Hi Carl, it's gettin' there, slow but sure.
Time to start testing and fixing all the bugs. First thing to play with are the two burners plugged into the boiler to see how they behave. Leave the top boiler plugs open so steam can escape during the test. Fill the boiler about 2/3 full. Have some heavy soap water and a Q-tip handy. Hook up a burner and light it. Wipe some soap water on each gas line joint to test for leaks. If there is a leak, then the soap water will make big bubbles. Right away there was a problem. The fuel tank started to overheat. Heat radiated thru the chassis and into the tank. The fix is to insulate the fuel tank from the chassis. Do this with a strip of wood under the fuel tank and wooden washers on the mounting screws. Something like this:
That did the trick. The fuel tank stays nice and cold now. I will come up with a better fix later, maybe. Probably 20 years from now it will still look like that.
The poker burner with a small jet is the one to use. While the blow burner lights up very easy and burns hot, it does not heat this boiler very well. The flame blows thru the flue too fast and just heats up the smokebox. I will experiment more later, but for now, go with the poker. The poker burner is a little difficult to light. At first it whistles like a jet engine, very piercing irritating sound. After warming up a minute, it settles down. After a little gas burns off it works very well. Total burn time on one fill: 35 minutes.
Now start assembling the plumbing parts. Before burning any real water, make a tommy bar spanner like this:
The pins in the spanner engage the holes in the top of the safety valve and allow adjustments while keeping fingers out of the way.
Get the engine, tools and supplies ready for steam testing. Mount a large pressure gauge in the fill plug.
The large copper tube loop below the pressure gauge is called a siphon. All steam pressure gauges need a siphon. When the boiler warms up and the first steam goes into the siphon, it condenses back to water and settles in the bottom of the siphon. Water acts as a barrier between the steam and the gauge. What actually operates the gauge is compressed air. Without the siphon, wet steam goes into the gauge mechanism and eventually damages it.
Now set the safety valve. This is done with live steam pressure, not compressed air. To set the valve, take off the locking nut and open the top until the spring is loose. Plug the remaining holes in the boiler and light it up. At first a lot of water will spit out of the valve, but when everything warms up, steam will flow. Use the tommy bar to tighten the safety valve until the steam stops. Note the pressure on the gauge, if any. Let the boiler build more pressure until the safety lifts again. Keep tightening and noting the gauge pressure. Repeat the process until the safety lifts at about 30 PSI. Shut down the burner and let the pressure drop. Re-light and makes sure the safety lifts at 30 PSI. If all is well, put the lock nut on and sinch it down. Repeat the safety valve test several times to ensure it reliably lifts at 30 PSI.
This safety works very well. At 30 PSI, it sputters open/close and keeps the pressure right at 30 PSI. So far, no problems with it lifting, sticking open and draining the boiler.
Now lets install the water gauge. Wrap teflon tape on the threads and screw into the boiler. Drop a #21 drill thru the water gauge top and adjust in/out until the bit fits nicely.
Tighten down the jam nuts. Make sure the drill bit is till free. They jam nut method is very secure. The compress the teflon tape and make a super water tight seal. They are the way to go.
The watertight seal for the gauge glass is from rubber O-rings. I used metric O-rings with a 3mm ID and 1mm wall thickness. They stretch nicely over the 5/32 glass and inside the 1/4 x 40 packing nut. Use 2 O-rings on each end of the glass. Tighten the packing nuts only finger tight, does not need much to seal. The olden days of using graphite yard for water gauge packing are long gone. Dont waste your time, just get the rings.
Fill the boiler to about 2/3 glass, fire it up, lift the safety.
Now for another disaster. The (**bad words**) gauge did not work. Water level would not register in the glass; it was nothing but a bubble. Then, it would only blow down water, no steam and not re-fill. Maybe the top end got plugged with teflon tape or something. So I took it apart and discovered I never finished drilling out the top end. So, yes, it was plugged all right, with about 3/16 of solid brass. After drilling it out and re-installing, the water gauge worked like a champ.
Thats a great water gauge from the old master, LBSC.
We are going to quit for now, had enough. We have a mega big disaster to solve next time.