Illinois Railway Museum Blog

Yesterday was a productive session at the Steam Shop.

On 1630:

Collin did most of the remaining sand blasting while Phil did a great job getting sand back out of the boiler, supported by a number of us who spent the day either pouring 50 lb bags of sand into the equipment or collecting it out of the chute as is was removed !!.  We should now be at the point of "tidying up".  The back tube sheet, parts of the belly and dry pipe need to be done but, aside from that, it is a case of inspecting and "touching up" any areas that are not clean enough to allow a good inspection.  This should be done next weekend.

Collin took a few shots inside the boiler where Nigel does not fit.  This one shows the critical seam between the rear tubesheet and the firebox crown.  Now largely clean, we need to clean back as far as the crown stays next week to allow the complete inspection of this area.

Crown sheet seam

This is the front tubesheet, still closed off by the ply sheets.  The cleaning is now done.  The area where the sheet joins the barrel has been subject of particular attention as this is an area where there is a particular risk of cracks.

Front tube sheet

Glenn and his grandson completed the cutting of the super heater flues.  A coat of paint on those not already done and this job will be complete.

Cutting in progress

All done and reading for painting

Work was also progressed on making good the mud ring ready for the firebox patch.  Dennis has built up a number of the rivet holes with weld and Mike was grinding the welded areas to allow these to be drilled to provide accurate holes for riveting.

Over the next few weeks we expect to carry out the thickness testing and, as soon as the weather looks suitable, pull her outside to sand blast the cab back head.  This will also allow much of the accumulated dust to be removed.

On the Shay there was a lot of activity:

Dennis has been welding during the week and on Saturday.  What was initially just the rebuilding of the smoke box has become a much bigger job that demonstrates the joys of inspecting old steam engines!!. 

We have always known that #5 had a major accident many years ago in which it fell on its right side.  As a result of this the motor was replaced and other repairs were required.  Possibly as part of this, the transverse beam which carries the locomotive on the front truck was cracked and strengthened with steel plates on both front and back faces.  Inspection revealed that this repair was not very well done (although I guess you can say that, having lasted 75 years, it was probably fit for purpose).  The plates were not heavily welded to the beam in the center so the plates themselves have now cracked.  Clearly this is not good as the weight of the boiler rides on this cracked area.

This view clearly shows the patches attached to the beam many years ago and the area where Dennis has cut back thru both the plate and the beam to get to the root of the crack.

Front with crack cut out

Rear with crack cut out

Dennis at work

Rear view now with crack reapaired

The repair involves extensive cutting back thru the plates to the beam where they are cracked and then building up again with a solid body of weld metal.  The cutting out has been done on both sides and, by end of day, the rear face had been completely rebuilt.  Once the beam is fully rebuilt Dennis can move on the smoke box.

Phil made good progress on the truck cleaning.  He has now removed much of the dry muck.  With the improving weather we will plan to shunt the truck (and 428) out of the South end as soon as possible to use the steam cleaner to blast off the greasy material.

Progress on cleaning the truck

On 428 forming of the steel plates that will be used to rebuild the axle boxes is well under way.  Attaching these will be a major job for Dennis once the Shay smoke box is done.

Steel plates will be welded into the axle boxes

Tom discusses the shaping operation with Cameron and Phil.

Shaping repair plates for the axle boxes

Nigel