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Sunday, April 10. 2016
After a week of planning, great progress was made on the turntable in the last ten days. This is critical as site clearing will start this month and we must have the table out before this happens.
JD and Phil travelled to Denver in a truck loaded with tools and equipment and have been working with Dennis and track contractors based locally.
The stages of the removal are:
1. Remove and ship the rails, deck, railings, circle rail and everything else that can be taken from the top of the main bridge beam;
2. Lift the main bridge beam from the pit and lay it on the railroad flat car that will carry it to Union;
3. Take the trucks and center bearing, along with the remaining ring rails that lie under the beam and load these for transport to Union.
A surge of activity early last week saw everything on top of the bridge beam removed, stacked and then loaded onto 3 flatbed trailers. By Thursday, all 3 were unloaded at Union. Many thanks to Dave and Carl for their efforts in unloading. Each trailer was unloaded in 45 minutes, which was an indication both of their efforts and the good work of the team in Denver ensuring that everything was carefully strapped and loaded.
Unfortunately, the weather meant that we have a future job. Heavy rain Wednesday night meant that we could not use the long term laydown areas for rail, ties, etc. and had to locate everything for outside storage on gravel surfaces. So there will be lot of relocating once the weather improves. However, the electrical boxes and other sensitive items are now all in covered storage.
After this rush of activity, the guys in Denver have been preparing the oak timbers that will be used to mount the bridge onto the flatcar but have now run out of work and are returning home.
Everything is prepared with heavy lift equipment lined up to lift the bridge from the pit and onto the flatcar. However, we must now wait for the flatcar to arrive on site, along with the idler cars that will travel under the overhanging ends of the beam. All this is ordered and in-transit via Union Pacific to the Burnham yard but it is currently expected to be late this week before they arrive. Once they do, there will be another rush of activity but, until then, there is nothing more that can be done.
Congratulations to Dennis and the team on a very successful job so far. Now we all wait in anticipation of the lifting and loading operation.
Thursday, March 24. 2016
I can now write about a huge development in the last few days.
A turntable has been a key element of the museum plan for many years. This will be the center of the long term plan to house and present our steam collection in a roundhouse setting. More than that it will present a fascinating visitor attraction, photographic opportunities and the ability to turn all types of equipment to present in different orientations to those with which we are familiar.
We have had on site for a number of years the C&NW table from Harvard. However, this is not of a length that would accommodate larger pieces of the collection. So various opportunities have been explored over the years to obtain a larger table, ideally thru donation. A couple of weeks ago we became aware that Union Pacific had included the table of the Burnham (Denver) repair facility, that we had hoped to obtain by donation, in an auction of all assets of this, now closed, facility.
This table was a target in many ways.
· It is one of the largest at 130ft. and capable of turning any equipment at IRM;
· It is an historic item, being a centerpiece of the Denver & Rio Grande works at Burnham;
· Dating from 1941, it was installed to support Challengers coming to the Burnham facility;
· In 2012 it was subject to a total refurbishment, believed to have cost at least $500,000, so is in virtually as new condition
· Despite its length it is of very shallow depth. This is a critical consideration at Union due to the high water table.
In view of this the board approved funding to try to acquire it by purchase at the auction.
I am pleased to say that we were successful and actually obtained the table at what was basically a scrap price of $10,000. This is our new acquisition giving some idea of its excellent condition.
Clearly this is just a beginning. We must now move it from Denver to Union, which is no small exercise and will cost several times the purchase price. Once at Union we will have to construct the pit in which it can be installed. This is a MAJOR construction project and will depend upon fundraising on a large scale.
However, as substantially the largest turntable in preservation, the expectation is that this will provide IRM with a major attraction in years to come.So watch this space. The next step is to get it to IRM.
Tuesday, March 22. 2016
Steam Department Update February / ... Posted by Nigel Bennett in Steam Department at 11:54
Another month of steady progress in the steam shop. There is rather less detail this month as I was away for three weekends visiting family in the UK.
Obviously the central focus is on getting #1630 complete in time for the start of operations in May. The regular work for the annual inspection continues in parallel with the major project of the valve overhaul.
The boiler and other work for the annual inspection is now largely done. A couple of weeks back, Phil cleaned and checked the arch tubes. After that the last of the wash out plugs were re-installed. Yesterday the testing of the pressure gauges was carried out so these can now be re-installed. The boiler will then have everything in place for the hydro-test.
We will now schedule this test with the FRA inspector. Once this is done we can conduct the internal inspection and, subject to any issues detected in testing, plan on steaming.
Obviously one essential part of the annual inspection is correcting those items that are considered out of or close to allowable tolerance. In this context, the spring loaded buffer on the front of the tender is was overhauled and the upper cross head bearing on the fireman’s side is being re-metaled.
The buffer has been cleaned, spacers made to take up the slack in the springs and painted. Yesterday it was re-installed onto the tender.
The tender is now complete and all that remains is to re-couple it to the locomotive by refitting the main drawbar. This has been removed, thoroughly cleaned and inspected for any cracks as required for the annual. Recoupling will be done as we prepare for steaming as this is best done by pulling the tender out of the shop and lifting the drawbar into place outside, where we have space to use the fork-lift.
A big job completed recently was casting the new Babbitt bearing for the crosshead. What does this mean?. Babbitt (alloys of tin or lead with copper and antimony) has been used for nearly 200 years to create a bearing surface against steel or iron. A favorable combination of relative softness, compression resistance and porosity, which facilitates the distribution of lubrication, mean that it is widely used for bearing surfaces to this day.
However, while modern usage is usually as a thin layer in a backing shell of a harder material, the more traditional usage made use of another property, low melting point. The metal melts around 400-500 degrees and casts well at 800-900 degrees. It will adhere well to iron or steel that is treated with a flux but not to a dirty surface. The principle is then simple. One iron or steel surface, normally a casting, does not need to be machined and is over-size versus the shaft or rod that moves against it. Molten Babbitt is then poured into the over-sized space in which it solidifies to form the bearing surface.
In the most basic form, the bearing is cast in situ. A smoky flame is used to soot the surface against which the bearing will slide, any gaps thru which the molten metal could escape are blocked and the molten metal is poured in. The contraction of the Babbitt as it cools provides a small clearance and the bearing should be ready to go with no machining necessary.
The bearing that we must replace is that in the top of the crosshead which bears on the slide bar. In theory this could be cast in place. However it was felt to be considerably safer and more accurate to cast the Babbitt in the crosshead shoe with some excess and then machine it to final size on the planer.
To do this the shoe, with a tray positioned in the center to make the “U” shaped channel, forms the mold.
The whole assembly is heated in the furnace so that the Babbitt remains liquid when it is poured into the mold. The shoe is tinned to help the Babbitt to adhere while the tray is soot coated to help it release after cooling.
Once the babbit had completely cooled, the tray was removed, the crosshead shoe was mounted onto the planer and Tom has started machining the babbit to its final dimensions.
Meanwhile the valve overhaul has progressed well.
Both valve chambers are now bored to size and the boring rig has been removed.
The valve rods were sent out to a specialist for surfacing to remove areas of wear that form over time as they run in the gland packing. These are now back and ready to start the reassembly of the valves.
The four cast iron blanks to make the new bull rings have now been machined to final internal and outside diameters. Needless to say, each of the spiders proved to be of slightly different diameters, so each of the blanks is now unique to one particular spider and therefore one of the four positions in the locomotive. They have also been tested in the bores and proved to be the required fit on the external diameter.
These are now off-site being machined to produce the finished bull rings.
Many happy hours have been spent in cleaning the spiders and valve bodies. It is essential to remove the hard carbon built up on these but, each has a small lip that secures the spring ring. So it is a long and careful process to carefully remove the carbon without causing wear to the lip.
In preparation for re-assembly the studs that hold the cylinder ends have been inspected and around 50%, that were excessively corroded, have been replaced. This provided interesting confirmation of the history of #1630. On the engineer’s side 15 of the total 20 required replacement but on the fireman’s side only 4 needed replacement. This is explained but the fact that, in the late 1930’s, she was involved in a head on collision with a Mikado, suffered heavy front end damage, and the FS cylinder casting was replaced. So the casting and studs on the ES are mostly 20 years older than those on the FS.
A minor set-back has been the conclusion that the bores need to be honed before the valves can be refitted. As with many things in the steam shop, this needs unusual equipment. Honing a 12inch cylinder requires a pretty slow turning motor. While we have such a motor, it has not been used in many years and proved to need overhaul before it could be used. That is nearly complete so the honing can hopefully be done soon.
Once this is done and the bull rings are completed, we should be able to start re-assembly of the valves.
Meanwhile work has progressed slowly but steadily on the Shay.
Work has continued steadily on the cab for #428. The riveting team have been making good a few final missing rivets. Dennis has been filling holes and shaping the roof to remove a few non-standard curves that it had developed and John has been painting and fitting the window guides.
In the shop.
So a lot of progress but still quite a lot to do for the start of the season. Watch this space.
Tuesday, February 9. 2016
Steam Department Update January 2016 Posted by Nigel Bennett in Steam Department at 19:56
A very busy month in the steam shop that can best be described as “so far so good”.
In the last blog I outlined the plan for work on #1630 this Winter. Thru January we have worked steadily on this plan. The discovery in December that the valve chambers were worn to the extent that both need to be re-bored turned the program for this Winter from one that looked relatively simple in comparison the last year into one that will be a challenge to complete for May.
However, we have now completed re-boring the first valve chamber (engineer’s side), which is a huge step. In this entry, I will describe what has been involved in getting this far. What we have found so far does suggest that, once this work is completed she will be substantially more capable than at any time since she arrived from Eagle Pitcher.
The detailed measurements of the two valve cylinders revealed a great deal of wear. The valve moves over a relatively limited proportion of the overall cylinder length (over and either side of the port openings. This means that the wear is very uneven over the length of the bore. In our case the worst area of wear (on the fireman’s side) was approaching 1/8th inch larger in diameter than the unworn areas of the same bore. This is well beyond tolerances that would have been acceptable during overhaul in steam days.
Each valve is a quite complicated assembly. This shows one complete valve just detached from its rod.
The seal between the valve and the cylinder at each end is made by two pairs of spring loaded rings. Each ring is made up of 4 equal segments. Between each pair of rings is a solid iron bull ring. It is the bull ring that forms the bearing between the valve and the liners of the valve chamber. When new the clearance between the raised section of the bull ring and the liner should be 1/32 inch. Not visible when the valve is assembled is the fact that the bull ring has extensions on either side of the visible bearing surface and about ½ inch below it. These form the base of the channels in which the spring rings fit.
At each end of the valve is a cast “spider” which has a central hole thru which fits the valve rod. The spider has a machined cylindrical body the end of which fits into the fabricated valve body. The spring and bull rings are fitted around the cylindrical body of the spider. When the components are fitted to the valve rod and the not tightened the bull rings set the spacing between the spider and the valve body and so set the critical width of the slots in which ride the spring rings. This is a very significant dimension as the spring rings must be free to move to maintain the seal but, as they are prevented from coming out of the valve only by small lips, excessive play can lead to a ring segment coming free and damaging the cylinder. The machining of new bull rings will be a careful and accurate exercise!.
The whole valve is assembled on the valve rod. The back of the valve assembly sits against a ring firmly attached to the rod. When the rods are separated from the valve, the retaining ring can be clearly seen
When assembled as below the ring is hard against the spider at the back of the valve.
The various parts of the valve are fitted moving from back to front and then the other end of the assembly is clamped into place by a nut threaded onto the front of the valve rod so holding the parts together as a single assembly. Here you can see the large castellated nut and cotter that clamps the assembly from the front.
Once the clamping nut is removed the front spider can be carefully driven away from the valve body. The amount of force needed varies depending upon the extent to which carbon has built up around the parts. Comparing this view to the previous one, the spider has moved far enough away from the valve body to open up the slot which traps the rear pair of spring rings sufficiently to allow the spring and rings to be removed. At this point the front pair of rings are still trapped in their slot between the bull ring and the spider.
Considerably later, the bull ring has been pulled off the spider releasing the front pair of rings and the old bull ring is now shown on top of the cast iron that is being prepared for machining to make the replacement.
With all rings removed the spider sits on its own and is in process of thorough cleaning to remove all carbon and allow the new bull ring and spring rings to be assembled onto it.
Similar cleaning is required on the valve body, here seen with both spiders removed.
Both valves have now been stripped to their components and cleaning of the valve bodies and spiders is well under way. We have new spring rings of various sizes that were obtained with the locomotive in the 1970’s. These were made in 1/16th inch increments between the nominal bore size (12 inch) and the maximum allowable re-bored size (12 3/8 inch). We do not have a complete range so the actual size to which we bore the cylinders will be determined by both what is required to remove the wear and reach a smooth, true bore and the rings we have available. The likely size is 12 3/16 as this is both slightly above the worst measured areas of wear and a size for which we have adequate new rings.
So far the ES valve liners have been bored. First the substantial mounts, that hold the bearing ion which the boring bar rotates, must be firmly bolted to to each end of the casting.
Once the mounts are in place, the boring bar itself must be carefully slide into the mounts. This is a fun exercise!. The bar must be very rigid as the objective is to hold the cutters so that they maintain accuracy of cut to within thousands of an inch along it whole length. This requires a bar of about 3 inch diameter. It took 6 guys to move it along the shop. So gently positioning and sliding it into position is no small task!. Just to make it more fun, the cutter head must be placed over the bar as it is fitted thru the rear bearing and before the bar can be pushed along the length of the cylinder.
Success. Here the end of the bar projects thru the bearing at the other end of the cylinder.
The boring itself is very difficult to capture. The gears that allow the cutter to be manually advanced and retracted, then locked to the screw mechanism to make the cut, have been attached to the shaft at the front.
An air motor then turns the shaft, with the cutter head attached, while the gears slowly turn a geared shaft running the length of the boring bar to which the cutter head is geared. In this way the cutter head is advanced a fraction of an inch at each rotation. Each cut takes about 30 minutes but it takes at least that long to accurately adjust the cutter head to required depth for the next cut
Once the actual re-bored size is determined, we can start to machine the new bull rings. These are required to be 1/32 under the bore size on their flat surface.
The bull rings and cylinder liners are made of cast iron, the wear properties of which were found most suitable for this application. This makes the first stage of producing replacements unusual. I suspect that, in steam days, blanks, from which the bull rings would be machined, were specially cast for the purpose and requiring limited machining to complete. Nowadays that is not economic on a small scale. Suitable rings are not available so we must start from a disk. The first step is therefore to produce the ring, of a suitable size for final machining, by cutting probably 75% of the total weight of the disk out of the center to produce a ring. This is a long and tedious process on the lathe, taking several hours for each ring. Brian has worked at this for several days and has now produced the 4 rings needed. All this was accomplished amid a deal of comments from the rest of the team around him going into the mass production of iron filings!.
In other areas
Works continued on producing the bracing that will allow us to rivet the smokebox of the Shay.
Good progress has been made on completing the cab of #428 to the extent that it is now being fitted with windows.
The large compressor for the new air system is now wired and was recently run in test mode. This was the first time that this compressor has run under load since it was salvaged from the Milwaukee Road shops many years ago. Testing allowed a number of adjustments to be made but also indicated the need to replace one valve and install an unloading mechanism. This will take a couple of week but then we should be ready for inspection and commissioning.
Thursday, January 7. 2016
Update on a locomotive you seldom ... Posted by Nigel Bennett in Steam Department at 21:15
Brian also provided an update on a locomotive that is rarely heard of.
In fact, we hope that this is a lead in to the sort of thing we hope to do more of in future. As space becomes available in the new barns in the South Yards, we hope to move smaller equipment stored partially stripped for restoration out of barn 9 so that larger pieces can be moved into this barn for conservation and cosmetic restoration.
Chicago, Burlington & Quincy 2-8-2 #4963
Everyone needs a day off once in a while. My trips up to IRM to work on the shay could, I suppose, be considered "vacation time". But even while on a work vacation I still need a break from working on the shay. But instead of doing what any normal person would do and take a day off away from the shop, I relax and unwind by working on little projects on other locomotives.
Chicago, Burlington & Quincy 4963 has become one such "little" project I have worked on for a few hours on each of my trips to IRM in 2015. The locomotive currently sits at the far south end of track 94 in barn 9. While the three other locomotives on display at the far south end of the barn--Milwaukee Road 265, the Pennsylvania Railroad GG1 electric, and DT&I 16--look quite nice cosmetically as viewed from the end of the building, the 4963 looked incomplete and out of place.
Looking at the locomotive every time I was in that part of barn 9, I decided there are a few things I could do to improve the appearance of the front end of the locomotive.
The smokebox was already years ago painted a light grey, and much of the piping, handrails, and such were in primer. The first step then was to paint the smokebox. The smokebox received a couple of coats of what is called Slip Plate paint. This is basically graphite in suspension in other chemicals that, when dries, looks very close in appearance to the graphite and valve oil mixture we use on 1630's smokebox, but unlike that paint it does not require heat to dry it. This Slip Plate paint is used in general industry as a lubricant, and is used by some steam locomotive operators as a smokebox paint. Following a couple of coats of this paint, all of the above mentioned parts on the front of the locomotive that were in primer received a couple of coats of black paint. This in itself created a remarkable transformation in the appearance of the locomotive!
Now the locomotive needed a headlight. While we do not have 4963's original headlight, fortunately for the locomotive there was one readily available. The past several years Phil has been putting a headlight on Chicago, Rock Island & Pacific 938 during the summer season. This headlight, while very nice looking on the 938, is not the proper headlight for the locomotive. We do have the headlight that 938 was retired with, and Phil has been working on restoring it to put back on the locomotive. The headlight that has been on 938 recently is, in fact, a headlight from another Burlington 2-8-2 from a class older than 4963. This headlight was brought out to barn nine and lifted onto the locomotive with the help of several Steam Department volunteers. So while not her own original headlight, 4963 now has a true Burlington headlight! The headlight was wired into the electrical power in the building, and now comes on when the lights in that part of the building are turned on.
The headlight looks great on 4963. However, there were no number glass plates in the headlight. Before my most-recent trip to IRM in October, I made two new number plates for the headlight. These were made by hand cutting individual numbers from heavy paper to use as stencils, then painting painting around these in black on plate glass, then covering the same side of the glass in white paint. This technique allows light from a bulb inside the headlight to shine through the numbers at night. There were several different techniques used to make number plates like these, such as using a metal or cardboard stencil between two pieces of glass, but my research shows this particular process was one of the techniques used on the Burlington. An additional piece of glass was placed in the brackets with each of these painted pieces to protect them, and special thanks needs to go to Tim Peters of the Electric Car Department for not only giving me the glass to use for this, but also for offering to cut it. Thank you, Tim!
At this point I thought it sure would look great if 4963 had a number plate on the front of the smokebox again. Luckily for us, Tom Schneider, curator of the Steam Department, was able to have a replica number plate cast years ago for the locomotive. The plate needed to have mounting holes drilled and tapped for bolts to secure it to the smokebox, then several coats of primer and black paint were applied, followed up by several coats of yellow lettering paint. Once dry, JD and I brought it out to the 4963 and bolted it on.
Now 4963 really looks like something to be proud of! I still need to add another coat or two of Slip Plate paint on the smokebox on the front and on the side the public sees, as well as several coats on the side of the locomotive facing the side wall of the barn. Over time I would like to add proper classification lamp holders and flag holders to the front of the smokebox. We have metal on hand that was cut long ago to make new class lamp holders. Eventually I hope to get these welded together and machined and painted. We have the correct lamps on hand. New flag holders would have to be cast. We have ones on another locomotive that are correct and can be used as patterns to have the new ones cast.
One nice feature on this locomotive's smokebox is a set of hinges that allow workers to open up the whole smokebox face and swing it to the side without having to remove it from the locomotive. Half of each of the two hinge assemblies are still bolted to the side of the smokebox. While looking around in the smokebox we found one of the two parts that bolts on to the front of the locomotive. We appear to be missing the other piece. If any readers out there know where we could acquire the other hinge piece, please let us know.
How much farther will we go on the cosmetic work on this locomotive? I don't know. Right now it is just being worked on as I have a few spare hours a few times a year, and that is how it will be for the foreseeable future. However, money also talks, and if you would like to see a little more cosmetic work done on the locomotive over time, a few more dollars in her restricted fund couldn't hurt!
Oh, and to answer the question which I know will be asked: Right now there is no plan to return the locomotive to operation. However, the locomotive has many good things going for it towards any future rebuild. The tender tank is in very good shape, as is the cab. The running gear is far from new and is missing a few parts, but is generally not in horrible shape upon initial inspection. The firebox also doesn't show any obvious problems upon initial inspection. However, there are many parts from in the cab missing, as well as the bell, whistle, auxiliary steam dome lid, and a list of other items. That being said, there is nothing I have seen to preclude its restoration sometime years down the road. And with her appearance improving, it is easier and easier to imagine what 4963 must have looked like in revenue service on the Burlington.Brian Davies
Thursday, January 7. 2016
Shay #5 from Brian Davies January 2016 Posted by Nigel Bennett in Steam Department at 20:34
Shay update, January 2016:
Happy New Year! My last report here regarding the Shay was back in September. I had fully intended to do a report following my three week trip up to IRM in October, but life has a way of intervening. It also doesn't help matters that I tend to like machining, painting, and mechanical work better than putting my thoughts on paper. But, here we go.
As Nigel has been reporting, great progress has been made since my last report towards returning the Shay to service. I will try to put some names down here to thank and acknowledge those who have helped on the Shay for all of their hard work. I will undoubtedly miss names, and to those people, I can't thank you enough for all of your continued help on this project. When you great blog readers visit IRM, please remember that everything you see running and restored is thanks to the hard work of our volunteers and the generosity of our donors. Thank you all!
On to the Shay. During my three week vacation work was progressing on the Shay on a daily basis. Many volunteers came in on weekdays when normally no one is in the shop, and this help really pushed our project forward. As Nigel has already given descriptions of much of what has been accomplished on the Shay during my three week "vacation" and leading up to today, I will attempt to add what I can to what he has already covered.
As of now all of the work to properly seal and form the ends of every boiler tube is complete. At IRM, we use the time honored, traditional methods of installing boiler flues used almost universally in the steam era. I can go into this process in further detail in a future blog if people would like, but suffice it to say for now that the methods we use take a lot of time, but result in a tube job that should give us a very well-sealed boiler for all 15 years of service until the next federally mandated boiler inspection.
One stay bolt was found to be broken the first time we filled the boiler with water, and a couple of days later it was replaced.
Trevor, with help from Ben, has finished preparing the inside of the water tender for painting with a protective coating. In the upcoming weeks Cody will be leading the project of painting the inside of the tender tank.
As Nigel has reported in previous shop reports, the boiler on the Shay has passed its federally mandated hydrostatic pressure test. This major milestone will now allow us to proceed with the jobs of adding parts back on the boiler.
The boiler on steam locomotives gets an insulation material applied to it. This is called lagging. Surrounding the lagging is a sheet metal skin called the jacket. We use a type of block insulation that, while quite messy and itchy to apply, works quite well and can withstand the pressure of engine crews standing on the jacket repeatedly while doing maintenance on the locomotive. Jerry has started the process of securing wires circumferentially and evenly spaced along the boiler which will be used to secure the lagging to the boiler.
The process of applying the blocks of insulation will begin shortly. This job consists of wiring individual blocks of lagging onto the boiler, one at a time, securing them to the previously mentioned circumferential wires to hold them in place. Once the insulation is applied, the task of refitting the jacket can begin. To prepare for this, several volunteers, including Jane, Ben and others, have been working to remove old primer and rust from the back sides of every piece of jacketing, and then priming and painting the back side to help prevent rust and keep the jacket in good condition. We have thus far held off on doing any cleaning up of the outside surface of the jacket, other than removing old grease and oil, until we decide whether to paint the locomotive over this winter or not. Painting takes a good amount of volunteer time that may otherwise be needed for other mechanical projects to get the locomotive into operating condition. If the mechanical side of the project continues at a good pace, some paint work may start in the next few months.
Once the lagging and jacketing is installed, work can then turn to reinstalling all of the piping necessary to make the locomotive operable. This includes water delivery pipes, steam pipes to the various appliances, and air piping for the bell, sanders, and brake system, as well as related brake control stands in the cab.
During the Shay's whole operating life, from the time it was built to the time it was retired from regular service, it burned oil as its fuel source. When the Shay was converted to burn coal by the Chicago and North Western Railway in preparation for its arrival at IRM in the late 1960's, an industrial grate system was installed. These grates performed generally well over the years. However, as they were not designed for locomotive use, they were at times cantankerous and hard to rock in order to clean clinker and ashes from them each morning. Also eventually, due to age and use over time, the grates would warp or break, necessitating periodic replacement. Around the time the locomotive was removed from service at IRM the decision was made to make the proper grates for this locomotive. To this end, Steam Curator Tom Schneider, following original Lima Locomotive Works drawings, made new wood patterns to have all new, proper, grates and side bearers cast. Phil and I spent time in the Shay's firebox in October measuring and laying out where the new studs will be welded in the firebox to support the new grate system. In the next few weeks the hope is that our welder Dennis, aided by Phil, will weld in these studs. Once this is done installation of the grate system and its associated linkage can be carried out.
Another large area of the locomotive, the smokebox, has seen a great amount of work done on it in the past couple of months. All of the holes needed to rivet on the new bottom portion of the smokebox have been drilled, and the bottom piece was bolted on, awaiting riveting and welding to the old portion. Several of the rivets that need to be installed are in an area inconveniently close to the frame of the locomotive. Because of these close confines, normal riveting practices are quite difficult. To make it possible to rivet in these areas, Tom and Dennis designed a special fixture that will allow us to use the frame of the locomotive to our advantage to aid us in driving the rivets!
Hopefully Nigel can describe this in better detail in a future blog update. Once the riveting is done, Dennis will weld the new bottom to the old part of the smokebox. Soon after this is done, installation of the superheater units and other front end pieces can begin. To prepare for this, our machinist, Eric, has been busy machining a few newly cast pieces that were made to replace old steam fittings for use in the smokebox that were very heavily deteriorated from years of corrosion and use.
There are always many, many small projects among the larger ones involved with locomotive restoration. One of these currently is replacement of several wood brackets used to secure lubrication piping above the motor unit. Over the years these pieces have rotted out to the point where they do little to hold the lubrication piping in place.
Phil and John have been working on replicating these pieces, and they should be reinstalled in the next few weeks.
Being away from the museum as much as I am can not only make it a challenge to manage a project in a way that moves a project along at a good pace and keeps everyone happy, but it is also frustrating when I wish I could physically do more to help while I am not there. Because of this I took on a project for the Shay that could be done from home. It was quite common for logging locomotives to have steam driven water pumps on them to use for firefighting for washing the locomotive, and I am sure for various other uses. Our Shay has had one of these duplex steam pumps on it most of its life. Unfortunately, when the locomotive was retired and before it came to IRM the pump appears to have been removed from the locomotive. In the early to mid 1970s, volunteers replaced it with a different pump. While not the same brand of pump the locomotive carried in service, the pump is an appropriate stand in. In fact, while doing research on this pump, I found that the pump is older than the locomotive! This pump has not been operable in the time I have been a volunteer at IRM (starting in 1995) and even Tom Schneider, who has been with IRM since the mid 1970s, doesn't remember the last time this pump was operable. For many years I have wanted to rebuild this pump and return it to operation. I started working on it in April of this year, and I am happy to report that its rebuild was completed on December 23rd; my Christmas present to IRM, the Shay, and the steam shop.
If there is interest I can write a blog about the restoration of this pump at a future time. But for now, I am excited that the pump is again operable, works well, and will be serviceable on the Shay hopefully for years to come.
Overall, work on the Shay is moving along at a fine pace. Much has been accomplished since my last report in September, and the list of things to do is growing ever shorter. We are still working towards the goal of seeing the locomotive operate in 2016.
As Nigel and I have both mentioned, we are actively seeking donations towards the rebuilding of the Shay. Nigel has informed me that since his last plea for funds several donations have come in for the Shay. THANK YOU!! We really, truly appreciate every donation we receive. I think perhaps us members don't always express well how much we really appreciate all of you who donate money to preserve and rebuild our equipment, but we couldn't do the work we do without your help. So again, thank you very, very much.
I would also like to say a huge THANK YOU to every member of the Steam Department who has helped on the Shay's restoration to date. Each of you will be to thank for the locomotive's return to service. This said, we always welcome new volunteers. If any of you reading this have thought over time, "Someday I would really like to go out there and try volunteering in the Steam Shop," well, why wait? The work is dirty and results can happen slowly, but there is a lifetime of learning available to those who are interested, and generally a good amount of fun as well. You don't need to know a thing about steam locomotives, but just have a willingness to listen, learn, and work. Come out and talk to us in the shop. There is always someone there every Saturday.
Whether you are a donor, a volunteer, or a visitor to IRM, thank you for your support, and here's hoping that 2016 sees us have two of our own steam locomotives in operation for the first time since 1999!Brian Davies
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CL Hogger about Its Here, Its big, Its long, Its needs lots of $
Sun, 06-26-2016 22:40
Do you really think a museum has ANY reason to install 2 tables?
CL Hogger about Turntable successfully unloaded
Sun, 06-26-2016 22:35
Maybe someday.... The sooner you donate to the Roundhouse Fund, the sooner it'll happen. Haha.
CL Hogger about From the Shays point of view
Sun, 06-26-2016 22:27
Raphael, I hate to bust your bubble, but the Shay has always had the wedge plow while it's been at IRM. While I dont know if it was a "factory option" [...]
Dick Cridlebaugh(member) about More from the Silver Pony Crew
Sun, 06-26-2016 21:50
It is good that Pony has a home. I am 80 and a great fan of CB&Q.I hope to be able to come there from East Peoria soon. Bob McCutchen(steam [...]
Ted Miles, IRM Member about From the Shays point of view
Sun, 06-26-2016 09:38
Roger, You all have a fine looking project there. But I while know it was the museum's first operating steam locomotive; i wonder about the [...]
Dave Cook about Steam Department update - Spring 2016
Sat, 06-25-2016 07:22
How is work progressing on UP # 428?
Kirk Warner about Steam Department update - Spring 2016
Thu, 06-23-2016 11:27
The steam department deserves high praise for the high quality of work which they have been producing. The videos that are out on YouTube of the 1630 [...]
Matt Maloy about Diesel Shop update 3/19/2016
Wed, 06-22-2016 18:25
I love hearing from the diesel department. Personally, I think the Illinois Railway Museum has one of the best (if not the biggest and most diverse) [...]
Nick about Steam Department update - Spring 2016
Tue, 06-21-2016 22:53
How is No.1630 doing?
Thomas Kaufman about From the Shays point of view
Tue, 06-21-2016 15:53
Bob Crosby was the engineer of the Shay when I first rode behind it. He was a close friend of my late Uncle Bill Girling of the CB&Q. I am sure Bob is [...]
Thomas Kaufman about From the Shays point of view
Tue, 06-21-2016 15:49
Roger, Really nice to see the Shay in the current condition. when I first started coming to the museum as a young lad in the late 60's this was the [...]
Raphael about From the Shays point of view
Mon, 06-20-2016 22:57
i don't recall the shay ever having a wedge plow.
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