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Messages - Rick Sisson

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Work and Events / Re: WW&F No. 11 - Official Work Thread
« on: April 18, 2013, 01:06:12 AM »
Hi Keith -

Dave is correct - here's a picture of the half-saddle cores:

Work and Events / Re: WW&F No. 11 - Official Work Thread
« on: April 05, 2013, 11:46:32 PM »
Alan - the 3D print is 1/16 scale and cost $14.77. The cost is determined by the amount of solid material in the parts. I had wanted a larger model, say 1/8 scale but that would cost 8 times (2 cubed) as much - $118! So I quickly settled on a 1/16 scale print.

Work and Events / Re: WW&F No. 11 - Official Work Thread
« on: April 05, 2013, 11:42:17 PM »
Bernie - Jason and I expect to use chaplets to secure the cores in the mold. I'm working on a model where I can "pin" the cores with dowels so we can assemble the cores and mold and disassemble the same to debug the model. It's become clear that the main lightener core has to be split to get the steam and exhaust cores to nestle inside it.

Work and Events / Re: WW&F No. 11 - Official Work Thread
« on: April 05, 2013, 01:31:32 AM »
I've been learning how to model number 11's cylinder/saddle casting in TurboCad using the detailed drawings developed by Jason. First, I modeled the cores:

The cores are: red - exhaust, green - live steam, light blue (and underneath dark blue) - main lightener, tan - frameway, brown - cylinder bore, dark blue steam port, darker green - outer lightener. My model represents only one quadrant of the complete assembly - the left and right cylinders are identical and formed from the same molds; the individual castings are symetric fore and aft, so only one half is modeled.
Then I encapsulated the cores with the casting outer shell:

I then subtracted the cores from the outer shell to represent the final casting with voids where the cores had been, and then I split the casting into 5 pieces so I could inspect the inside of the casting at various points, as you can see in the picture. You can not see the interior details unless the casting is opened up.
Finally, I sent the CAD file to a 3D printing company called Shapeways, and 5 days later the UPS guy brought me little plastic pieces!

My design is on the Shapeways web site and you can see the model here:

If you click on the right arrow or the shaded cube the model will revolve for you. You can actually follow the live staem and exhaust passages as the model revolves.

After I had studied the 3D printed parts for quite some time, I found a small number of errors that were hard to find in my CAD model even when I could see them in the plastic model.

I started this effort last fall - it took quite some time to become familiar with 3D modeling with the TurboCad software and quite a while to become comfortable with Jason's design.

I'm currently working on the outer shell molds and I am trying to get some more parts to the 3D printer soon. This is a very complicated casting and it hasn't been easy to get my arms around it, so to speak.

Work and Events / Re: WW&F No. 9 - Official Work Thread
« on: March 26, 2012, 01:42:54 AM »
Some photos from this weekend (hope this works!):

Mike grinding off bolt heads insdie the rear frame using the rail saw (Saturday morning).

Jacking the rear frame upward (Saturday afternoon).

Jason grinding stubborn bolt heads inside the rear frame (inside the firebox) (Sunday morning).

The rear frame is finally positioned, the boiler is cross leveled, and the saddle position is located in the smokebox (Sunday afternoon).

We're glad to have this work behind us!

Museum Discussion / Re: Julius Stuck Recovers
« on: December 21, 2011, 05:14:48 PM »
I visited Julius today and he tells me his physical therapy is progressing well, and he expects to be released sometime after Christmas (not sure when).
Julius told me this is the first WW&F Victorian Christmas that he's missed!

Museum Discussion / Re: Julius Stuck Recovers
« on: November 29, 2011, 08:06:05 PM »
I was able to visit Julius today at the rehab facility in Falmouth, MA. He's alert and looks terrific, he's going to physical therapy and he's eager to get home. I believe he'll be in rehab 2 more weeks. I know he'd like to receive cards and/or notes from us: Julius Stuck, c/o JML Care Center, 184 Ter Heun Drive, Falmouth, MA 02540.

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