Illinois Railway Museum Blog

It was a productive day at the steam shop although the weather was rather unkind, given our priorities.

On 1630 the whole focus was upon continuing the fitting of fire tubes.  As noted last week, our first priority was on trying to make the smaller air motor work with sufficient power to drive the tube rollers and so avoid trying to handle to the large motor in confined spaces.

Moving the Sullair to the North end and rigging a holding reservoir to assure minimal pressure drop as the motor works should have been simple.  It took Phil and me rather longer with a few challenges such as melting the wheels out of huge blocks of ice that had frozen it to the ground !.  However, Glenn's good work over the summer paid off.  The compressor starts well even at 15 degrees.

The effort was a success.  The smaller air motor with this enhanced air supply will successfully drive both the straight and flaring tube rollers.  This unimpressive looking reservoir, close to the locomotive, proves invaluable in maintaining pressure as the tube is rolled.

A reservoir close to the tool is critical

 The results were impressive.  We were able to both largely complete expanding the tubes in the firebox and reach about 25% completion of rolling at the smokebox end.

Tubing progress 02/16/2013

We now have just two tubes in the main area to refit.  We decided to expand all tubes before addressing the ones where the ferrule "popped" during expansion. Only one did so this week.  So we have that and the one from last week to refit before we have all fitted (aside from those between the super heater flues).

Rolling the tube ends is now a rapid process but is driven by preparation for the next step, which is flaring those tubes that are to be beaded after the first hydro test.  These need to be fairly accurate to 1/4 inch projection at each end and the flaring is more effective if the length is adjusted before this is done.  So, next week, a number of tubes that have excess length will need to be cut back to 1/4 inch with the angle grinder before flaring.  This was expected.  The tube sheets are not flat so each tube length is unique and must not provide less than the required projection, so you cannot hope to get each tube correct to 1/16th as they are fitted.

Tubes rolled into front tube sheet

Here you can see some of the tubes (for example the two just left of the lowest super heater flue) that project further and will need to be trimmed before flaring.

Tubes rolled into front tube sheet

Hopefully in the coming weeks we can get two teams working.  Once the smokebox end of a tube is rolled, the firebox end can be flared.  So it should be possible to have teams working in both firebox and smokebox at the same time.  The developing number of tubes with blue paint marks is an indication of substantial progress

In other areas:

·         The move of the McCabe was completed.  This location will allow it to be used without further movement but keeps it out of the way.

McCabe in it new location

·         Jeff managed to get the scissor lift moved to the shop despite the icy conditions.  This will allow work to start next week on installing the new air system into the South shop.

Scissor lift ready for use

A demonstration ride on the lift provided a rare opportunity for a look at work in the shop from above.  Looking the length of the shop, Jerry is relocating material to make way for the McCabe and, at the far end, work continues rolling tubes into 1630.

Aerial view of the shop

Looking toward the West wall, the team is working on the shaper.

Aerial view of the shop

·         Stu and Mike worked on reassembly of the planer.  Sorting out how the levers should link to the hydraulic control block appears to be a challenge judging by Stu's expression!

Do we have a problem?

So, overall another week of good progress.

Nigel