Flying Scotsman in 2004 - A Comedy of Errors and Owners:
Ok - so this is something I've been sitting on for a while now, but I feel like with 'The World Famous Engine' now being uploaded to Ao3, now is the right time to cover this rather insane topic. See, we all know the story of Flying Scotsman and the NRM: the NRM bought the engine for the nation, and then sent it into the Works for 1 years' worth of work in 2006... One year of work that ended up spiralling into ten years and £4.2 million.
But behind that story is a rather more shocking story, and one that really needs more recognition to help people understand just how absolutely shockingly Flying Scotsman had been treated before that overhaul.
Our story most likely begins under Alan Peglar, but I have a rather sneaking suspicion it actually gets interesting under McAlpine. Sir William McAlpine bought 4472 Flying Scotsman in 1972 to save the engine after Alan Peglar went bankrupt in San Francisco, leaving the engine on a US Military Base.
He brought Scotsman and had the engine restored at Derby Works in England, and then successfully owned and ran the engine for another 23 years, making him the longest-lasting and most successful of all Scotsman's owners.
But, during this era, Flying Scotsman visited Australia, broke the record for the longest non-stop run by a steam locomotive, pulled the Royal Train, ran on a multitude of heritage railways and mainline excursions, got an overhaul three times - including one at Barrow-in-Furness (story idea, anyone?). This is not where the worst of the issues arose from, but it does give you a good idea of the kind of work this engine was being tasked with.
And then in 1995, it was involved in an accident at Llangollen Railway. When put back into steam, smoke emerged from a crack separating the boiler and the front cab. It was deemed a total failure and immediately withdrawn from service immediately - and that's what did McAlpine in. He sold the engine off to cover some debts, and Tony Marchington
What do I think went wrong here? I have a feeling that Scotsman was run pretty haggard in Australia (which, fair - it's not always a very nice country to machines) and when refitted to his BR livery, several... shortcuts were made to get the engine back in service. All the same, this isn't where the trouble came from.
And here's where things went south. Fast. Flying Scotsman was bought, went through a three-year long overhaul worth £1 million and then was set to work. Thing is, that overhaul had a number of red flags surrounding it - perhaps most notable being the fitting of an A4 boiler working at 250psi. Now, for those unaware - the original A1 class ran at 180psi, and the upgraded A3 class ran at 225psi. The engine was being run at a pressure it was extremely unfit to operate with.
It would be a bit like fitting a massive V12 motor to a Honda Accord. Yes, the car will move extremely fast and look impressive and move for a while, but every other piece of that car will deteriorate rapidly due to the pressure it's all under. Now transfer that to a steam locomotive - one where to reach that pressure, the firebox is under a lot of strain.
Flying Scotsman failed a lot during the Marchington era, and it's not surprising why. The poor engine was literally falling to pieces - as one NRM staffmember noted: "On our first inspection, the rear drivers had been removed to deal with bearing problems. The visiting NRM team was most unimpressed with the quality of work being done on the bearings. Other examples of poor workmanship (of which I cannot remember the detail) were evident on inspection.”
Please note, the bearings and valves had all recently been replaced.
Also note, Tony Marchington was under pressure from the shareholders of Flying Scotsman PLC - a company he set up - to make money, and so many of the fitters working on the engine may have been given far, far too many constraints in time and budget to properly overhaul the engine, in essence needing to just 'do the bare minimum to get it back in service'...
And this is the condition the NRM bought 4472 Flying Scotsman in.
The National Railway Museum:
All of the above is an indication of the condition that Flying Scotsman was in when bought in 2004 - but that only tells about half of the story. The other half is a bunch of issues surrounding the purchase, certification and understanding of just how bad things were. And make no mistake, the NRM is not blameless in this circus - it just managed to inherit a bad situation and then fumble with it until they sat down and figured out what had happened.
Let's take a moment to look at the AEAT report that the NRM got, then compare it to reality:
The AEAT report stated that:
"Whilst it was not possible to complete a thorough examination of the locomotive, or to witness it in steam, the condition of the locomotive has been monitored regularly as part of the VAB audit process. Taking this into consideration, it is considered that the general mechanical condition is satisfactory for continued operation, subject to effective maintenance, until the next General Overhaul in 2006. The scope of mechanical overhaul is not anticipated to be extensive but will involve strip down of the motion and axleboxes to gauge wear and remedial action. The cylinders all require re-lining and boring to nominal diameter."
The reality of the condition of the engine was far from this rather rosy portrayal given by AEAT. For starters, the engine was not properly examined, and several areas of testing were 'not possibly to be checked adequately' for a variety of reasons, including:
the locomotive was being prepared for a test run
4472 Flying Scotsman not being in steam
Anyone notice something off? Why exactly can the company not see how the engine is when in steam if the engine is being prepared for a test run?
Furthermore, AEAT had been the VAB (Vehicle Acceptance Body) for Flying Scotsman for 14 years by this point and finding a huge number of faults at this point very much would have raised questions about their work. More probably, the company had grown accustomed to the engine working, and simply assumed everything was satisfactory unless demonstratable to the contrary. Like the NRM admitted:
"[T]he previous owner’s VAB may not have been the best choice of inspector."
Thing is, AEAT included pictures in their report, but most of these were of the air brake compressor, locomotive air brake, tender air brake cylinders, TPWS antenna selection switch and the TPWS antenna mounting arrangements, which while critical to obtaining permission to operate on Network Rail, don't say much about the actual condition of the engine. And the photos that were of the actual mechanical parts of the engine were... telling.
The Stay Nuts in the firebox are rusting, melting and missing. And that wasn't the only major issue with the engine - several of which were extremely dangerous:
the Robinson superheater header doors had been seal welded;
other inspection doors had also been seal welded;
Repairs to defective studs on the superheater header were needed;
the smokebox door locking mechanism was broken;
the firebox stays needed caulking;
the boiler mountings and pipework in the cab was considered dangerous;
the air brake reservoirs were overdue re-certification;
two tender springs needed replacing;
Re-metalling one crosshead was needed, which resulted in having to remove the bogie, and led to the discovery that the piston rods were incorrectly fitted to the crossheads and required extensive repairs in order to make them fit properly;
Removal of the 'belly' access door in the bottom of the boiler barrel in order to remove a build-up of some 6 inches of sludge;
one of the tender wheel tyres was flat;
the air pump needed repairs;
the vital axlebox oil pads which were long overdue for replacement;
the tender handbrake just didn't work and needed repairs;
121 boiler tubes needed replacement (2004);
the boiler itself needed replacement (2006);
Foundation ring heavily corroded and cracked;
a large number of latent fractures throughout the whole of the locomotive's frame assembly;
the valves and bearings were faulty or broken;
there was a serious crack in the right-hand cylinder;
the entire firebox itself was in desperate need of replacement;
the boiler washout plugs had been fitted with domestic gas plugs;
the wheels are all in need of re-turning;
the frame hornblocks are all cracked;
one of the driving wheels was bent;
the frame stretchers were all cracked and beyond repair;
The centre-cylinder motion bracket also had cracks;
The frames were wrongly aligned;
And the frame's horn ties were scrap, and needed to be remade.
That is thirty separate issues that the NRM discovered between 2004 and 2012 restoring the Flying Scotsman. The Flying Scotsman needed such a complete overhaul to be restored that some people argued that it would cheaper to just build an entirely new engine.
A completely new version of this engine:
And remember, AEAT certified this engine to run on the mainline. The Flying Scotsman had turned into a literal moving death trap under its various owners, and I am not surprised it cost the NRM £4.2 million to rebuild Flying Scotsman.
In summary, 4472 Flying Scotsman was about as sick as an engine could get when it arrived at the NRM. The amount of work required to fix the poor engine was extensive - and some may argue unjustified. Personally, I disagree. Yes, Flying Scotsman cost a ridiculous amount of money to save and rebuild - but this is not an engine who would ever accept living on a plinth in a museum. This is an engine with a fascinating history filled with trials, tribulations and triumphs; and in my opinion the Flying Scotsman's place is on the mainline. Will there be a day when the old engine has to be withdrawn and placed in the NRM? Probably - it's the oldest mainline certified engine in the UK already, and it's not getting any younger. But by that same token, Flying Scotsman went through a massive, extensive overhaul to ensure that generations to come could see the majestic A3 doing what it always did best, and there's something truly inspiring about that.
A big thank you to the NRM for saving Flying Scotsman, and an even bigger 'what the hell?' to the people who almost destroyed it by being careless.
The pictures used in this post do not belong to me. All pictures belong to their owners. If you wish to read the NRM Flying Scotsman report yourself, this is the URL, and a hyperlink to its archived form on the Wayback Machine:
