3801 overhaul full steam ahead

3801 arrived at the Bogie Maintenance Centre in Chullora, Sydney on May 13th - its home for the next 18 months.
Shortly, work will get underway to loosen the first nut and begin dismantling the more than 200,000 parts that make up the 201 tonne locomotive, whose entire frame and cylinders are made from a single steel casting.
The 3801’s tender tank will also be removed and repaired offsite at the Hunter Valley Training Company facility at Maitland.
The overhaul of the locomotive is being managed by 3801’s custodian and operator, the NSW Rail Transport Museum (RTM), with RTM member and professional engineer Craig Mackey managing the project.
The project will draw on the skills of a number of apprentices, volunteers and paid staff, as well as providing opportunities for local engineering firms to provide services such as fabrication and machining work.
On the other side of the world, Dampflokwerk Meiningen, a division of Deutsche Bahn AG, Germany’s national railway, is designing and manufacturing a new all-welded boiler to replace the existing one of 1940s-era design.
RailCorp awarded the contract to Deutsche Bahn in April after an international tender process. With an excellent reputation around the globe and over 90 years experience, the company is known for its precision, high quality engineering, with customers ranging from narrow-gauge steam railways to mainline locomotive owners.
Chris Hoskin, a senior consultant with Halcrow is acting as RailCorp’s agent during the boiler design and manufacturing process as well as providing technical advice for the overall project.
Dampflokwerk Meiningen will use the original NSW Government Railways' (NSWGR) riveted boiler drawings, along with hundreds of high-resolution images of 3801’s existing boiler, to assist with design work.
Locomotive 3801, introduced to service in 1943, is the sole surviving example of the five streamlined Class 38 ‘Pacifics’ that were followed by 25 ‘non-streamlined’ examples. 3820, also in RTM’s custody, and the Powerhouse Museum’s 3830 are the only other remaining intact examples.
The C38s were the ultimate development of express steam locomotion on the NSWGR and became the principal motive power for most major express passenger trains across the State. They worked under the highest operating pressure of any steam locomotive in Australia and allowed for the introduction of heavy air-conditioned expresses, leading to new levels of service and comfort after World War II. 3801 itself travelled over 2,090,000 kilometres until it was withdrawn from service in 1962.
3801’s high profile within both the community and among rail enthusiasts has been established through its role in major civic celebrations in NSW and extensive heritage tourism operations since the 1960s.
The current major overhaul of 3801 is planned so that the locomotive will be back on the tracks by the end of 2010.
Funding for the overhaul and boiler manufacture is being made available by the NSW Office of Rail Heritage under the NSW Government’s Sustainable Rail Heritage Asset Management Strategy.