Cleveland Transit System 4223

Trim Panels

Dick Cubbage and Dave Rogan are discussing methods to remove many layers of paint (and rust below that) for two trim panels that go over the last two side windows at the rear of the car.

Sparks Flying

Dick is not one much inclined to 'watching'.  In short order he was out in the barn and the sparks were flying!

A Tutorial

Simon Harrison watches as Dick gives a tutorial on the finer points of this work.  No, it is not simple grunt work!

It Takes Two

To Tango?  Maybe for the dance but more hands here make for fast work.  Simon and Dave were both in a sort of competition cleaning the sheet metal so it can be prime painted this weekend.

Glistening

These are barely recognizable compared to how they were a few hours ago.  See the first image in this entry.  These have almost a mirror finish and are typical to the ten items completely stripped today.  Not that I was counting - they may have done more than that.

This entry will be picture heavy - we accomplished something with the reinvigorated and larger project team that has been in the works for some time.  Inside the car body is a large sheet metal ceiling panel for the rear end of the car.  We have been tripping over it, moving it, and even cleaning and priming it.  But it is too large to remove from the car for storage elsewhere, so the logical step is to install it where it belongs.

Up in the Air

Here the so called 'clamshell' is already up in the air.  Shown is Frank Sirinek fastening new screws into the rear margin while Dave Rogan mans a brace to keep it in position.  The exciting part was getting six guys into a cramped space to do the heavy lifting and wrestle the ungainly piece into place.  Lorne Tweed, Dave Rogan, Frank Sirinek, Buzz Morisette, Victor Humphreys, and Bob Kutella helped.

Screwed

There are a precious few screws holding the rear edge into place, while Dave Rogan and Lorne Tweed try to align and place some fasteners along the front edge.

Advice

Lorne is adding more screws while Frank Sirinek offers advice.  Frank might justifiably be nicknamed "Mr PCC" on site and he cheerfully stopped what he was working on and joined the crew.

Almost There

I said I took too many pics, this one from the outside through a window while Frank, Lorne and Dave add more screws.

Priming

In the shop, Simon Harrison was applying new primer to some of the panels cleaned last weekend and is explaining the finer points to Dave Rogan.

Done

So here it is, looking for all the world like it has been there all along.  But a milestone nevertheless as the restoration moves forward.  NEXT?  There is another 'clamshell' waiting for attention, to be installed in the front end.

Electrical

Eric Lorenz and Lorne Tweed are going over an electrical cabinet that lives below the front dash at the end of the car.  The old one is in pretty sad shape and a lot of the framing and cabinet work will need new parts fabricated.  This step is all part of the work needing to be done and getting wires pulled, before installing the new glass windshields and painting that area.

Innards

Here is a better look at the switches and fuse blocks that live in the above cabinet.  Sketchy schematics, lots of cut wires, missing elements and fuses.  Did I mention it was dirty?

Windows

Of course we need to mention windows in any such BLOG entry.  Alex Randow works on these pretty regularly and he is checking the growing pile of completed sash.  17 large sash and 18 small sash are now complete.

Panels

Alex also worked on cleaning up several old panels and trim work needed for the car interior.  These represent items in good enough shape to re-use, and as explained previously, several items need to be re-installed before the side window areas can be completed.  Note that these now shine like new metal, you would not have thought this possible if you examined them before his work.  It did not happen by accident.

More Windows

Keith Letsche walked in Sunday and volunteered to do more window sash.  This project is mostly a Wednesday/Saturday crew and this unexpected work only adds to and advances the work.  Thanks, Keith.

Apologies since it seems the volunteers doing the work can accomplish results faster than I can post entries here.

Tracks

Lorne Tweed is working on the smallest of the track parts, an insert with steel spring leaves behind it.  Needless to say many of those are about destroyed by rusting, so here he is dong 'blacksmith' work to try to remove some bad ones.

Back in the Carbody

The mild winter weather continued so Lorne Twee is assisting Eric Lorenz with installation of more of the new car interior wainscotting panels below the windows.  Very nice!

Window Sash

Steady work equals steady progress.  Alex Randow just will not give up, and continues to clean and restore aluminum sash for this car.  Note that he is wearing a NY GIANTS hat!  Alex hails from the New Jersey area and it gives one pause to gain such insight into the character of your workmates.  Is it a good move to wear that in the Midwest?  Just kidding, Alex.

Tracks

It is no less attractive to remove crud, bend the tracks straight, and clean the tracks needed for these windows.  Many surfaces, grooves and folds in the metal.  Lorne Tweed grits his teeth and continues the process.  He is nothing if not persistent.

Let There Be Light

Meanwhile, Bill Wulfert (above) located a headlight lens while Eric Lorenz proceeded to fabricate a reflector, install socket, wiring and bulb.  In short order a temporary power supply was rigged up and THERE WAS LIGHT!  This car looks to be ready to leave at any time if we have a long enough extension cord.

Wainscotting

Work continues.  Perhaps the most visible and exciting thing to happen was delivery of new fabricated panels for the interior of the car.  Eric Lorenz went to work quickly to start installing them.  These are the panels which go below the windows and are pre-painted the correct interior color.  Why now?  Well, the puzzle of the car construction as designed by the builder requires these to be installed, to allow window post caps to be installed in the interior, to then allow installation of the window tracks, and ultimately the windows.

Finished Windows

Alex Randow began the day stripping masking from many of the sash which have by now been cleaned and clear coated.

Back to Cleaning

Alex pitched in on a few other tasks then went back to never ending job of cleaning the aluminum frames on still more sash.

Making Tracks

Not exactly making them, but trying to make them new again.  Lorne Tweed and Eric Lorenz are going over a pile of them, trying to set aside the hopeless ones.  I think there are seven different varieties of these parts for ONE WINDOW, making the scope of this something north of 200 pieces.

Let There be Light

On the carbody out in the barn, Eric Lorenz continues to install trim and more parts.  The headlight is now complete visually, although a new reflector bowl inside and the bulb and wiring remain.

A Step Up

The last of the two fold up steps to the roof have come back form the painter and are now installed just to the rear of the mid car exit doors.  Eric checks the last screws to be sure they are secure.

Windows

What would any of these posts be without the ubiquitous window work?  Keith Letsche returned to the shop and is working on reducing the large pile of sash that remain to be cleaned, and coated with clear finish.