Illinois Railway Museum Blog

It was a productive day at the steam shop leading to a fairly short update.  We were able to do what we planned to with no significant setbacks, which is always a good thing to be able to say !.

On 1630 the focus was on the tube fitting and the set up for riveting:

·         The remaining 6 super heater flues were expanded into the front tube sheet.  After the problem a couple of weeks back I was in the firebox watching very closely for any sign of movement.  But nothing happened.  They all rolled into the front sheet with no sign of a slide toward the front.  So what happened before .... I have no idea.

·         With those flues in place we moved on to the last 9 small tubes.  These were cut to length, ferrules checked and fitted where necessary, then the tubes were expanded into the rear sheet and rolled into the front.  After 180 we are getting quite good at this !.  So a big milestone, every small tube is now in place and ready for the water test.

Phil rolls the last small tube

·         The one remaining tube to be fitted is the large one that had to be cut out two weeks ago.  This is being safe ended and will be ready for pressure testing next weekend.  We prepared for this by filling the water tank in the back of the truck.  A week standing in the sun should have the water warm for use in testing next weekend.  If the test is successful, we should be able to fit that last tube immediately.

·         Mike, Tom and Dennis worked on fabricating a frame that will allow the bucker to be held firmly against each rivet as it is formed.  It looks as if we are getting close to the set up for fitting the rivets into the patch, which is the last major step before we can fill the boiler and ensure that the tubes are water tight. 

Repair riveting is about as difficult as it gets!.  When the boiler is made or subject of major repair it is riveted upside down or off the locomotive so you have full access to the mud ring.  In this case the trick is to ensure that everything can be placed and held in this fairly confined space.

Work area for bucking rivets

So the area has been cleared ready for riveting and the next stage will be to start setting up the fabricated frame to hold the bucker in place.

·         Dennis repaired the cinder protection plate on the last of the super heater elements.  These simple looking pieces of sheet are most important.  When the element is in place in the flue, the pipes bending up to the header are in the path of cinders being sucked thru the flue at great speed, so would be subject to extensive erosion.  The rough sheets, wrapped around the element  are "sacrifice plates" that suffer the erosion rather than the element itself.  The picture was taken prior to the repair and shows how a hole has been cut thru the protector by the abrasive effect of hot, fast moving, cinders.

Damage to element protector

·         Tom and Cameron worked on machining the guides required to drill the holes for the new firebox stays.

In other areas:

·         The tubes for the Shay were strapped into bundles and moved back to the boxcar, freeing up the space in the fabrication area;

·         Tom continued machining the wedges for #428

·         Stu worked with Phil and Cameron on sizing the rivets for the cab on #428.  This is a job that we will fit in when we have spare resources as it will allow the cab to be refitted freeing up a useful area for fabrication;

·         Stu also continued work on the control system of the planer;

·         .... and beside this we were able to assist the US Army (re-enactment version) with the odd bit of metal bashing to keep their tents upright!

So overall a good day's work.

On a less cheerful note, we talked to Rod, who visited Glen during the week.  He remains in the ICU at Rockford Memorial and was heavily sedated.  The prognosis remains unclear, particularly with regard to one leg which suffered major damage to the knee.  Our thoughts and prayers are with him.

Nigel