Wood Shop

New Window?

Buzz Morisette was taking advantage of the Christmas time off at his job and here he is starting on new windows for the MILW 01984 caboose.  I know he is going to do this the 'right way', but it might be easier to take that slab of wood and just drill and saw out a hole in the middle of it.

Some other work was continuing in the shop, including Tim Peters working on new windows for the CRT 1268, and more machining of stock for the new windows for the N&W 2050.  Behind the scenes we constantly have to maintain and repair our machines and tooling and yesterday the Berlin Sander and our table mounted router saw some attention.

As you may have guessed form the previous two entries today, Kirk Warner was back in town for the Holidays.  He was able to use a camera to capture a lot of work and in the sharing spirit of the month, you are getting to see a lot of them posted.

The volunteers at the Wood Shop and in the Freight Car Department would like to extend best Holiday Wishes to one and all!

Caught in the Act

The project here is making new windows for the cab of N&W 2050.  Today we jointed all the rough lumber, cut it to rough length, and here, John Faulhaber is ripping the stock to the needed width.  The picture caption?  Yes, you see my bandaged hand grabbing wood just fourteen days after the surgery.  Promise me you will not tell anyone.

Still at the Saw

Still at the saw, Bob Kutella and John Faulhaber are addressing the need to make 48 pieces of stock for the planned windows, not counting the custom beading and moldings.

More Sawing

A Little Help

Dick Cubbage joins us in the fun as the pile of pieces grows larger and larger.

Mornings Work

So here are the rough sized parts labeled with a secret code so we hope they do not get mixed up.  But they are still too thick.

Plane Truth

Dick Cubbage is catching the planed parts while John Faulhaber keeps them coming at the infeed end.

Measuring

Well out of the way, I am measuring and setting up the next cuts and adjustments for thickness.

There has been an annual tradition that those volunteers who work in the wood shop and Barn 4 Electric Car shop, stage their own pot luck Christmas Party each year.  This year was no exception but was the first one I was forced to miss, due to some hand surgery just last week.  But our faithful reporter, John Nelligan in this case, sent these pics for you all to share in the good cheer.

Early Starters

The tables (workbenches) were set with care, in the hope our volunteers would soon be there.

Surprises

They all heard a clatter and before you would know, new bags of goodies came in form the snow.  John Wozniak delivers a bagged 'donation' while Pete Galayda grins in anticipation.

What a Table of Treats

The main buffet table was set up in the Wood Shop and the usual suspects soon gathered to partake.  It does not look like those guys have missed any meals lately!

Grazing

There was no shortage of grazing as repeated visits were made in an effort to consume everything in sight.  While many dishes totally disappeared in short order, there seemed to be too many dessert items!  So some got be be rescued to be consumed later after returning to home. How could that be?

Party Annex

Extra tables and seating were set up in the 'party annex' where we see George Clark, John Faulhaber, and Tim Peters.

Retirement!

And the guest of honor this year was our faithful Phyllis Schauer who has announced her retirement at the end of this year.  For years she has been the guiding light of so many of the needed efforts to keep the 'business' of the Museum on track, we cannot thank her enough and will miss her fine work.  She does seem to be enjoying the special cake made for the occasion, though.

Making Tenons

Rich Witt has been helping out in the wood shop the last few weeks.  Here he is seen cutting the cheeks for tenons on window rails.

1268 Windows

Scott Greig watches, Victor Humphreys is behind the Berlin sander to catch the window frames as they come out, and Tim Peters is feeding the frames in.  Working at warp speed, I think 18 new upper sash windows have been assembled and glued, and we took the opportunity to sand both sides before beginning the finishing steps.

Locomotive Foot Boards

Buzz Morisette is working on the second set of new footboards for the TM locomotive L 4.  This is really a heavy assembly as they are being constructed of white oak.

Windows, windows, EVERYWHERE!  If you have been following recent updates, you will remember hints of window work in progress.  Maybe we ought to open a production shop and see if we can get outside work.

Upper Sash

Tim Peters is making good progress on his goal of 44 new windows for the CRT 1268.  Here are numbers 5 -8 fitted and glued, setting overnight in our press.  No window is simple with true mortise and tenon joints, but these take it to a new level.  One side of each is curved; and pairs, one right and one left, will make up a two window wide arched effect when installed to replace the existing upper sash windows.

Parts

Stacked on the shelf are some more of the many pieces needed for the 1268 window project.  An old window panel rescued from the scrapper many years ago provides patterns and insight into the original sash construction.

Quarter Round

John Nelligan is checking out new window beading we produced.  He is holding something over 100 feet of quarter round of 5/16 inch radius and using true mahogany.  Of course nothing like this relatively common profile can be purchased commercially - so WE MAKE IT!  Also on the bench are parts made for five new windows for the Passenger Department, and pieces for a replacement sash for the Sand Springs 68.

Mortising

Here is a close look at John Nelligan mortising a side rail for a window destined for Boston & Maine 1094.  This vintage machine was manufactured about 1925 in nearby Rockford, IL and has been restored by IRM and is used to drill SQUARE HOLES.  That is correct; and a row of those square holes forms a slot for the tenon in the mating window piece to be inserted.  At the far end of the rail being processed you can see a completed slot.

Steam Department Too

Finally, we are in the process of beginning to construct multiple copies of three different windows (eight in total) for our Steam Dpeartment.  [If they cannot weld it, torch it, bang it, machine it, or bend it - they cannot make it]  John Nelligan is doing the layout and engineering work needed to plan the work and make a purchase list for material as he studies a vintage Norfolk and Western company drawing.

I hope you have all been playing along at home and get the same total I do.  FIFTY EIGHT new window sash are currently being processed at the IRM woodshop by a handful of part time volunteers.  WOW!!