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Tuesday, May 22. 2012Wood Shop Update - May 19-20, 2012 Lest We Forget It is tradition that we remember the sacrifices of our servicemen and women this weekend, but it also marks the 30th anniversary of a very significant milestone in the growth and development of IRM. The button on the hat above was issued May 31, 1982 marking the opening of a mainline extension project that added over a mile of operations to IRM. Note to self: Do not try to take a picture of a white button on a black hat.  One Done Part of the reason this report is late this week is that I have spent the last three days at IRM striving to get the lettering completed on our hopper, Great Northern 70104. That, and very balky computer this AM. But the first herald is done and this completes all lettering on the right side of the car.  Onward The transfer pattern we created is in place on the second or left side and ready to move onward. The pattern was traced and the inner black circle has been painted.  Side Patch Victor Humphreys is at the drill press fabricating the second side patch for our B&O wagon top boxcar.  Dust Shields The set of eight new dust shields has been finished, and ready to have a coating applied. These slide into place over the axles behind the journal boxes on the car being restored on our TMS project, Milwaukee Electric 972.  Windows The crew was in high gear this weekend doing work on Cleveland Transit System 4223. Here, Lorne Tweed is using the torch to apply heat and to remove bound up screws in a window frame. This will allow replacement of damaged glass and weatherstripping.  Window Tracks Out in the barn, Eric Lorenz was busy drilling and tapping many holes in the window posts, ready to install the tracks for these windsows. I forget - was it 34 holes done, 382 to go?  And Painting Never a minute wasted! Lorne moved on to prime painting many of the parts that have been cleaned over the last few work days. These are pedestals, sort of a truncated pyramid in shape, that fasten to the roof of the car for ultimately holding the many next layers of parts and finally, the trolley base and pole.  Sanding Ray Schmid was out inside Barn 4 on a scaffold where he was sanding and doing finish work on the roof of Michigan Electric 28. What great weather for this work - 90 degrees at ground level and probably 105 up close under the metal roof.  Bending Jeff Brady resumed the fussy work of bending and installing thin basswood slats for the rounded roof at the back end of the 28. Here he is engineering the curvature and bends for each custom fitted slat. Sunday, May 20. 2012Steam Department Update 5-19-2012Another good day in the shop although I think most people were moving a bit slower due to the 90 degree temperatures. Work on 1630 continued as planned: · Despite the heat, Dennis put in many hours in the firebox and has now built up the inside face of the mud ring.
Now Mike has a lot of work to carefully drill the rivet holes thru the new weld, at which point the mud ring will be ready to receive the patch. This will be a slow and tricky job requiring the accurate drilling of small pilot holes that must be steadily enlarged as creating an accurate hole thru the weld is never easy; · Work continued with Bob on the form 4. We now have a detail plot of all the measurement points and a few new ones marked up for the next UT testing session (hopefully 6/2); · Several of us worked on completing the diagrams that Bob will need in support of the form 4 showing the location of each thickness measurement point on the particular boiler sheet. Boring work but at least it is good to see the book that will support the form 4 starting to come together; · Part of Phil's extensive sand blasting effort was the dome cover as noted last week. Now we have the "after" view ready for inspection and testing
· We located a length of tube suitable for safe ending the super heater flues so now we can progress with this when resources are available; · One unfortunate set back was that the piston rod of the McCabe flanger broke during test bending of steel for the patch. Several of us spent quite a bit of time checking the storage for a spare but this proves to be one of the parts for which we do not have a spare. The broken rod has been stripped out and sent for analysis. Once we have this a similar steel rod will be acquired and machined. Phil did a solid day of sand blasting and, aside from the dome cover for 1630, also did all four of the axle boxes for 428 and the bolster for the Shay. This was quite an effort given the heat. Unfortunately one photograph I missed was Phil after working most of a hot day in a cloud of black dust. The trouble was that, like most of his sympathetic colleagues, I was too busy laughing and joking about his appearance to hold the camera!!. Sorry Phil. The results of his efforts can be clearly seen on the bolster for the Shay. This now looks very different and, aside from the improved appearance, appears free of any cracks after detail inspection.
In other areas: · Ed and Rick worked on setting up the rivet furnace to cast the new brickwork. · Stu and Cameron continued work on the planer. · Bob operated the water supply to provide treated water ready for Leviathan. I will not be providing an update next week as I will be out of circulation for a hopefully minor operation. Nigel Friday, May 18. 2012CGW X 38 Update - May 18, 2012Some research work has been done and thanks to the generosity of several owners of vintage images we are able to share them here with you.  Don Vaughn Collection Photo I really like this photo, and it is an early color image, shown here in Clarion, Iowa about 1950. I THINK this represents the second paint scheme our plow wore, still in the scheme with the classy Corn Belt Logo, but with air horns revised and wedge and wings painted black. Lettering and logo in white.  Don Vaughn Collection Photo As close to a builders photo as you will likely find, this is our plow as delivered to the CGW at Oelwein, Iowa in 1936. The headlight is covered for transit, and there is the temporary ladder at the plow end, an AAR requirement to allow crews to climb to the roof from either end.  Don Vaughn Collection Photo  Don Vaughn Collection Photo And these photos are true Builders Photos, but of the X 37, identical and one number lower than our X 38. Both images taken at the Russell Plow Works in Ridgway, PA in 1936  Rex Beach Photo, Joe Pierson Collection Finally here is great image of our plow in Oelwein, Iowa wearing what I believe is the fourth paint scheme in the many colors it wore. In this case almost everything was dipped in a bright safety orange color. Black numbering, no herald.
Thursday, May 17. 2012Wood Shop Update - May 16, 2012Is this report too long? Should I have divided it?  Engineering Department Rich Witt is back in the shop and very productive, as ever. Here he has made a new drawing and is laying out the needed cuts to make what we call dust shields for the TM 972 trucks. These are wood inserts that fit over the axles and behind the wheels to keep debris out of the journal boxes.  All Cut Up All of the blanks needed (eight) are made up with the next step to bore four inch diameter holes in them.  Taking Shape The iconic Great Northern herald is taking shape on the right side of our hopper, GN 70104. About another hour of painting will do it, completing all lettering on the right side. Then, on to complete the left side.  Cutting Victor Humphreys completed cutting a slot in the next section of rusted out car sides on our wagon top boxcar, B&O 374065. Buzz Morisette brought in some artwork samples for choosing size and fonts to begin cutting the patterns for the lettering.  Fuse Box The crew was busy on Cleveland Transit System 4223. Here is a shot of a fuse box to be mounted on the roof, after cleanup and restoration. They were busy on several other tasks, not pictured here.  Snapshot in Time Henry Vincent and Gerry Dettloff look over the large restored photo mural of a Pennsylvania Railroad steam locomotive. Plans are underway to return it to the depot as one of our exhibits.  Inspection Father and son team, Randy and Frank Hicks are in the final stages of inspecting CA&E 309, something we do every year for every operating car. CA&E 309 has just come off the pit and looks great out in the sun.  Side Door Trimmings Gerry Dettloff shows the state of progress on Lake Shore Electric 810. George Clark is leading this project with help from others including Gerry and Henry Vincent.  Illuminating Pete Galayda and John Nelligan continue restoration of the steeple cab locomotive, Charles City Western 300. Here they are working on a headlight resistance box, something allowing the head light(s) to operate. And of course this was only part of the activity. What is that SOUND? Not making much of a picture, we heard a melodious thrumming coming from Chicago & West Towns 141. The car was 'hot' with 600 volts and the air compressor was working away. It had been tested for a short burst previously, but today ran for an extended period, checking for leaks, checking the cut in and cut out pressure settings on the governor, working the valves. A few minor leaks will need attention, but smiles all around at the end of the day. Monday, May 14. 2012Wood Shop Update - May 12, 2012 New Telegraph Station Volunteer Frank Carraro has been working to update the bay window desk in our depot to accurately portray a Train Order Station. Here, he has just re-installed several telegraph 'instruments' and the resonator. They are beautifully restored and are in working condition. If anyone out there wants to donate a pad of old train order forms, they would indeed be useful in this new display. We have a supply of the once common double sided carbon paper that was used for copying train orders.  Trolley Base Eric Lorenz is working with new volunteers Stan and Tom Bernacki on dismantling the old trolley base from the roof boards. This is the equipment that was on the Cleveland 4223 when it arrived from Toronto. We also have some of that area that was salvaged from a Boston PCC. Neither of them appear to be 100% accurate for this car as it was in service in Cleveland.  Stuff On to the quiz and prize portion of the program. What are we looking at here? OK, I give up. This is some of the electrical equipment that must be restored and then roof mounted adjacent to the trolley pole spring base (seen above) and before the hot lead goes down into the car body. There is a large capacitor which serves as a lightning arrestor, a coiled length of wire which serves to provide the inductance, a fuse box in serious disrepair, and two deteriorated wood planks which served as trolley boards on the roof.  Paint Victor Humphreys is applying primer to areas of the side of the B&O wagon top boxcar. Most of this area was wire brushed and cleaned by the famous TWO BERNACKIS. Actually, those new volunteers asked to help on this work. Welcome and thanks, fellas. FACES IN THE NEWS - - - -  Conductor Our reliable shop worker, Rich Witt, looks pretty spiffy as he dons the apparel and volunteers in train service on our operating railroad.  Time Warp Saturday was Scout Day at IRM and several docent led tours and events were being held. I happened to see this elegant lady from another time and place. Actually, Nancy Ring greeting visitors before they went on tours inside our private Pullman cars. Sunday, May 13. 2012Steam Department Update 5-12-2012Generally a successful and productive day in the shop. The best news is that Tom was sufficiently recovered to be back at the shop. A lot was progressed on 1630: · There was a change to the plans for the thickness testing as Ralph's brother will not be able to come back to complete this for several weeks. However, this is not necessarily an overall delay as we already have enough information to start reviewing the calculations for the form 4 (engineering analysis of the boiler) with Bob Hunter, who will prepare it; · We did an initial review with Bob, who is now working with the previous form 4 data to determine what operating pressure we should consider. I now have a bunch of "homework" to plot all the measurements on diagrams of the sheets. One benefit of the second set of measurements being later is that we can review these with Bob and decide if we need any additional data points on the main sheets before Tom next comes; · All the remaining sections of the boiler are now marked up with points for testing aside from the dome top. In view of the successful sand blasting set up noted below, it was decided that this part would benefit from sandblasting before we test it;
Hopefully we will have an "after" view soon !! · Collin and Jeff did close examination of the back head braces using a boroscope. These braces are of particular interest as it was calculation of the loads on these that resulted in the reduced operating pressure from 2001. They are very inaccessible (running from the top of the wrapper to the back head above the inner firebox and among a forest of crown stays). The conclusion is that their condition is excellent. The camera shows no sign of wastage and, where we can get to them with a micrometer, they are still pretty much at the size shown when the boiler was built in 1917. So, if the conclusion is that these are not considered sufficient for 180 psi operation, it will be due to requirement for a greater safety margin than historically required rather than any wear or damage;
· Jeff and I worked on the firebox stays. All the stays must be proved to be sound either by demonstrating that a tell tale hole is clear thru to the head of the stay or by removing the cap and hammer testing. Most have tell tales that we have ensured are clear but a number are solid so must be hammer tested. This was a job approached with considerable concern as the caps look very rusted and, should they break as you try to remove the caps, the stay must be replaced. Each replacement would be a substantial job. Much to my surprise this task proved not to be as bad as feared. Having identified the outer ends of the stays to be examined we started heating each one and then tried to remove the cap with a wrench. To our great surprise, once heated, each cap unscrewed smoothly from its socket. The rusting is far more superficial that appearance suggests and, once heated and the cap removed, the stay head looks relatively clean. Building on our success in removing the required 9 caps on the engineer's side wrapper we tried some on the back head. While these do have good tell tales we were concerned from appearance that the sockets were so rusted as to require replacement. Again the experience was not only that the caps removed without issue but that the sockets are actually much thicker than they appear so few if any require replacement. Altogether a lot of potential work avoided.
The three lower stays, now with the caps released, looked like the row above earlier in the day. Amazing how much of the apparent rust damage is actually superficial. Elsewhere Stu, Matt and Glenn fitted the new cast face to the small rivet furnace. This is now ready to cast the fire brick interior. Once this is complete we can hopefully complete the cab for 428.
Bob has de-winterized the water supply ready for Leviathan, which is expected next weekend. Jeff and Phil set up for sand blasting parts outside using material recovered from the boiler cleaning. After a few issues with screening the used material, the process was established and proved using the hood of the Bay City. Now it is proved we can set up quickly and next week should be able to work on parts of 1630 and 428. Paul and Bob continued on the Shay truck. One small but time consuming job is caused by the fact that a number of the raised metal washers that stop the springs moving are missing. In this view you can see what should be two rows of 5 spring retainers. The wear around each shows where the spring resting against the bolster carried the weight of the locomotive. You can see in this view two washers missing leaving just a broken pin.
These prove to be held in place by rivets driven into a blind hole. This is no great problem where the rivet has pulled out but "great fun" where the rivet has sheared off and must be carefully drilled and then removed in pieces to make the recess into which a new rivet can be driven. One that was removed, as it was loose, shows the way in which the rivet expands into a groove to hold the assembly into place.
Significant progress was made on the bull rings for 428 where Mike was finalizing the machining of the third ring while Tom and Ralph were starting the fourth and last one.
Nigel Friday, May 11. 2012B&O Boxcar Update - May 9, 2012Spring is here and that means on good weather days, the Freight Department crew is at work in our outdoor 'shop'. Here is a sort of photo essay (not much text) on work this week, lots of participants and onlookers encouraged to learn and get a 'feel' for this sort of blacksmith work and tools involved.  Rust Out Gerry Dettloff is getting ready with an acetylene torch with Dick Cubbage and Simon Harrison looking on.  Cutting Some sections of the side at the bottom were badly rusted out. The first step here is to use an acetylene torch to burn off the old rivet heads. Gerry is using the torch and Victor Humphreys ready to help as needed.  Peeling The metal is being peeled back by Victor, Gerry, and Dick.  Next After cutting the rivet heads form the outside, shards of old metal siding and layers of rust are removed. Some additional grinding of the torched off rivet stubs might need to be done. Then out with the small sledge hammer and a punch pin to poke the rivet out the back.  The Stubs Not much left after the torching, but some medallions of remaining metal sides need to be peeled away, pried away, or otherwise coaxed to leave.  Punching Then on to the satisfying part of punching out what remains of the rivets. Sort of like an 'aggression therapy' session. Jim Leonard takes a turn. That entire section is complete. The next step is to fit and cut a new metal patch, drill it for placing new rivets, weld it in, grind, fill, paint - you get the idea. |
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Comments
Sun, 05-19-2013 22:13
Hello again. I had an idea that was (somewhat rudely, mid-sentence) dismissed in talking to a museum volunteer a few years back, but here it goes [...]
Thu, 05-16-2013 21:52
Looking good Bob! I hope to come out soon once I'm done with school.
Wed, 05-15-2013 21:28
I was not around at the time. General discussion suggests that it was "pretty marginal" in a number of areas. Nigel
Mon, 05-13-2013 11:08
"THUMBS UP!"
Fri, 05-10-2013 02:15
No, it will not be necessary to hold any of the work waiting for the plow to be turned, end for end. Weather will be the major factor, but there will [...]
Thu, 05-09-2013 19:54
The CGW X-38 plow is really coming to life. Bob Kutella and Vic and crew need to be very proud of your collective efforts. I am very appreciative of [...]
Thu, 05-09-2013 15:20
The snowplow looks great! Are you going to apply the door and upper windows befor it is turned to continue work?
Thu, 05-09-2013 09:09
Max, Is there any progress to report yet, in regards to the installation of the poles and overhead wires? Have a good day, sir.
Wed, 05-08-2013 18:40
Thanks for the update! I still don't understand why Commonwealth #5 was removed from service. Do you know why?
Tue, 05-07-2013 09:28
Mr. Kolanowski.....I was just wondering if the Spaulding webcam will be up and running soon for us stay-at-homes. Thanks!2FP
Mon, 05-06-2013 23:04
Max, Has work begun yet on the construction phase of erecting the poles and putting up the wire? Wish I could be there to watch it happen.
Mon, 05-06-2013 23:02
Keep up the good work, Bob. Wish I could be there to help!!!!!!!