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Thursday, February 20. 2014
Steam Department Update 02-15-2014 Posted by Nigel Bennett in Steam Department at 09:31
The report this weekend is entirely second hand as I have been on vacation in Mexico. Thanks to Jim, Phil and Collin for detailed input. The common theme seems to be that, with Nigel out of the way, there was a good turnout and they were able to get a lot done.
As ever, the primary focus is on 1630 and getting everything in top shape for the season:
Jerry spent most of Saturday scraping grease off the frame on the fireman's side of the engine.
Jane put more of the frame in primer. She also painted the portion of the frame that was already put in primer by Jeff.
Trevor crawled under the boiler and cleaned the interior of the frame.
Jim painted one of the two remaining wheels on the engineer's side and the two back wheels on the fireman's side of the engine.
Jane and Jim also put the last wheel on the engineer's side in primer.
On Sunday, Jerry and Jim gave the fireman’s side frames and wheels a final power wash to get ready for full priming on that side. As part of this they tested the painting of the wheels on the engineer’s side. We had some doubts as the paint used is really old but seemed to apply and adhere very well. It also passed this test with no sign of any flaking under high pressure washing.
Intensive work started on the smoke box where we need to fit a thicker gasket on the front ring and Dennis has to fit the spark arrestor assembly into the box.
Removing the appurtenances from the front of 1630 was challenging due to the weight associated with the bell and smoke box door & ring. Typically, we would prefer to use either the large CAT forklift or, preferably, the boom truck to effect such moves, however, that equipment is currently inaccessible due to the accumulation of snow around the property. We therefore made the most of the small shop forklift, which Ralph maneuvered around. Rick, Eric & his Dad rigged the bell and Ralph lowered it down.
Phil & Paul worked on the new smoke box baffling and hardware. This had been assembled in the fabrication area and then had to be disassembled, brought up front to the locomotive, and reassembled. During this time Eric & Collin worked on burning out the netting channels and Paul finished up by grinding to smooth the smoke box interior. Dennis will now be able to plan the replacement of the mounting hardware.
In the evening
Dennis worked on the weld repairs to the cab sides and roof interior.
On the Shay:
Ralph, with help from Jason, removed several brake rigging pieces to allow for access to stay bolts on the throat sheet.
Despite the appearance he is not cutting the rigging but heating a rusted nut to allow its removal. This is a common technique that usually allows even very old and rusted nuts to be removed without sheering the bolt or stud.
After this work the firebox front is clear for work on the stays.
Dennis worked on the welding of the boxes and pedestal braces. Work progresses on all of them at once as the most effective method is to weld one until it gets too hot then move on the next. By the time the 4th is too hot you can move back to the 1st.
On Sunday Tom, Cameron, and Philip all worked on machining various parts including the brake rigging.
In other areas:
Jerry and Bob about the planer tried longer bolts in the pump block and this seems to have overcome the problem of the gasket blowing. There are still minor leaks but, unfortunately the table still does not show any sign of moving under pressure. It is hoped that we have found an outside expert who may have some experience of this type of machine and is willing to come by and advise.
Hopefully this coming weekend we can do as well as this with me around, otherwise I will really start to wonder!.
Sunday, February 9. 2014
Steam Department Update 02-08-2014 Posted by Nigel Bennett in Steam Department at 16:17
Back again after a week’s gap. Last weekend was the worst yet. Saturday working was cancelled on February 1st as the forecast suggested so much snow. In retrospect that may have been overkill as we did work yesterday when more snow fell than actually arrived the previous week ….. the forecast just did not seem as bad!!.
I have been out at the museum more this week as I take on the role of museum Treasurer. The museum site is an incredible Winter wonderland. Dave and the B&G team have done a great job keeping the roads open. He was saying yesterday that the plough truck has run about 220 miles so far this season simply clearing on site. However each working day we have to dig our way into the shop, clear drifts to get to equipment like the compressor and any idea of moving equipment or getting at boxcars or containers is a joke. There are considerable drifts or barriers of ploughed snow everywhere you look.
Anyway, Phil and Tom braved the elements last Sunday and did some work on 428.
This Saturday I was heavily involved in the Board meeting and some follow on Treasurer activities so was not very productive in the shop. However, there was a good turn out and substantial progress.
The major step forward was reaching general agreement of the plan for painting. This does not sounds much but is actually rather complicated. We have two (or effectively three) methods of painting different areas. Large parts of the loco will be sprayed. However, there are substantial areas that are so confined and irregular in shape that it seems impossible that a decent finish could be achieved with a sprayer. So brush painting seems logical for these. (The third category is areas in so deep and covered in grease that the logical approach seems to be leave well alone, for example the leading truck frame). The whole process is complicated by the fact that, while everything is painted black, it is expected that the two painting methods, using different materials, will show shade differences. So we do not want the two methods used directly next to one another.
The final plan is that the wheels and frames will be brush painted while the upper works (cab, boiler, tender) will be sprayed. The wheels were a particularly tough choice. There is no doubt that 4 and 5 could be sprayed. Also 3 could be sprayed, but would require several moves of the loco to get at all the spokes. However, 1 and 2, heavily concealed behind connecting rods, cross heads and slide bars would be a near impossible target for spraying. (The picture below of #1 is taken looking vertically down behind the slide bars so imagine getting at this with a substantial sprayer!). So all will be brush painted as the likelihood is that a shade difference would be very obvious if we sprayed just the ones we could.
With this done progress started to become visible.
Jim had brought in a much more powerful pressure washer. He and Jerry did a further degreasing run on the frames, wheels, and everything that was not in the leave well alone category.
Following this preparation much of the lower part of the locomotive is now assessed as ready to be primed once dry or requiring just a small amount of wire brushing to allow priming. (A key part of the need to agree how each area is to be painted was that the spray epoxy does not require a primer while the brush applied finish does).
Substantial areas were dry by afternoon. So painting began with priming the wheels. While Jim did most of the work, our General Manager came by the shop and spotted the need to fill in a gap. It is a rarity to seem Jamie at work in the Steam Shop so we have recorded this event as our ceremonial first painting on 1630.
By end of day three wheels were primed. The ability to start painting created a lot of enthusiasm. I received the picture below from Jim. By Sunday several of the wheels are finished with the black top coat.
On the superstructure, part of the preparation for spraying is removal of pipes that will create shadows when spraying. One of these is the steam supply for the air pump that runs from the governor high up on the fireman’s side of the firebox.
Collin needed to re-lag this anyway so he and Paul managed to release a union and remove it. As with lots of things on an old steam engine, one thing leads to another. It was obvious that moisture trapped in the lagging had caused some corrosion on the steel pipe. After thorough wire brushing and hammer testing no obvious failures were found but it was clearly not in good condition so the decision was made to have a replacement fabricated. In matters like this we want to avoid any doubt and there is currently time to have the replacement made before the season.
Jason and Phil worked on the manifold for the stoker. The casting was damaged and Dennis fixed this some time ago. The threaded holes into which fit the steam connections had to be recut and then the steam connections fitted. By end of day the manifold was ready to refit.
As a “British” fireman who has never seen a stoker in operation I learned something. The stoker on 1630 is not operational at present as the screw drive in the tender needs work. So I had assumed that the steam manifold (which controls the jets fire the coal around the box from the distribution plate) was simply decorative at this time. It seems this is not so. If the fireman is feeling tired he can put coal onto the distribution plate manually and then use the steam to fire it up to the front of the firebox. You live and learn!.
I did my penance for spending most of the day out of the shop by crawling into the firebox to test fit a sample of the new fire brick. Although I spent days in there when fitting tubes, fitting the fire hole door casting has made this a whole new experience. What used to be a simple exercise is now more like getting toothpaste into a tube for one of my build. Anyway the conclusion after Jason and Phil had put in a few more of the arch bricks is that the shorter F5 bricks, that are readily available, cause only a marginal lift in the arch bricks so should be usable.
On the Shay, Phil took advantage of the degreasing set up for #1630 and did a thorough job on the truck. Hopefully, once dry and examined, this will also start to see new paint applied.
On #428 quite a lot was happening:
Dennis started the long job of building up the axle boxes. The first step, on which he was working yesterday, is to build up the damaged areas that will be behind the plates which will be added to the box castings. Once built up, these areas will need to be finally ground to shape so that there is a solid surface to which the plates will be mounted;
was back after his trip to Arizona and restarted work on the air pump. Not much visible progress today. The first big step was to locate the many
substantial parts of this 3 dimensional jigsaw and work out exactly how they
must fit together. What fits where is only part of the challenge. It is immediately clear that it would be very easy to assembly a lot of it and then discover that a key part should have been fitted earlier in the sequence!.
Jane was hard at work on the frame binders that join the frame at the bottom of each axle box guide. Dennis has done a good deal of repair work on these and they now need to be cleaned off, ground smooth and then machined to fit accurately into the frames.
In the shop in general:
It was a worrying day on the planer. Mike, Bob and Ed worked on preparing it for a further test of the hydraulic drive system while Jane completed painting the machine. Unfortunately a second attempt to start the hydraulic pump caused a blow in the gasket that failed last time, although we are now confident that the surfaces are flat after surface grinding. This leaves us with a puzzle. Documentation of this machine is distinctly limited. We know it should operate at a high pressure (suggested around 1200psi). The key question is whether this seal is failing at a pressure at which it should not or if some blockage or error in assembly is causing pressure to build substantially above the intended level. Needless to say there is no tapping that would allow us to fit a gauge.
So back on the job and a lot was achieved in the day. I am off to Mexico for a week so will miss next weekend but look forward to seeing a lot more paint when I get back
Sunday, January 26. 2014
Steam Department Update 01-25-2014 Posted by Nigel Bennett in Steam Department at 16:03
Well, I am glad to say that the continuing atrocious weather seems to have increased the determination of the steam shop volunteers. We had an excellent turnout on Saturday and made good progress on some items that have been holding us up for a while.
One large team focused on preparing the cab for spray painting.
The edges of the cab sides where there were signs of blistering in the paint were all needle chipped. This revealed a few areas where Dennis will need to make good some holes and cracks. Nothing too major but we do want to get this thoroughly sound before we paint;
The arm rests were removed from the window frames … and identified another job. The wooden base of one of them looks more like sponge than timber. That will need to be remade;
A section of the inner cab lining on the fireman’s side proved to be corroded thru. This was cut out, the rust and scale removed from between the inner and outer sheets and the whole area primed. Dennis can now weld in a new section of sheet metal;
The cab sides were rubbed down ready for painting.
A big area of concern has been preparing the frames and wheels for painting. Ideally it would have good to have blasted the grease and oil from these using the high powered steam cleaner. Unfortunately the extreme weather is against this. There are serious doubts around the practicality of using the steam cleaner in the shop and the obvious concern over how long it would be before there is any chance of moving outside again.
Jim, Jerry and Vince decided to try the liquid degreaser that was obtained for the Shay truck. This proved very successful.
One or two passes with subsequent washing off using a small pressure washer took large areas of the frames and wheels back to bare primer that we had never seen before. We are unclear whether these areas were not previously painted black or if the top coat was so badly adhered that it came straight off with the grease. However, it is certainly clear that the method is getting back to a sound and grease free surface.
Hopefully a second session next weekend, with a more powerful pressure washer to do the final washing off, will bring much of the lower part of the locomotive to a suitable condition for painting.
Jason finished testing all the cab gauges and also trained Phil in this operation.
One of the gauge faces is much worn. It raises a question of how it was originally painted. All the black lettering is indented, even the fine detail of the maker’s name.
On the Shay:
Eric and his Dad worked steadily thru the job of fitting the long bolts thru the frame and truck pivot casting. By end of day, all six of the bolts were properly fitted. Nuts are noticeable by their absence !. Tom did not make it to Union because of the weather but a telephone discussion indicated that supplies of 1 inch nuts were likely to be in the container. Ah Yes!. That thing sitting out behind the 3 foot snow drift at 10 degrees in a gale !. Nuts will be for another day;
The bolster was turned over and Eddie cleaned the other face to allow it to be primed.
In the shop in general:
Stu and Bob finished painting the planer, which Phil and Jane had progressed over the last week. Unfortunately it was not possible to reassemble the valve block and test the machine. The distorted face of the valve block has been surface ground to ensure that it will seal but was in Tom’s car in Chicago.
They then worked on rebuilding the lubricator for another of the machines.
Phil has now made a big difference to the storage area and is planning what to do with the adjacent areas..
So overall a pretty successful day.
Sunday, January 19. 2014
Steam Department Update 01-18-2014 Posted by Nigel Bennett in Steam Department at 12:21
What a year!. Another Saturday somewhat disrupted by the Winter weather. There was a reasonable turn out at the shop but a lot of people left at lunchtime as the rate of snowfall increased. For those of us that stuck it out, the snow did cease by evening and the slither down US20 to the expressway was what we are becoming used to.
It was definitely a day for work inside the shop and the absence of some key people and parts meant that testing of the paint sprayer could not proceed. However work progressed in a number of other areas.
Matt primed the area of the engineer’s side walkway that was cleaned off last week;
On the Shay:
In the shop in general, some significant reorganization was achieved:
So overall a successful day despite the weather.
Sunday, January 12. 2014
Steam Department Update 01-11-2014 Posted by Nigel Bennett in Steam Department at 11:28
A rather more normal weekend allowing quite a lot to be done in the Steam shop on Saturday.
All credit to the team that made it to the shop. The main roads were fine but the local roads toward the site were rather icy in places and the museum site is a nightmare. Although the air temperature was above freezing, the ground is still frozen. So, despite efforts by B&G, large areas, including all the roads and walkways around the shop were thickly covered in smooth wet ice!. The team cautiously slithered their way from cars to the shop and stayed inside !.
I spent the morning at the Board meeting but the team got to work and a lot was achieved.
By the time I got back to the shop the small air tank was already back in place on the locomotive. So we are now able to power the reverser with compressed air to allow the measurements of the piston valve rings to be made;
Eddie and his sister made good progress in preparing the walkways for painting. Jane is setting up to prime these next weekend;
The paint sprayer has arrived but unfortunately the correct nozzle for the material we have to spray was not available until next week. Anyway, we have the machine and will hopefully be able to do the first test run next weekend;
We are hoping to avoid having to reapply all the main lettering so Jim was hard at work masking the cab lettering;
Phil and Jane removed the blower ring from the smokebox so that Dennis can start on fitting the new plate work for the spark arresting system;
The pressure hose for the injector overflow / cab wash down (what I as a Brit would call the slacker pipe) arrived and was fitted;
Jim and Jane primed the first of the main air tanks;
Eric loosened the nuts on the smokebox front and hand rail. We are preparing to add more gasket material to this joint as the seal was not as good as we would like during the test run;
Jason and Collin finished cleaning and reassembling the steam regulator for the air pump. Jason decided not to refit it but rather to duct tape the pipes to which it is fitted. Having produced this nice clean brass regulator he seems a bit sensitive about it being in place when people are spraying paint around it!.
On the Shay there was quite a bit of activity:
Phil finished caulking the rivets, both below and inside the smokebox. This was a lot of work but the result is a very neat job. Well done Phil. Another big benefit to completing this is that the rest of us can now work around the shop without our teeth suddenly starting to rattle in our heads as he uses the air hammer;
Jason and Eric made good progress on reaming and threading the holes for the crown stays that are being replaced and were able to test fit some of the new stays.
With no further swaging planned for some years, I finally took down the swaging machine for storage. This will allow much easier access thru the doors at the South end of the shop. The machine and the mounting timbers were marked with paint to provide a clear pattern for reassembly when next required and then it was taken down for storage.
With a bit more reorganization we will be able to fully use the door again.
So a good day of progress. Hopefully if the weather remains moderate we can get the painting under way next weekend.
Saturday, January 4. 2014
Steam Department Update 01-04-2014 Posted by Nigel Bennett in Steam Department at 20:13
Well the first weekend of 2014 proved to be a virtual wipe out (or maybe white out) in the Steam Shop and probably most other areas of the museum. The forecast made it clear that snow and brutally cold temperatures can be expected Sunday thru Tuesday but I had hoped that the snow was not to arrive until afternoon / evening on Saturday. This looked plausible on the drive out from Chicago but, once I left the expressway, the last 8 miles to Union was an unpleasant surprise. Wind was whipping drifts across US20 and it certainly looked as if new snow was falling even at 9 a.m.
The museum site was challenging. The few who made it had to break thru a drift at the gate and dig their way thru a drift at the trolley loop crossing by barn #9. 5 of us made it to the Steam Shop and I found a similar hard core at the Car Shop.
We did a number of jobs to prepare for testing of the paint and spray equipment next weekend:
The small air reservoir was moved back beside the locomotive ready for fitting;
Jane painted the walkway and supports so that we can refit this tank next weekend;
The two large air tanks were moved to the South end ready for painting.
However the major task turned out to be the response to a phone call from Phil who, in attempting to be the 6th shop volunteer had ended up in a ditch on US20. Luckily Eddie has a 4WD pick-up so he, with Collin, Rick and a couple of sets of shop chains, went to the rescue. Having got Phil back on the road they were also able to pull out at least one other driver who had encountered a similar problem. US20 was deteriorating rapidly.
So, having completed the jobs above, we headed out at 11:30. There was little sign of improvement and a definite forecast of much worse late in the day. Much as we love the museum, I do not think anyone liked the idea of being stuck there for a couple of days that threaten record low temperatures.
So we can only hope that the weather next weekend is more helpful.
Sunday, December 22. 2013
Steam Department Update 12-21-2013 Posted by Nigel Bennett in Steam Department at 12:08
This Winter is becoming a bad joke !. Today was the official start of Winter but we have been in the deep freeze for several weeks. Amazing to look back and see that this time last year we were working outside on the KCS tender that had recently been unloaded. This year we had a crew much reduced by a forecast of a substantial ice storm reaching Union in the afternoon. In practice, although the forecast caused several people to leave in the early afternoon, the air temperature held up better than forecast and the last of us were not driven out until 7, when the rain started to freeze on the cars.
Setting foot outside the shop was an adventure all day as the ground was well below freezing and any unsalted areas were simply sheets of ice which built up further as the rain fell.
However, in the shop we were able to progress steadily.
On the Shay, Phil and I worked with Tom to plan the next
steps on refitting the front truck. Six
large bolts need to be acquired and fitted to secure the casting in which the bolster
of the truck pivots. The holes for these
need to be reamed to allow the long bolts to be fitted. Phil will caulk the rivets that were placed
several years ago so that Dennis can go
ahead with refitting the smokebox bottom sheet.
Elsewhere in the shop:
So more steady progress despite the weather.
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