Two steps forward one step back again!

I had a whole day to myself, in the workshop.  SWMBO was happy painting or something, and the kids did not need us to baby sit the grandchildren.  So, let’s make the 6″ boiler fire door and ash pan door.

But first, I silver soldered the 4 joins on the super heater, and all went well.

The firehole is oval shaped, and the plans call for a rectangular door.  So I spent some time planning the machining for the rectangular door boxed section.  Then I thought … hang on…. this oval is really nice… why am I hiding it behind a rectangle ?

So back to the computer, and I worked out a method to make an oval door.  A bit like a hobbit door, with an adjustable vent.

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And here I am, machining it with a 2mm cutter.  In 1mm deep bites.  That brass is 4mm thick.

And I made a bracket to complete the hinge….

Drilled the holes for the 1.5mm pin…..

And the f*****g drill bit broke!!!!

I could not get it out.  It was a cobalt bit, and all of my methods for digging out broken bits were tried, taking a couple of hours, and failed.

So I reshaped the hinge end of the door..

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and I will silver solder a hinge end on tomorrow.