A major stumbling block has been reached in the restoration of Standard Class 4 -2-6-0 No. 76077.

During the dismantling of the boiler, additional work needed to be done because extensive star cracking was found around most of the stay holes in the copper firebox.

This would require the lower sections of the sides of the firebox to be replaced.

There were also concerns about previous repairs to laps in the copper doorplate done at Eastleigh in 1964, and it was agreed that the doorplate should be removed so that a boiler inspector could examine the quality of the previous repairs.

A few localised areas around the firehole door were built up with copper weld before the doorplate was removed, because localised heat from the welding could cause the copper to deform if it was not held firmly in place; the surrounding stays and rivets ensured the copper did not distort during the welding process.

However, soon after welding started, what appeared to be blow holes were found in the copper plate around the door ring rivet holes. They led to the cessation of the welding so that the copper doorplate could be removed to determine the cause.

Cracks were found in the platework around the firehole door joint, and they had opened up and developed into cavities below the surface of the platework.

Further examination revealed star cracking radiating from many of the stay holes, similar to those discovered in the firebox side sheets.

Assessment of the doorplate revealed that repairing it would cost up to 75% of the price of a replacement, without considering the possibility of further unseen issues in other parts of the platework.

A solution was found at the North Yorkshire Moors Railway, which had a former for flanging a doorplate, and agreed to its use in return for a donation to one of their locomotive appeals.

The decision was made to renew the copper doorplate, but there is a 12-week lead time to deliver the copper. The order has been placed, and the copper is expected to be delivered to the UK early in 2026.

To highlight the value of spending money on 76077’s boiler, the boiler of another locomotive at the Gloucestershire Warwickshire Steam Railway (GSWR), 7820 Dinmore Manor, was recently lifted out of the frames after 11 years of service.

That has received similar repairs to 76077, and that work done appears to still be in excellent condition, due no doubt, to the quality of GWSR’s water treatment.

Work on 76077’s boiler is being carried out by engineering specialists Leaky Finders at Exeter in Devon. As well as boiler making, machining, fabrication, and painting of steam locomotives, it recently acquired its own steam locomotive, Great Western Railway 5700 Class No. 9629.