Over the last few years, it has become clear that work would be required to Covertcoat's boiler. A new firebox, which is 20% larger than the one she was carrying, was built over the winter of 2005/6. When Covertcoat was dismantled at the end of the 2006 season to fit the new firebox, it became apparant that the boiler was in a worse condition than expected, so the decision was taken to build a new boiler, incorporating as much as possible from the original boiler.
The boiler barrell was rolled at Deepdale Engineering, whilst the rest of the boiler construction was undertaken on site at the Launceston Steam Railway. By April 2007, the basic shell of the boiler, incorporating around 5% of the original boiler, was finished, work continuing in the period between Easter and Whitsun when the railway was closed. Tubing of the new boiler started at the end of May, and the boiler was finished by early June, ready for inspection and acceptance by the boiler inspector and insurance company. By the 18th June, the boiler was complete and had been hydraulically tested, an initial steam test being planned for the 19th June.
1st July saw work being undertaken on the expansion brackets which hold the boiler in place. Since the 18th June the boiler has been fitted into the frames, and pipework completed in the smokebox.
Covertcoat was moved from the museum workshop to "Toad Hall" in July for refitting of the cab and saddle tank. Following succesful trials, Covertcoat re-entered service at the end of July.
