Mamod steam loco - removing the smokebox

I decided to start with this project by removing the smokebox casting and straightening the buffer beam (it's all cast in one piece).

I don't have any instructions for this, so I'm working things out as I go along.

To remove the casting I first removed two self-tapping screws either side of the smokebox. I then removed two 6BA screws that connect the casting to the frames, these sit behind the cylinders. I then wriggled the casting from boiler (a tight fit) and the loco front;

Showing the damage;

Removing the coupling hook releases the red buffer beam overlay.

I used an adjustable spanner to gently straighten the buffer beam. It's far from perfect, but good enough for now;

The front end appears to be cast in Mazak or some similar pot metal, and is fairly pliable although I wouldn't want to bend things too far.

I plan to fit wooden buffer beams, which will help disguise the damage. Replacement castings are available should I wish to go down that route.

I also cut off the coupling hook, which was also damaged;

Here's the front end, showing the reversing block and lever;

I'm replacing the fixing screws back into their respective holes where possible as I'm working, there's every chance that this loco will remain in pieces for some time and I don't want to lose any parts or forget where each screw fits.

The next job will be to remove and clean up the bodywork.

Paul.