Wood Shop

Despite the title of these BLOG entries we try to show other activities, as appropriate, and when we are able to snap a picture.  So, to start out this BLOG, here is a short report on activity in the Freight Car Department.

Air Brakes

Victor Humphreys is testing air brakes on two freight cars, scheduled to be operated in a special freight train on April 30.  He has completed inspections and maintenance for five cars so far, with a lot of help from other departments. 

Hand Tools

What would someone from one of the many TV handyman shows say?  Buzz Morisette is using a hand plane to size new moldings for the MILW 01984 caboose project.  What a concept!

On the Bevel

On to some of the operations for the new IC 3996 window frames.  You might think wow, look at that new frame for a window.  But realize that to produce just one there are many steps along the way, and jigs and fixtures to be made.  Readers here will have seen many of the needed steps in earlier BLOG entries, now we are close to the finish line.  Here, Rich Witt and Loren Tweed are cutting a bevel on the bottom rail of these windows.

Stile Rabbet

With a special profile routed on the bottom rail, and the bevel cut, a bit has been installed in the router, and fences and guides set up to cut a rabbet on each side stile.  Even with the guides, it requires careful work for Rich and Loren to do each side of each of the eleven frames.

The Ledge

Rich eyeballs the new ledge or rabbet created on this frame, while Loren helps with the inspection.  We check each cut on each frame before moving on.

Lift Hardware

Brass window lift castings (two per window) need to be inserted into the bottom rail.  Another special jig or fixture was constructed to locate these and provide a consistent unchanging pocket for the hardware.  The jig is in place and Rich Witt is using a router, with yet another different bit, to plow out the recessed pockets.

The Pocket

Here is a better idea of the finished pocket.  Looks simple, huh?  One down, twenty one more to go.