101/4" gauge Miniature Railways
D7054
– A genuine Diesel Hydraulic in 10 ¼” gauge - Aidan Favell I guess the story of
D7054 started at Christmas 1967 or ’68 – Giles or Dad may remember - at the
family home in This was received by both of us as an excellent present, and as
we had four hours or so to kill before appearing in the Church Choir on
Christmas morning we began what for me became a deep acquaintance with this
loco (I have it still!) Ironically we were at
the time living only five miles from the famed Lickey Bank, where the Hymeks
performed so admirably right up to withdrawal, but believe it or not we were
never brought up to be “train spotters” ( a popular misconception) so it meant
nothing to me. Something in the aesthetics of the Big Big made its mark, and
while school friends reported on their recent acquisition of a Tri-ang Class 37
or a Joueff Playcraft North Brit I only had eyes for the Tri-ang Hymek. At about this time,
Dad somehow discovered the Hilton Valley Railway, and we began to make
excursions there on a Sunday afternoon (we could get there and back before
Evensong). Whilst Giles began a lifelong love affair with “Queenie” and narrow
gauge, I would dream of driving Lorna Doone or one of the diesels. The HVR
affected both of us in a way I can’t overstate. Dad always used to say that 10
¼ “ would be better, but as I don’t believe either of us had ever seen a 10 ¼”
gauge railway we were more than happy with the HVR. The end of 1969 saw a
move to our Grandmother’s house in Edgbaston nearer During the time at Edgbaston,
after a couple of OO gauge railways, I eventually joined Dad in his first love
– 0 gauge, selling all my elderly Tri-ang OO at the Warley MRC show, of which I
was a member. The new railway ran across the end of my bedroom, through the
roof void in a boxed tunnel, into the box room, and was fine scale, the track
being old Tri-ang Series 1, Series 3 and Super 4 rail dog-spiked onto stained
balsa sleepers. It included several points and a single slip. I did the
electrical bit linking all the contact studs and installing H&M point
motors recovered from my OO layout. Motive power consisted of a scratch
built L&Y Pug, and the Hymek, now also painted green (by me – still not a
good idea), and fitted with a Lionel motor bogie purchased from the Warley
show. The two Big Big trucks were joined by a couple of kit built wagons Dad
produced (with the Pug) one I left home at sixteen
leaving Giles on his own at last; he proceeded to make friends with my
Form-mates who had sensibly stayed on for A levels, pursued his love of narrow gauge,
and went off with Stephen (Sam) Holland to join the Welshpool and Llanfair
Railway, where they teamed up with Steve Bell, many years later to be met as one
of my colleagues from the excellent Evesham Vale Light Railway. In 1976 Dad accepted a
Parish deep in the valleys of
Dad immediately
produced plans for a battery electric railcar and with a week’s holiday from
the Forge looming it was suggested I might like to bring some odd bits of steel
and a welder, cutting list to follow! A couple of days work in the heat wave of
August 1976 produced two bogie frames of welded hollow section with angle iron
horn guides. The rest of the week involved riding round Over the next months
the railcar gained a main frame and body work largely produced from the remains
of the up-and-over garage door which the Parish had agreed to replace. Traction
motors consisted of two car dynamos with the field wiring modified from series
to shunt, each driving one axle via a vee belt. Dynamos were used rather than
starter motors because of their continuous rating. The resulting vehicle served
at least once at the Church Fete giving rides, but I never did see it working
properly. The biggest problem was batteries – none of us could afford a new
one, so we were limited to car batteries which had already failed in their
first life, and so were less than startling in their second! At this time Dad began
to have grand ideas about building a half size version of Rev. Teddy Boston’s
Bagnall, ‘Pixie’, of which much more elsewhere; Giles left home to work in
Manchester, and Dad’s health declined, the railway declining with it. A routine
phone call from Dad advised me that he was breaking the railcar and what should
he do with the bogies? In one of those rash moments, I said that I would like
to build a Hymek around them: I had no idea how long it would take to do,
perhaps it’s just as well! By now (1988) I had
married Nikki; we had a daughter Katie, and were living in Cowfold, At this point some
fresh enthusiasm arrived in the form of a schoolboy called Chris Knibbs whom we
had introduced to the Lavender Line, a small steam railway in In fairness, there
were technical problems that I hadn’t sorted in my mind, and which were
critical to the way the project would develop. In short- how to transmit drive
to bogies. There are various ways to achieve this, and each has its own
benefits and problems. This is the most straightforward,
and was for the most part the favourite. Traction motors can be mounted on the
bogies, with batteries carried within the loco body. The control equipment can
be bought relatively cheaply and is very effective (4QD and Parkside). Cost was
always going to be a major consideration, and the cost of sufficient suitable
batteries was a worry. For motors I considered the Sinclair C5 motor, readily
available in the early ‘90s and which I had used successfully in a small car
for Katie. The problem with this motor lies in the mounting and drive
connection. It has an integral epicyclic gearbox (very effective), with a
pulley for a tooth timing belt drive, all made of plastic, making alignment and
careful mounting critical, and I couldn’t see it standing up to the sort of use
I wanted the loco to be capable of. Also considered was the motor found at the
time on battery electric version of cylinder motor mowers. Not a bad motor, and
designed for chain drive – a big plus, but they were already getting a bit rare.
I had one in the back garden, and although I had no figures for it I guessed I
would need at least two, and possibly four, for it to be any good. The problems
of multiple motor control were a worry too; a single controller would work if
all axles were driving ok, but in the event of slippage, how do you prevent
dumping all the current into one motor? (Not a problem in practise, I suspect –
G.) Petrol Electric This was my preferred
solution, as I really wanted an engine in the loco and didn’t want to rely on
batteries. What I wanted to do was use a 24v bus alternator, engine driven, to
directly power traction motors. I hoped that by replacing the separate
regulator with a field controller I could use the 200amp output to do anything
I wanted. I had a bit of experience with them and there was generally an old
serviceable unit lying around the workshop; in addition they were easy to
mount, and vee belt driven – easy. However a discussion with the guy who
rebuilt our alternators said it couldn’t be done and I would have to have
batteries to provide traction current and charge them with the alternator. Back
burner time again. Petrol Mechanical This, for much of the
time seemed the most likely solution. I could get hold of a suitable engine and
gearbox easily; the Ford 1100 There are two
complications, first turning the drive through 90 degrees, and second, reverse.
Any normal engine installation would result in a north/south crankshaft with a
cardan shaft (prop shaft) over the drive bogie. Chain drive with carefully
located shafting will cope with up and down axle movement, but small suitable
gearboxes to drive at 90 degrees are not common. I considered several options
from my earlier life – many grass cutters and pasture toppers in farming use
robust versions of such a unit – the Votex springs to mind, however I no longer
have access to parts like that, and I couldn’t quite face the thought of having
to buy a whole machine from Cheffyns’ sale near Cambridge, much as it would
have pleased Nikki’s cousin David. Any engine/gearbox configuration I
considered would have had a reverse gear so at first this may not seem a
problem, however the idea of four gears going one way and only one going the
other offended my engineering sensibilities. In fairness, this arrangement is
widely used where normal travel is in one direction as at Pulborough and need
not cause a problem, however we didn’t have a railway, and I couldn’t envisage
ever going to one that didn’t require bi-directional running. We did talk about
building a short 10 ¼” line at Isfield (the Lavender Line), and there was
always the beautiful Manor Railway, Ingfield from which one might hope for an
invitation. Thus although I had at one point a 1300 Petrol Hydrostatic This seemed a great
solution if I could find the right kit. A hydrostatic system uses a closed
hydraulic loop connecting a piston pump of variable displacement to a piston
motor. The pump and motor are of the “swash plate” type with multiple cylinders
grouped around a central shaft like a western revolver. A circular plate
mounted on the central shaft runs on the outer ends of the pistons, its angle
being variable from perpendicular to the shaft where the disc does not depress
any of the pistons, and a maximum of about 30 degrees, where on each
rotation, every piston is pressed once to maximum displacement. The output is
piped to a motor of similar construction but with fixed swash plate. The more
fluid displaced by the pump, the faster the rotation of the motor swash plate.
The motor exhaust is returned to the pump, such that when the pump is in
neutral or “out of stroke” the motor is stalled out. A side benefit of this
system is that no brakes are required as the system forms an hydraulic lock (an
emergency/parking brake should always be fitted). Hydrostat units are readily
available commercially at reasonable cost, but these commercial units are in
one piece, which seems to me to be at odds with the flexibility of the concept,
and to install such a unit I would still have had to located the 90 degree
gearbox. Oh well. I did at one point
acquire an old Kubota tractor with hydrostatic transmission, which was duly
stripped for parts, including a drive unit with separate pump and motor. This
may well have done the trick and the diesel engine was a bonus. However the
engine was a non runner and it all lay about for ages before being passed on. John
Scovill took the engine and rebuilt it with many new parts at great cost to go
in his Drewry diesel loco which has subsequently run beautifully as a bare
chassis, so it wasn’t all wasted. Petrol Hydraulic With this arrangement
the engine drives a gear or vane pump, the resulting pressurised oil being
controlled by a proportional valve to either drive one or more motors, or
diverted back to the storage reservoir. The valving can also be set up to
reverse, most motors being capable of reversing (check the vent pipe). Ideal.
All tractors have a hydraulic pump in the bowels of the rear axle, and vane
motors are widely used for commercial conveyor belt drive. Should be easy to
find good ones I could use. Ho Hum. Bogie Mounted
Engine I should mention this
arrangement in passing as it is a legitimate solution which I did think about,
but not for long. A small lawn mower type industrial engine can be mounted on
the drive bogie such that it moves with the bogie. Simple mechanical
transmission using perhaps the once ubiquitous Over the intervening
years a great deal of thoughtful pondering took place, never really coming up
with any solutions. We became more involved with full size steam, Chris
achieved his A-levels without my help, followed by university, ending up as the
Operations Manager at the Blubell Railway; whilst periodically I would fall
over a bogie or the chassis frame. The latter was even rescued by Chris from a
scrap skip at Isfield where a non-engineering member had deposited it. The turning point came
at Christmas 1997 during a family party at I still had the Kubota
engine at this point although it was a non-runner, and no pump, but this didn’t
seem insurmountable. As the weeks passed, however no solution appeared, and
Giles wanted an answer. The turning point
arrived at a chance meeting with Kim who I knew from the past at Isfield. He
had a diesel hydraulic breaker plant liberated from a SeeBoard skip for the
loco he was going to build one day, but couldn’t see it happening. He offered
me the unit on condition he could drive the loco when it was finished. Half an
hour later the unit was in the back of my car, before he changed his mind! The unit was quickly
taken to the workshop at Billingshurst, and surplus tinwork removed. A new
battery and a little diesel fuel was all that was required to get it to run –
cracked it! From this point I had
a running loco chassis in about 3 months. In the intervening years Giles had
bought a Coffee Table Book on diesels with drawings in 4mm scale. Some
measurements of the power plant and some careful scaling showed that the engine
wouldn’t fit in the body by about 1 ½”. A decision was quickly made to scale up
the whole body pro-rata, adding 1 ½” to width and height and about 4” to the
length. That way the end result would look right even if it wasn’t dead to
scale. By this time our involvement in miniature railways had grown, and I had
seen lots of diesels referred to as Hymeks, that did nothing to capture the
careful coach lines produced by Messrs. Beyer, Peacock. I was determined that
anyone seeing my loco would be in no doubt what they were looking at. In
addition all the construction was to be welded steel – I had no plans to do any
of the work again, and in the railcar I had seen what happens to wooden bodies.
Steel is my preferred material of work anyway having welded commercially
regularly since the ‘70s. The bogies needed
lengthening so they were cut, and 2” inserted. The wheel sets were sent back to
Dad to re-machine to scale profile at the local technical college; the original
profile, intended for 20lb/yard rail would be no good on the scale track I
hoped to run on. Two 1” self-aligning flange block bearings were obtained from
Trafalgar bearings in Billingshurst, made in At this point the
position for the engine was decided upon. The breaker came as a skid unit, with
all the components mounted in a steel cage. The design was such that it was
possible to use the base frame and cut off every thing else. The base frame was
attached to the chassis with 4 Volvo Bus exhaust mounts. These are just like
the Mini bobbins of the ‘70s, but much bigger. After discussion
direct with the hydraulic valve manufacturer, a spec was agreed upon, and the
valve ordered through Hose and General. This was to be my birthday present from
Giles, albeit a little late by the time I got it sorted! The Important Factors
with a hydraulic system are pressure and flow rate. These will be stated by the
pump manufacturer, subject to rotational speed. In many case the engine and
pump were supplied as a governed unit, with a clearly stated pressure and flow
rate. Pressure relates to output torque, and flow rate relates to speed; the
motor(s) used need to be compatible, remembering that a motor supplied with
half its rated flow will run at half rated speed. Running below rated pressure
will reduce available torque. Some adjustment can be made in final drive ratio,
but it is important to ensure by doing some simple sums in round numbers, that
the chosen combination will do what is required. Our simple sums based on a
required maximum speed of 8-10 mph produced a likely gear ratio which enabled
me to order sprockets and chain from Trafalgar. I decided on steel plate (pilot
bore) sprockets, which I bored to size and welded to the axles before the
wheelsets were finally reassembled. They were very cheap (between £2 and £4
depending on size) and if I ever need to change them I will cut them off and
weld new ones. A very good friend and engineer took great exception to this
method, but I stand by it. Fenner taper lock fittings are the alternative, but
to me at least, the cost is too great. As it turned out the performance of the
loco fell beautifully within the chosen parameters, and there has been no need
to interfere with the gearing at all. The hydraulic motor is
slung under the drive bogie, driving one axle. A second chain links the two
axles. The second axle also carries a brake disc (turned up from ¼” plate and
welded) onto which acts an hydraulic brake calliper thoughtfully declared
redundant from a BMW motorcycle by our local Police. The master cylinder
previously supplied the clutch of a The new valve duly
arrived, and didn’t look much for £160. It was very compact, and they had got
all the functions into a single spool. The requirement stated to the
manufacturer was for proportional speed control in both directions> after
asking questions about the use, I was told that it needed to have what they
called a “freewheeling spool”. This in effect connects the two ports on the
motor together when the control is release, allowing oil to freewheel around
the motor on overrun. The normal arrangement is to block both ports, which
would cause the pump to run dry or “cavitate” on overrun – a very damaging condition
for hydraulic systems. The whole unit was the size of a smallish cigar box with
a single centre sprung control lever. I was enormously impressed. The installation of
the new valve and hoses (made up by Hose & General) produced a chassis that
would theoretically propel itself and so plans were made to make it drivable. An invitation was
kindly made by Lynn Stratton of the Manor Railway, Ingfield to bring the
vehicle for running trials. A plastic stacking chair appeared from somewhere,
and this was welded to the chassis frame. Temporary controls were rigged up for
transmission and brake; the transmission control worked like a tram controller,
but not as well! I seem to recall a dry
autumn day for the chassis trial; this was quite an event as this was the first
I/C powered loco ever to run at Ingfield, and I was keen for it not to be a
disaster. Once the line was cleared of leaves the rails began to dry and the
initial traction problems receded. A judiciously positioned Snap-On tool box
helped, and the hydraulics performed perfectly. I had intended to modify the
engine speed control, and possibly link it to the hydraulic control, keeping
operator controls to an absolute minimum, but it turned out that the unit’s own
governor control was better than any thing I could invent. Hydraulic pressure
from the pump produced as soon as the engine starts holds the engine at idle.
As soon as the driver draws hydraulic power the governor opens to working
speed, just like the real thing really! In every respect the machine performed
better than I dared hope, actually drawing a passenger train and even venturing
up the bank. Traction was of course very limited by the absence of weight, and The next week or so
saw the removal of the temporary controls and fuel tank, but not much else
happened. Early in the New Year
a sudden change of job meant the loss of storage and workshop facilities which
was a bit of a problem. The loco ended up on the large dolly made as a working
platform, wrapped up in a black rick sheet outside a neighbour’s garage, while
I spent several months working abroad. My embarrassed friend sadly informed me
on one visit home that his neighbours were going to get the council to scrap my
“junk” if it wasn’t removed immediately. A busy day helped as usual by my long
suffering friends Chris Knibbs, Roy Harwood and Nick Kingshott, cleared enough
space for the loco and dolly to hide behind my garage under the plastic sheet,
and there it stayed, while I changed jobs again and adjusted to being an Electronic
Security Systems Engineer in central London. A group of like minded
friends had formed the South Downs Light Railway Society around
Chairman Barry Metcalf and his unfinished Bassett Lowke ‘Royal Scot’ together
with the other locos owned by various members. Every one was on the lookout for
a site for our own railway. Around Christmas time
negotiations started with the Garden Centre at Pulborough, and suddenly we had
a home. The development of the railway is chronicled elsewhere, but it was
apparent that there was going to be an initial shortage of motive power. From
my full size experience, I was convinced of the benefit of diesel traction for
instant power and tossed the Hymek into the ring; the only problem was that it
wasn’t built yet! Once again, Giles came
up with the incentive to proceed, offering his services and the use of his
workshop at RADA. Chris and I took the chassis up to The only aspect of the
construction that was less than a complete success was the cab end roofs. These
are compound curved of varying radii. Giles did a very clever fabrication with
laminated MDF, which when sanded and filled looked really good. Unfortunately
several years of damp have causes the sections to delaminate, and ultimately we
will have to do something different. With the Railway’s
planned opening on Good Friday, and only Chris’ veteran loco John Terence in residence, it was only
with one weekend to spare that the Hymek arrived at Pulborough on another
borrowed trailer, rather less than resplendent in several shades of red oxide.
The weather was beautiful, however, and a couple of hours with a spray gun and
some hastily mixed paint meant that we ended the day with a recognisable loco. The first trials on
the newly re-laid section of track produced some enormous grins, and several
people who had expressed reservations about diesels on what was going to be a
“steam railway” had to be surgically removed when it was time for someone else
to have a go! Subsequent jobs
included applying detail, black vinyl for windows, and the lime green stripe. I
was right to be concerned about cooling, and several modifications have been
made to help this, including boxing in the supplementary silencer, and latterly
adding an expansion bottle. This seems to have finally stopped the loss of
water from the already very small cooling system. Direction lights have been
added as a toy, and two-tone horns fitted, but the latter sound unrealistic,
and will be changed. Much detail needs adding, and the roof sections need
replacing as mentioned earlier. In addition some repairs are much needed to
exhaust mountings and other bracketry. Desperately needed is
a supplementary alternator, as the charging facility on the engine produces
only 50milliamps, the same as the fan uses. Consequently the battery works on a
loss basis and requires regular charging. Addition of an alternator would
remove this necessity and enable the fitting if an electric compressor for air
brakes – always an intended installation. In operational terms
the loco has exceeded all expectations, and is regularly the chosen form of
traction for early and late trains. It not infrequently acts as stand-in for a
failed loco, often towing the failed loco and its train to shed, before
deputising as train engine. During close season
public interest in the railway is such that the diesel is often left ready in
the station with a coach, so that a member of the track gang can fire it up to
give rides to public to save disappointment. On these occasions guests are
generally invited to put a donation in the box rather than pay a formal ticket. The loco has travelled
the Great Dorset Steam fair twice, and visited the excellent Birchley Railway
in Kent, Bob Symes’ garden railway in Surrey (where the Deputy Director of the
Austrian State Railway had to be removed with a crow bar to let other people
have a turn), and by kind invitation returned to the Manor Railway for a lovely
Easter day. I had no idea that
such a project could inspire so much enthusiasm or give so much pleasure. I
guess if I had I would have been too intimidated to start. I don’t drive it very
often, I don’t even go to see it every week, but like the family narrow boat it
gives me a warm feeling knowing its there. Many thanks are due to
Roy, Chris and Nick all of whom got cold and/or dirty helping and Giles for
nudging me towards the dream and helping with the bits I couldn’t get my head
round. Thanks to Mum and Dad for the original incentive and to Nikki and Kate
for being there when I wasn’t, and still being enthusiastic! Aidan F Favell


