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Messages - Harold Downey

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Work and Events / Re: Coach 9 - Official Work Thread
« on: February 27, 2020, 07:06:31 PM »
Merci, Alain!

Thanks Bernie.   I do eat and sleep.  ;)  Actually I spend on average about a half a day out in the shop every day that I can.  I recorded about 300 hours for the114 window sashes, coming to about 2-3/4 hours each.   I admit that this job became a serious grind.  Each operation takes hours, since there are so many parts.    For the last 23 days, to glue up three windows, clean up the three from the day before, check and fit the parts for the next day's glue-up of three, and then final sanding three, took almost 3-3/4 hours per day.   And that's nearly all I did each day on this job.    That was a slog; every day the same thing.   

Just picked up the wood for the two doors and their respective windows today.   There's an odd market for white oak.  The rage in architecture today is to use rift sawn white oak, which is grain about 30-60 degrees from vertical.  That gives a very linear grain, and no rays that you see in quarter sawn.   So for the door which will be 1-3/8" thick, I had to pick through the rack of rift sawn oak looking  for the few pieces that are actually closer to quarter sawn.  Without the demand for all the rift sawn oak, they wouldn't carry anything in that thickness.   This job should be more enjoyable -- only two doors and four windows!  And I know how to do the windows. 

Oh, and I won't be there for SWW this April.   I don't think the windows will be needed that soon.    I also want to complete the salon (toilet) walls and door as well.    Then I should have a big enough load to justify the drive again.   Or maybe I will just crate it all up and ship it freight. 

Work and Events / Re: Coach 9 - Official Work Thread
« on: February 26, 2020, 11:35:27 PM »
It's acting weird.  I can't see them in incognito window, but can as guest in normal chrome window.  Let me try to fix it another way.   Sorry about that.

Work and Events / Re: Coach 9 - Official Work Thread
« on: February 26, 2020, 10:22:06 PM »
In the first photo, the edges of the boards are painted. Did they come that way, or did you mark them?

Jeff S.

Jeff, that's how they came from the lumber supplier.  They paint the ends to keep them from checking (drying and cracking from the ends).

Work and Events / Re: Coach 9 - Official Work Thread
« on: February 26, 2020, 10:08:32 PM »
I think it's fixed now.  Other than the large size...

Work and Events / Re: Coach 9 - Official Work Thread
« on: February 26, 2020, 08:47:58 PM »
While Eric is busy in Bay 2 starting the frame, I have been making the window sashes.   There are 30 sashes needed for the side windows, 4 in the ends that are narrower, and 30 clerestory window sashes.   In addition, I assessed the state of the windows in coach 3.  None of the main window sashes are original, and most need repair.  Not only that, they are either the wrong type of wood, or don't have the correct design features.    The end windows do appear to be original -- they are made of quartersawn white oak, and have the original anti-rattle springs on the sides, as well as a number stamp on one edge. One of the end windows is in poor shape, in the end where there was a fire at one point.    So we decided that as long as I was to go into production on one set of windows, I would also add 30 new window sashes for coach 3 sides, one end window, and 15 clerestory windows.   That led to a grand total of 110 new window sashes. 

Here is the pile of 200 or so board feet of rough quartersawn white oak that I started with (mid November):

After a few weeks of planing and machining, the pile was reduced to the component parts cut to final length and width:

The first task was to do all the mortises, a total of about 450, each requiring multiple passes:

Then cut the tenons, which require 6 different setups in total.  Here is one of the clerestory rail tenons next to the corresponding mortise:

Here's what it looks like assembled.  I like the stopped chamfer on the inside edges, it adds a nice touch.

A stack of the finished clerestory sashes waiting for final sanding and bottom bevel:

The pieces of the main windows ready for assembly.   The odd features on the rail sides are for the anti-rattle leaf springs.  I attached a picture of one of the originals below.

This is a stack of about half of the main window sashes, fully glued and sanded:

Moving on next to the main doors....

Work and Events / Re: Car Barn Extension - Official Work Thread
« on: February 05, 2020, 08:58:56 PM »
Wow, we can't even get the roof on, and it's filling with rolling stock already!

Two Footers outside of the US / Re: New sugar 2-footer in Australia
« on: January 15, 2020, 11:48:46 PM »
I calculate their cost is $428k per mile. 

Sign me up for joint tightening crew. All days as required.

Work and Events / Re: B&SR Tank 14 - Official Restoration Thread
« on: August 16, 2019, 08:24:07 PM »
This is from the 1909 Car Builder's Dictionary, under Interchange Rules.   This governs repair splices to sills.   1895 edition did not allow center sill splices, but now they are allowed with a reinforcing timber as shown in figure 9A.    But I read from this that center sills can't be spliced right in the center.   Cross tie timbers are also known as needle beams. 

Rule 65. Draft timbers must not be spliced. All longitudinal sills may be spliced once, with the exception of center sills, which may be spliced at both ends.
Not more than two adjacent sills may be spliced at the same end of car.  The splice may be located either side of body bolster, but the nearest point of any splice must not be within
12 inches of same, excepting center sills, which must be spliced between body bolster and cross-tie timbers and not within 24 inches of either. Longitudinal sills other than center sills where less than 12 inches in depth, the plan shown in Fig. 8 is to be followed. When the sills are 12 inches or more in depth the plan shown in Fig. 9 is to be followed. When center sills are spliced the plan shown in Fig. 9a is to be followed. The size of horizontal or cross bolts shown in Fig. 9a should be 5/8 inch.

Work and Events / Re: B&SR Tank 14 - Official Restoration Thread
« on: August 15, 2019, 06:59:12 PM »
Wow.  It looks like the tank was holding the flat car together. 

How are the sills?  I see some already have scarf repairs.   There is a spec in the 1895 Car Builder's Dictionary on how to do these scarfs, and also the acceptable location.  They don't recommend repairing the center (draft) sills).   Since railroads interchanged cars, any RR could do repairs, but had to meet specs.   It is interesting that they also had a valuation method for charging back to the owning RR. 

Work and Events / Re: Coach 9 - Official Work Thread
« on: August 01, 2019, 09:33:15 AM »
Thanks for the kind words.  I am enjoying it.   The weird thing is how accurate it needs to be.   Unlike house framing, where window openings are called "rough in" for a reason, the window openings in the coach framing are the actual window frames.  The window sashes are 1/4" narrower than the nominal openings, and there are leaf springs on the sides to keep them from rattling.  So at most there is 1/8" to play with -- over a 40 foot length. 

Volunteers / Re: July 2019 Work Planning
« on: August 01, 2019, 09:27:05 AM »
About 140??

Work and Events / Re: Coach 9 - Official Work Thread
« on: July 31, 2019, 07:49:59 PM »
A few pictures to show some of the interim progress.   

The Main Deck End Sill (which goes across the ends of the coach above the windows and the door):

The platform end beams and the platform deck carlines, all loosely assembled:

This is all the material finished, stacked and banded.   But, there is more to do...

This is a picture of the lower clerestory beam from BRV's #11, showing the stepped scarf used (photo by Alan):

I made a fixture to do these scarfs for all of the long structural stringers and beams.  It's an 8:1 scarf with 1/4" steps.  The final scarf, on a test piece, looks like this:

Here are a couple of shots of the fixture:

Next up -- the clerestory beams consist of a bottom stringer, a top stringer and short vertical members connecting them.   The verticals are the only part of the coach structure that is visible in the coach interior, so they are made from quartersawn white oak.  They are made with tenons that engage mortises in the stringers.     They are about 7" long and 4" wide.  Here is one of them.  Note the center bead and the stopped chamfers on the front edges.

This is a portion of the assembly.  You can see additional joinery: the mortises in the lower rail receive the clerestory deck carlines, the notches in the top receive the main deck carlines, and there are vertical holes that go all the way through and will receive a 3/8" bolt to hold it together at each post.  In between the posts are where the clerestory windows are mounted. 

Similar to the clerestory beams are these pieces that are at the ends of the coach above the doors.  There will be a pivoting panel that goes in the opening. 

Work and Events / Re: TCDA No. 65 (Reefer) - Official Work Thread
« on: June 26, 2019, 06:48:17 PM »
Here's our chance to add the missing period after ASS'N   . 

Work and Events / Re: Eames Train Brakes - Official Work Thread
« on: June 16, 2019, 05:35:24 PM »
You may be missing it.  Click on the double arrows in the top RH corner of the picture, then zoom way in and drag it to see the bottom left corner, just to the left of the brake wheel on the baggage car.  The truck is cut off, but peeking up above the side boards of the flat car. 

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