI for well over eight hours.
The burner I cast in ductile iron and drilled it with 4000 holes. The venturi tubes are oversize from the original of 1-1/4 to 1-1/2. The vaporizer and pilot, burner, nozzle are as the original and the fuel is as original gasoline.
The water level indicator is of my own design and was incorporated into a Stanley type gauge. Modern but very reliable and accurate. The Stanley EX originally used the bucket type level indicator.
The operation of this boiler is manual for feed water, except for the steam pressure regulator that turns the burner fuel on and off.
I was really trying to have some one make this for me but after many frustrating attempts I finally bit the bullet and took a stab at it. I had spent many hours checking all the EX cars I came across and not one hood had the same dimensions. All varied as much as a half-inch, to an inch. I did my own drawings to fit my car and used all the old photos to acquire original details.I ran into Daryl Kendall at the Eastern Steam car tour and he agreed to punch me out the louvered panels that could be welded into the sheet metal. I saw him do this once several years earlier. I had to buy a bead roller to make the joint on the sloped section of the hood. If I could make the brass sections well enough I knew I could make the rest.
I had made and laid out cones before and the front of the hood was only half a cone.
I set up and cut and rolled the brass, it looked good, I knew I was half way there. I bought a sheet of cold rolled sheet steel and went to town on the rest of the panels.
About that time the UPS truck delivered Daryl panels. I set up and machined the trim for around the lower edge and ordered the brass angle stock for the trim around the back.