THE famous locomotive The Flying Scotsman will soon be steaming into a new era, thanks to a West Devon firm. The locomotive became a movie star in 1929 when it was used in the film 'The Flying Scotsman' and in 1934 it achieved the first authenticated 100mph by a steam locomotive. More recently, in 1988, it made the longest non- stop run ever recorded by a steam locomotive — 442 miles — while in Australia as part of that nation's bicentennial celebrations. The locomotive was given an overhaul and in 1999 recommenced its role as a star of the heritage railway world. In 2004 it was bought for the nation and housed at The National Railway Museum. But the boiler needed a major overhaul and the copper pressing was assigned to steam boiler specialists RK Pridham at Pitts Cleave in Tavistock. Paul Pridham said while the boiler has been repaired on a smaller scale in the past, the work being carried out this time was on 'a massive scale' and would ensure the loco would 'run for many more years to come'. Paul said the boiler was made up of two main components, the outer steel shell and the inner firebox made of copper. 'Our task is to produce a completely new copper firebox and replace a large amount of the outer shell,' he said. 'We have been working to manufacture the formers to press out the complex shapes required in our 700 tonne flanging press, and at this stage we have produced two tube plates, an outer door plate and firebox doorplate. 'These components are now being assembled along with other plates which have been rolled and attached back to the remaining boiler.' Pridham's plate forming press is a unique piece of British Railways history in itself, originally installed at Crewe works in 1975. Paul said: 'It was acquired by our company around seven years ago. It is probably the only machine left in the country with the facilities to produce the parts required for a job of this size.' The National Railway Museum in York, which is overseeing the project, found the firebox needed more work than first anticipated and the problem was compounded by a shortage of the specialist copper needed for the firebox, causing a delay of nearly a year. Paul said he believed the copper had to come from South Africa. 'We don't have the facilities in the UK to handle the size of material needed. The last mill closed down a few years ago,' he said. Once Pridhams are happy with the components they will be returned to Riley Engineering to be riveted together — thousands of stay bolts will have to be fitted between the plates to ensure the boilers integrity once it is fired up. It is expected the boiler, more than 30ft long and weighing more than 25 tonnes, will return to Bury for the final assembly, before being reunited with the chassis and put back into service on mainline operations early in 2009. RK Pridham currently employs ten people but is looking to recruit. 'There is a skill shortage in this area for heavy engineering,' Paul said. The company is one of the country's premier steam boiler specialists, and has been manufacturing and repairing boilers for locomotives and traction engines for more than 25 years. The company recently carried out extensive repairs on the boiler for the 'Lord Nelson' locomotive. The Flying Scotsman locomotive was originally built at Doncaster works and completed in February 1923 at a cost of £7,944. It pulled its last train for British Railways on January 14, 1963, and then went into private ownership, earning money pulling rail tours around Britain. As well as a visit to Australia, the Flying Scotsman had previously been to the USA, but debts threatened its future until William McAlpine bought it, settled its debts and shipped it home via the Panama Canal.