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Sunday, January 27. 2013Steam Department Update 01-26-2013Steady progress on a number of fronts in the steam shop this weekend. There are no photographs this week as I spent most of the afternoon inside the firebox with an air hammer !. On 1630 it was a case of pushing on with the same key tasks:
· We had a setback in the morning when the new tube roller, that had finally arrived, proved to be too small in diameter for the firebox tube ends. The intent with the new roller had been to simultaneously seal the tube end into the tube sheet and make the flare, which is the first step towards beading the end of the tube. Plan B was therefore adopted !. The expander can be used to fully seal the tube ends into place. It is just a slower process requiring a good deal more heavy work from the operator, which my wife would probably say is a darn good thing in my case !. Essentially, instead of air hammering each tube once to set it into place, fully sealing the end requires that you do this three times. Each time the expander must be released by hammering the central pin, turned a little, hammered back into the tube end to seat it and then air hammered again. Using this method, by end of day, we had set all but a few tubes higher up on the fireman's side. All the tubes we set this weekend were subject to the full process so they are sealed and ready to rolled in the smokebox to seal them into the front tube sheet. (The firebox end must be fully sealed to ensure that the tube cannot move before the front end is rolled ). In addition a number that had been set last week were fully sealed. The objective of this approach is that we now have a substantial number of tubes that can be sealed into the smokebox tubesheet, so that we can keep on working in the smokebox when the patch team needs access to the firebox. · This week we had free access to the firebox as Dennis and Mike were finalizing the remaining holes in the patch away from the firebox. The patch should be ready for final fitting next weekend. · Ed continued with the pipe fitting. We have now reached the stage where I have to locate the pictures of how the cab fitting looked before stripping so that the cab end of the new pipes can be set up correctly. · Richard and Lorne removed the timber supporting the cab awning. That became a fairly brutal process. Since it was held to the cab by coach bolts and the timber had rotted, allowing the bolts to turn, cutting the nuts off in the cab was about the only method of getting the timber off the cab; · Vince was setting up for machining the spacing ring that we need to fit one of the super heater flues. No one is real clear why but the hole for the top right super heater flue is about 1/4 inch bigger than all the others so requires a spacing ring when the flue is rolled into the sheet. In other areas: · The decision was taken to set up the new compressor as a direct replacement of the existing one. That means we will not set it up fully until the weather improves. However we will need to ensure that it is fully tested before we start the replacement as we will have nothing but the Sullair as an air source while we do the switch; · Lorne continued the cleaning of the Shay truck. Hopefully we should be able to finally inspect and repaint that shortly; · The new high pressure line for the planer was assembled; · A number of tasks were progressed on 428: o Tom is working on machining the new axle box wedges on the shaper; o Jerry continued grinding out the axle box channels in preparation for welding in the reinforcing plates; o Work restarted on reassembling the air pump. Nigel Sunday, January 27. 2013Wood Shop Update - January 26, 2013Here is another report, heavy on photos, aided and abetted by images taken by Jon Fenciki, and just a whole lot of activity by the volunteers.  Jon Fenlaciki Photo This a a very good example of how projects should work in the shop. Four days ago Jon Fenlaciki brought in a window that needed repair, from Indiana Railroad 65. We noted what we thought should be done and supplied info to Jon on purchasing new wood. Jon did exactly that and delivered some new mahogany Saturday morning. Before you knew it the stock had been roughed out and planed, and here - Bob Kutella, Rich Witt, and John Faulhaber are setting a jig for cutting the stop cuts for new tenons. Jon was on the spot, making decisions as needed and helping with the work. A real team effort.  Tenons The tenons are being nibbled away by Rich Witt and John Faulhaber on the table saw.  New Bottom Rail Rich has the new bottom rail complete, ready for final fitting, while Jon displays the original piece, the reason for the work.  What Is It It is always good to throw in a quiz question to see if the class is paying attention. What is it? Maybe some peanut butter and a glob of creme filling? See next photo for the surprise answer.  Jon Fenlaciki Photo The new bottom rail has been fitted and the window reassembled. Rich Witt is using an epoxy product that is both an effective adhesive and also serves as a wood repair filler. The window is clamped up and will be ready for sanding and refinishing the next visit to the shop by Jon. Our new motto - "One day and done!"  Caboose Grab Iron Victor Humphreys is making some final fit checks and careful readying three end fittings for welding to the curved caboose grab iron. A lot of metal grinding and filing, foreign to a sawdust maker like me. It is looking good.  More Window Work Victor Humphreys and William Peterson are busy completing the gray primer on all eight new windows for Chicago Great Western X 38.. Bill is a relatively new volunteer in the shop and seems intent on completing his 'apprenticeship' and joining the old hands club. Thanks Bill  Set Up We finished up a lot of 'small' projects early in the day before quitting time, so went on to the next steps for the two new doors for CGW X 38. That means setting up the mortising machine to plunge many slots in the door stiles and rails. William Peterson is making and installing new wood blocks for the 'hold down' clamps on the mortiser. Basically, almost every job is a different size and set up, and it takes some small time to get it ready. Set up complete, we made two mortises and hung an OUT TO LUNCH sign on the machine.  Molding Work Now to continue the story of Chicago Rapid Transit 1024, from last weeks report. Tim modified (sacrificed) a carbide router bit and ground it for the custom profile needed for the "UPPER" tack molding on the 1024. That is the piece that finishes the edge of the large flat roof, while a similar but different piece is needed alongside the hip roof areas, that called the "LOWER" tack molding. The best product is very long pieces of stock to minimize joints in this rail. It takes many hands to to this work carefully, here done by John Faulhaber, Fred Zimmerman, and Tim Peters.  Finishing Fred then hand sanded many pieces of this, and finished the effort with prime painting all of them.  Mock-Up It can be difficult to visualize how a project's parts need to be made and to go together. Here is a mock up of a key element needed for the next two windows for Boston & Maine 1094. The small heel or haunch on the side stiles will support and anchor the rounded top rail. We used a variety of steps, jigs and tooling to make this part shown by Rich Witt.  Molding Buzz Morisette is slicing thin strips of oak on a bevel cut. These will be replacements for damaged ceiling moldings in the private car ELY.  Jon Fenlaciki Photo Dave Fullarton, Greg Kapka, and Richard Schauer were in the Barn 4 pit working on the group switch underneath rapid transit car CTA 2154. As usual a lot of other work going on in the shop and around the property. I did not catch a pic of this, but we finished running six windows for heavyweight passenger car Illinois Central 3996, working with Roger Kramer, and also completed and surfaced the first of the door panels for the new CGW X 38 doors.
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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!!!!!!!