On And Off The Rails (Part 4)
September 27, 2009
Location: Rhodesia Railways Mechanical Workshops, Bulawayo
Still in the Erecting Shop, 1973
I would like you to meet my Erecting Shop Journeyman.
His name was Brian Kelly and he came from Ireland. I am convinced he was an IRA hit man but this was probably my overactive imagination at work, but he did strike me as a dark horse whose passive and quite nature merely concealed his other side.
Brian was a great guy, spoke with a wonderful Irish accent (obviously) and we got on really well although I made a number of serious fuck-ups while I was with him. We will not discuss them at this time.
The ten o’clock tea-time was reserved for playing bridge in the Erecting Shop welding cubicle. We had our own little hide away where our wooden lockers were. Brian spent many frustrating months teaching me the game. He had a lot of patience with me and I think I got the hang of it in the end although I still don’t really know what “vulnerable” and “rubber”means. Anyway during tea time we used to sit around a steel table we had made and four of us would drift away into a make believe world of soft carpets, cigar smoke, and waiters dressed like penguins. We really were a quartet of grand gentlemen in our oily, sooty overalls, greasy safety boots and chipped tin mugs that burned ones lips whenever a sip of tea was taken.
Brian’s wife also made the nicest mince sandwiches which I used to readily devour, normally not having anything of my own.
One of the jobs I was taught by Brian was a boiler tube replacement. This was a bitch of a job and involved first the cutting out and then the welding back of up to 400 tubes that form the steam making heart of a steam locomotive. The idea was that once the boiler was safely on its stands, the welder, in this case me, would climb inside the firebox and cut the old tubes out using an electric arc. Quite a mission as you have to get the arc inside each tube to cut it out and the arc would flash all over the place. If you have never welded electrically you wont understand what I am talking about but try to imagine it anyway. Once they were all out the boilermakers would come and clean everything up and new tubes would be fitted which I then had to weld back in. A long and back-breaking process, done in isolation and under a strict time scale. Once all the welding was finished the boiler tubes were pumped up using water pressure so you could see any leaks in your welding. And then it was back in again to seal off any water spurts.
In have to say here that I was complimented by Jack Crilly on my ability to carry out positional welding much better than the easier and normal flat welding. This is quite strange as positional welding means upside down or vertical up/down welding and normally takes ages to master. I got it right within a year and found it quite an accomplishment. Boiler tube welding was all positional stuff and tested a welder to the limit both physically and technically.
I have never been a small lad. In fact I am what you would call over average in build…..overweight or fat actually. I was known as the little fat fucker in the workshops. Getting into the boiler was always fun and getting out even more fun as a persons body expands when hot….I jest not with you here. And it is really hot inside a boiler that is being welded. The sweat literally pisses off of you. Remember you are wearing elbow length fireproof gloves, your Jack the Ripper apron, boots, spats and your overall. Oh yes and you have a welding helmet and cap on as well. The cap was to stop any welding sparks burning the shit out of your exposed head which resulted in intense pinpoint pain, swearing, and the sickening smell of your own hair and flesh on fire.
If you do not manage to get your kit on correctly, some sparks do manage to get inside your overalls and I had one rather painful experience of a blob of molten metal coming into contact with the side of my dick….I have the scar to this day. Lucky, lucky.
Sometimes blobs of metal got inside my boots….very painful too and you just have to grin bravely, swear, jump about, and wait for the bit of metal to cool down while being in direct contact with your skin. There is no way to get your laced-up boots off.
As in the wagon shop there was also a graveyard for weary locomotives…..those fire breathing monsters that have come to the end of the line. This was also a sad place where once proud giants of the railroad found their final resting place…..out in the open and unprotected from the elements.
It was an undignified end for these truly wonderfully majestic machines, and my love of and fascination for steam locomotives remains with me to this day.

Rhodesia Railways 20th Class Garrett hauling a passenger train.....what a majestic beast! There is a more than even chance I worked on this grand old lady.

Rhodesia Railways locomotive graveyard, Bulawayo

Inside a locomotive boiler showing steam tubes

Boiler tube plate where I would cut out and weld back the tubes

Inside a boiler
On And Off The Rails (Part 3)
September 26, 2009
Towards the end of 1972 and early 1973…..still in the Rhodesia Railways Mechanical Workshops, Bulawayo
Second Mission: The Erecting Shop
I know what you are thinking. Erecting Shop. What a strange name and why would they call it that? I thought the same myself and of course this part of the workshop complex was always going to be rife for a whole lot of strange comments.
So why is it called the Erecting Shop and what debauched activities take place there? Patience dear reader…..all will soon be revealed.
Towards the end of 1972 I was told that I would be transferred away from the Wagon Shop. My destination was not made clear at that time as there was a lot of shuffling around going on. A large majority of the Journeymen and senior apprentices (3rd, 4th, and 5th years) were spending more and more time in the bush on Territorial Army (TA) call-up duty, and this was putting a severe strain on those of us who either had not yet been called up for National Service, or those that for one or other reason were unable to serve in the Rhodesian Army. I suppose that this was when I first realised that one day I would be going on call-up and others would have the pleasure of cutting up smelly meat wagons.
To be very honest I was extremely sad to be leaving Jack Crilly. He had become like a father to me and mentored me in everything I needed to know about my work and more importantly, about life itself. He treated me as his son. As an apprentice I never earned much money. In my first year I took home 77 Rhodesian Dollars per month. Out of this I had to pay for my lodging, buy clothes, and eat. I had moved into the Railway single quarters in Raylton, the railway suburb right next to the workshops and staff canteen. So I lived in the shadow of where I worked and the sulphur smell of burning coal was ever prevalent. Each month I bought my little book of meal coupons and that’s where I basically ate all my meals. Not bad food, but pretty much the same menu each day.
I got to know quite a few of the married personnel who had their houses next to the single quarters and ever so often I used to get invited round to someones house for a real supper of hot beef stews, hearty vegetables, and guavas and custard. One couple I became very attached to was Bella and Keith Harris. Keith, a giant of a man with a heart as good as gold, was a locomotive fireman…..the tough guys that shovel coal into the ever-hungry maw of a steam engines firebox. And dear Bella….what a wonderful person……she just had a way of making me realise what it must be like to have a real home. Wonderful people who never had too much of the good things in life but shared what they had.
Back to the Erecting Shop.
Erecting Shops are places where things that were previously un-erect (not flaccid as in penis, but rather dismantled) are re-erected. Normally this process involved enormous machines. In this case huge black steam locomotives. Great big Beyer-Garrett monsters that could haul thousands of tons of cargo up and down the many miles of Rhodesian rail tracks.

Beyer-Garrett 15th Class
These were massively powered beasts that prowled Rhodesia’s open spaces taking goods all over the country and over the borders as well.
Life was quite hazardous in the Erecting Shop. What you have to understand is that Rhodesia Railways locomotives could weigh between 30 and 120 tons depending on the model, and when it arrives at the workshops it is still on its bogeys, or wheel units. So it is easy to move about with little shunting engines or winches. However one of the first things that has to be is to remove the bogeys. The only way to do that is by lifting the whole locomotive into the air and pushing the bogeys away. The locomotive, suspended on huge overhead cranes was then lowered onto giant stands. It would remain there for at least 21 days, the time it took for a full strip and rebuild. Rhodesia Railways were known to be one of the most experienced organisations as far as this type of work was concerned.
I have described the removal of the bogeys as if it was a really simple activity but in fact it was an extremely precise and dangerous operation. The first thing that is done before removing the bogeys is that the sanding pipes must be cut off using oxy-acetylene cutting equipment. Sanding pipes are used to spray sand onto the rails in front of the main driving wheels of a locomotive when extra traction is needed, for example on steep inclines. This cutting of pipes was one of my jobs and again rotten meat comes into the story. You see there is a thing called a cow-catcher at the front of all locomotives and their job is to catch cows standing and minding their own business on the track…..basically a massive fast moving 100 ton meat tenderiser. The problem was that the now mushy cow normally got caught up under the locomotive after being hit and bits of pieces of processed meat and bone ended up being sprayed up the front bogey assembly that included the sanding pipes. So we are back to the 3000 degree flame burning minced up rotten beef.

Lifting a locomotive in an Erecting Shop (non-Rhodesia Railways)

A typical Erecting Shop (non-Rhodesia Railways)

Rhodesia Railways Erecting Shop where I worked as an apprentice Plater-Welder













