The 2008-2012 Overhaul
The overhaul comprises a new all-welded boiler & firebox and various mechanical repairs. This was timetabled to be complete by the end of 2010. A new boiler and firebox was ordered from Dampflokwerk Meiningen in Germany. The tender tank was removed from its bogies and was transferred to the Hunter Valley Training Company at Maitland for repair. On 19 August 2009, the old riveted boiler of 3801 was removed from the frame of the loco by a 30-tonne overhead travelling crane at Chullora Workshops. 28 of September 2009, the frame of 3801 was lifted off the wheels by two mobile cranes to facilitate the overhaul of the running gear. On the 5th of September 2010, 3801s new boiler was completed and was put on display during the 16th Meiningen Steam Loco Open Day. The boiler passed its hydrostatic test and was certified by TÜV Thüringen for a working pressure of 16.89 bar (245 lbs/in²), the original 38 class working pressure. The Boiler left the workshops on the 8th of September, being transported to Bremerhaven to be loaded on board a ship. The overhaul of 3801's tender was complete on the 20th of October 2010. It has been refitted to the framework of the tender. On the 27 of October 2010, a mile stone was reached with the arrival of 3801's new new all-welded boiler & firebox arriving on Australian shores at Port Kembla. The boiler was moved to Chullora Workshops where it was test fitted with the frames and smoke box. In May 2011 a statement updating on the locomotives progress was issued by the NSW Office of Rail Heritage: "Following delivery of the new boiler for Locomotive 3801 in late October 2010, the NSW Rail Transport Museum, as the operator, began a detailed assessment in preparation for its installation on the overhauled engine frame. During the inspection process and test fitting of the boiler into the locomotive frame a number of issues were identified. Further mechanical assessment and communication with the manufacturer, Dampflokwerk Meiningen (DB) followed. DB agreed to send representatives to hold discussions in Sydney in late April; this visit included an on-site inspection of the boiler and the locomotive at RailCorp's Chullora workshop. The outstanding technical issues were fully considered and options for rectifying them identified. A 'Heads of Agreement' was signed which commits the parties to a process to bring the matter to an expeditious resolution. The first steps in that process are underway." Work is due to be complete in Late-2011 to early 2012. The boiler was then returned to Germany where it has apparently remained. As of November 2012, due to corporate confidentiality, no new information has been released regarding further progress. This is causing concern regarding the technical feasibility of DB repairing this boiler to sufficient standard as that it may be reinstalled. At the same time the delay has allowed the remainder of the work needed on the engine to be completed.
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