Skip Channel4 main Navigation
The Build
The Clagsters
There were no surprises when Jim and the Clagsters decided to use their favourite power source and build a traditional paddle steamer. With steam engines a bit thin on the ground, they had to make one from scratch. They quickly scavenged a ready-to-go hull from an old navy assault boat, a helpful time-saving find. But they were still going to need every spare minute if they were to finish on time.
They happened upon an old coal-fired boiler to raise steam in OK condition, which was just as well as the pressure built up to make steam would make even a hairline crack fatal.
With steam creation cracked, the Clagsters turned their attention to harnessing the power. When they found some old cylinders they had the answer. The steam would be injected either side of the piston. This would push the piston up and down in the cylinder. The in-out movement of the two pistons would then turn into a rotational movement using a crankshaft. This would then rotate the paddle wheels that overhung the edge of the boat.
Confused? You will be. The Clagsters then took leave of their senses and decided to make life very difficult for themselves…
It's obviously important to time when you want the steam to be injected and exhausted either side of the cylinder. In order to do this, the team planned to utilise microswitches that they found in a destroyed excavator. The only problem being that solenoids are electrically powered. Yes, I know what you're thinking – electrics, steam, water – not a match made in heaven!
Each piston had four electric solenoid valves; two injecting steam and two exhausting steam. By placing the micro switches on the pistons (moving in and out) they could use the movement of the engine to control the timing.
Great in theory, but far from simple in practice. The Clagsters spent an eternity positioning and re-positioning their solenoids ensuring that the build of the world's first electronically controlled steam engine went to the wire.
The Nerds
The first thing the production team noticed about the Nerds was they talked a lot. I mean a lot. No part of the build was too minor for a big pow-wow. This was to cause serious problems later on.
The Nerds' initial plan was to stick with their 10-minute rule and go as simple as they could. They decided to use a diesel engine to turn a paddle mounted on the rear of the hull. The only problem was they chose part of the set as their hull – a massive cement mixer bowl.
So while Steve the expert began chopping this to pieces, Crash and Geo chatted and drew complicated drawings. Expert Steve was adamant that they'd need as big an engine as possible to move the hefty hull and gave the thumbs up to a giant BMC tractor power plant.
His enthusiasm was not matched by his American comrades. Getting the donor vehicle back to base turned into an epic struggle for scavenger Jeff and when the engine was finally removed it became apparent it would never fit in their cement mixer hull. Cue one of the biggest bust-ups ever seen on the 'heap with Geo referring to Steve as 'Mr One Tonne Engine' and Steve venting his frustration at the Nerds' talk-now-build-later attitude. What a way to end day one!
The Nerds came back a different team on day two – Geo had realised they had to stop talking and get decisive. They ditched the heavy BMC engine and gearbox and decided to utilise a very lightweight engine from a small van.
The only problem was this would end up turning the stern wheel at a huge RPM – churning the water rather than pushing them. They solved this with the addition of a second gearbox in-line, allowing them to gear down the rotation to something that is better suited to turning a paddle wheel than a road wheel.
Cunningly, they decided to use an axle as their stern wheel. Barrels were cut up and mounted on the wheel hubs. This allowed them to brake each wheel and so turn the boat in a 'skid steer' fashion like a tank. They also thought long and hard about where to put the paddle wheel. It's very important not to have it deep in the water as this puts too much stress on the blades.
In the end they made sure the whole stern wheel was on a massive pivot. Near the water they welded barrels filled with air, so no matter where the hull sat in the water the paddle wheels were always at the right depth because the barrels supported them. So despite throwing away almost a whole day's work, evil geniuses the Nerds clawed their way back to be ready for test day.
