Author Topic: 10 + 11 = 21: WW&F needs 2 New Boilers  (Read 50293 times)

Brendan Barry

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Re: 10 + 11 = 21: WW&F needs 2 New Boilers
« Reply #60 on: January 06, 2017, 12:44:40 AM »
Jason's pictures.

No. 11's barrel sheet after being cut on the water jet table.



11's barrel sheet being lined up with the rolling mill.



11's barrel after rolling.



Part of 11's fire box and outer wrapper sheet. In the picture is Jim Heuber, his son Grady and nephew John. Jim runs Mack Bros Boiler & Sheet Iron Works Co., Inc. where the rolling for 10's and 11's boiler parts was done. Jim also donated the riveters that are being used to assemble the boilers.

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Robert Hale

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Re: 10 + 11 = 21: WW&F needs 2 New Boilers
« Reply #61 on: January 06, 2017, 10:43:54 AM »
The project is looking really good! Very interesting to see how this process is done.

Paul Uhland

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Re: 10 + 11 = 21: WW&F needs 2 New Boilers
« Reply #62 on: January 06, 2017, 03:02:28 PM »
Spectacular photos!!

So will 11's main elements be riveted together there? What else?
Has 10's pieces/parts/partial assembly been done yet?
Will WW&F haul the projects back to Sheepscot for completions?

These pics should give the 21 Project a big boost! :D

And, there's something really macho about creating with heavy steel.   ;) 
« Last Edit: January 06, 2017, 03:10:36 PM by Paul Uhland »
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Bill Baskerville

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Re: 10 + 11 = 21: WW&F needs 2 New Boilers
« Reply #63 on: January 06, 2017, 06:09:00 PM »
It is just amazing how much is being accomplished is so short a period of time.  From the discovery a little over a year ago, that No. 10 needed a new boiler, to the decision making, design of 10 & 11's boilers, fund raising, contracting, and now cut and rolled steel.  I can't think of any private, commercial or governmental organization that reacts and implements as quickly as our cadre of volunteers. 

Simply amazing..... truly amazing!

Bill
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Ed Lecuyer

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Re: 10 + 11 = 21: WW&F needs 2 New Boilers
« Reply #64 on: January 06, 2017, 06:36:12 PM »
Quote
So will 11's main elements be riveted together there? What else?
No. The boilers for #10 and #11 will be assembled at Sheepcot under the direction of our boiler fabricator, Boothbay Railway Village.

Quote
Has 10's pieces/parts/partial assembly been done yet?
The parts for #10 and #11 are being produced together in order to achieve the best pricing. #10's boiler will be assembled first, and placed into service before work on #11 will begin.

Quote
Will WW&F haul the projects back to Sheepscot for completions?
I do not know the details of exactly how the parts will be transported from Syracuse, NY to Alna Maine.
 
Quote
These pics should give the 21 Project a big boost!
We hope so. While we have enough funds raised to complete #10, we still need about $57,000 to fund the fabrication of #11's boiler. Contribute today at: https://fundrazr.com/21campaign

Ed Lecuyer
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Joe Fox

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Re: 10 + 11 = 21: WW&F needs 2 New Boilers
« Reply #65 on: January 06, 2017, 08:28:51 PM »
As I continue my mailings, I can't help but think maybe we could update the fundrazr page with new progress photos if possible, and or maybe include an update printout with the items being mailed for those who may or may not be seeing updates?

Jason M Lamontagne

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Re: 10 + 11 = 21: WW&F needs 2 New Boilers
« Reply #66 on: January 06, 2017, 08:42:36 PM »
Mack Bros has rolled all sheets for both boilers.  The order was based on how they were piled at aquacut.  For interest sake, the order was:

Wednesday:
1.  Opening liners for both
2.  10 firebox
3.  11 firebox
4.  10 barrel

Thursday:
5.  10 smokebox
6.  11 smokebox
7.  11 smokebox liner
8.  11 dome liner
9.  11 wrapper
10.  11 barrel

Friday
11.  10 wrapper

See ya
Jason

Ed Lecuyer

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Re: 10 + 11 = 21: WW&F needs 2 New Boilers
« Reply #67 on: January 06, 2017, 08:47:57 PM »
#10's new smokebox, firebox, and wrapper:

Ed Lecuyer
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Ed Lecuyer

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Re: 10 + 11 = 21: WW&F needs 2 New Boilers
« Reply #68 on: January 06, 2017, 08:52:25 PM »
maybe we could update the fundrazr page with new progress photos if possible

The "Updates" section of the Fundrazr page gets regular updates (although not as frequent as I would like.) Photos can (and have) been included, but things get messy when there is more than one, or there are links included.

All 21 Campaign Contributors (100 of them!) that we had email addresses for got an end-of-the-year wrap-up/status report, which had lots of pictures. I'll try to format it for posting into this forum thread.
Ed Lecuyer
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Joe Fox

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Re: 10 + 11 = 21: WW&F needs 2 New Boilers
« Reply #69 on: January 06, 2017, 09:12:26 PM »
Excellent. I think seeing or hearing this amazing progress will give some inspiration.

John Stone

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Re: 10 + 11 = 21: WW&F needs 2 New Boilers
« Reply #70 on: January 07, 2017, 01:58:11 PM »
Absolutely amazing! I'm in always in awe of skilled individuals who can turn raw materials into beautiful, useful machines.
You folks continue to amaze me.

Ed Lecuyer

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Re: 10 + 11 = 21: WW&F needs 2 New Boilers
« Reply #71 on: January 07, 2017, 02:43:28 PM »
As promised - this summary was sent to all "21 Campaign" donors. If you didn't get one, I either couldn't find your email address, or you haven't made a monetary donation specifically for the 21 Campaign. (Of course there are MANY ways to support the campaign - not just by sending money.)

---

WW&F Railway Museum
21 Campaign
News Wrap-Up: 2016 In Review


Thank you for your continued support and interest in the WW&F Railway Museum's "21 Campaign" to build two new boilers for locomotives #10 and #11. We've been very busy on this project, and wanted to take this opportunity to recap the amazing progress that your donations have helped make possible.

While it was our intent to send out email newsletters to our sustaining donors on a monthly basis, we've been occupied with the business of running the WW&F. That, and personal/family commitments have prevented these email updates. Fortunately, we do post a regular update every Tuesday on the 21 Campaign's Facebook page:  https://www.facebook.com/wwandf21campaign/ (You need not be a member of Facebook to see these postings.) We hope to return to providing monthly emails to sustaining donors in 2017.
 

2016 in Review
January:
Locomotive #10 is taken out of service for its annual boiler inspection. Non-destructive testing reveals that the boiler may be suspect. The boiler is cut open; a staybolt is removed and sectioned. The sectioned staybolt confirms that the boiler must be taken out of service immediately. A cost analysis of repair vs. replacement is done; it is determined that the best course of action is to replace the boiler entirely.


The condemned boiler of #10.
 

February:
In order to maximize savings, the concept of building boilers for #10 and the planned locomotive #11 in close succession was conceived. More analysis showed that the approach had merit, should sufficient funds be found. With the in-house fundraising (through the annual Fall Fundraiser) for 2016 already complete and allocated to various projects, but not wanting to delay the construction process, the "21 Campaign" is conceived. The concept would be to reach out to the fans and followers of the WW&F via social media to help drive this project. While museum members could contribute to the campaign, the goal would be to raise the money outside of the already successful Fall Fundraiser.


This drawing shows the planned modifications to #10 in conjunction with its new boiler.
 

March & April:
It is decided to use riveted construction and traditional fabrication techniques whenever feasible to build both boilers. Cost estimates reveal that $130,000 will be needed to construct the boilers. Restoration of the Allen deep throat 2-ton portable riveter (necessary for the construction of the boilers) begins.  Planning for the "21 Campaign" occurs and testing of various social-media web sites for fundraising. Official websites are established at www.fundrazr.com/21campaign and www.facebook.com/wwandf21campaign. The "21 Campaign" is revealed to the WW&F members and followers during the Spring Work Weekend.

$1871 is raised (just a few days into the campaign.)


An advertisement for the Allen riveting machine. Note that one of their customers is The Portland Company - builder of WW&F locomotive #9 and much of the motive power and rolling stock employed by the Maine two-footers.

Want to see the restored Allen riveter in action? See:
https://youtu.be/-X64d06D1Wc

 

May:
The "21 Campaign" is announced on various railroad-related discussion forums and on Trains magazine's News Wire.  The design of #10's new larger profile is finalized, including the new headlight, larger smokebox, and taller steam dome. A new machine, based on a 1937 Beatty Flanging Machine is designed to shape various components such as the tube and door sheets. This machine will save the machine thousands of dollars over the course of building both boilers. The design of both boilers is ongoing. The restoration of the Allen deep throat 2-ton portable riveter is completed.

$10,242 is raised by the end May.


The 1937 patent for the W.R. Beatty Flanging Machine. The Beatty flanger is a 'universal' flanger, meaning it can accomplish a variety of flanging operations using different dies. 


June:
A headlight for #10 that matches the size and style used by the historic WW&F is found as well as a rare Nathan Hydrostatic Lubricator (which was found on the original locomotive #7, and was hoped to be included its reconstruction - #11.) These are purchased for use on the locomotives (but not using "21 Campaign" funds - which are specifically designated for boiler construction.) The Beatty Flanging Machine design is completed. The boiler designs are completed and the review process (with the various contractors and regulatory agencies) begins.

$22,401 is raised by the end of June.


Parts needed for the locomotives... the new headlight for #10 and the Nathan Hydrostatic Lubricator. Both will be restored for use on locomotives 10 and 11, respectively.


 
July:
The boiler designs are reviewed; some changes/improvements designed. Parts for the construction of the Beatty Flanging Machine are ordered and arrive. Seven WW&F Museum members have become "sustaining" donors – each pledging to give $21 a month for the duration of the project.

$23,794 is raised by the end of July.


The completed initial designs for both locomotive 11 (on left) and locomotive 10 (on right). Each design consists of five pages of drawings and several pages of calculations. The boiler designs for #10 and #11 were prepared concurrently to save on design and regulatory review costs.
 

August:
The final boiler designs are completed and await approval. Construction of the Beatty Flanging Machine begins in earnest. The estate of David C. MacDonald selects the WW&F's "21 Campaign" as the recipient of his $18,000 bequest to the museum.

$42,549 is raised by the end of August (one third of the $130,000 goal.)


By December, 2016 the Beatty Flanging Machine was nearly complete.


September:
The WW&F Railway Museum hosts the National Narrow Gauge convention. Besides raising national awareness of the "21 Campaign" a demonstration of the Allan deep throat 2-ton portable riveter is conducted. The MacDonald bequest is announced – including coverage in Trains' News Wire. The final design for both boilers is approved by the ASME – clearing the way for their construction. It is decided to purchase the plate for both boilers together, so to achieve significant savings – and ensure the continuity of the two projects. Contracts are finalized with Boothbay Railway Village and Mack Brothers Boiler and Sheet Iron Works.

$46,910 is raised by the end of September from 82 individual donors.


Mack Brothers Boiler and Sheet Iron Works of Syracuse New York is rolling the boiler components for #10 and #11. We already owe them a debt of gratitude, as they were donors of two historic riveting machines (including the Allen riveter) that will be used in the construction process.


October:
Logistics for the ordering, fabrication, and delivery of boiler plate are arranged. The Beatty Flanging Machine sees significant attention during the Fall Work Weekend.  A steel dome flange is designed for both boilers – which will present a cost savings and allow a riveted connection of the dome to the barrel.

$50,603 is raised by the end of October.


Parts for #10 (in black) and #11 (in red) laid out on 10 x 10' sheets of boiler plate. This is just one example of the careful planning that took place this fall. It also illustrates how building both boilers saved considerable expense by not wasting materials.
 

November:
Over 800 rivets are ordered (enough to build both boilers.) Work continues on the Beatty Flanging Machine while other logistics are attended to. Museum member John Houghton donates over $10,000 to the "21 Campaign" – the largest individual donation to date.   

$61,070 is raised by the end of November.


Aquacut of Lakeland, NY is the site of the waterjet cutting. For this project they cut several 10' x 10' pieces of 3/8" and 1/2" thick boiler plate.

Want to see the water jet cutting action? Visit:
https://www.facebook.com/wwandf21campaign/videos/vb.362031527300787/461024004068205


 

December:
The plate necessary to build both boilers is accepted and transported to Aquacut, Inc. of Lakeland, NY. Waterjet cutting is completed, with components (such as the mud rings, dome rings, and door rings) delivered to the museum while others sent to Mack Brothers Boiler and Sheet Iron Works for rolling. The dies for shaping #10's boiler components with the Beatty Flanging Machine arrive at Sheepscot.

$70,727 is raised by the end of the year (over half of the $130,000 goal) from 101 individual donors. This includes $8697 transferred from the WW&F Museum's Fall Fundraiser – which designated that money raised above the goal for 2017's capital projects could be used towards the "21 Campaign."



And the parts begin to arrive. One pallet has the mud rings for #10 (the smaller rectangle) and #11 (the larger rectangle.) The dome covers and rings are also ready for machining. Note the much larger size of the components of #11 versus #10.



Gaining Steam in 2017
We have a lot to be proud of in 2016 – and the above is just a snapshot of the progress made. It is important to note that this occurred simultaneously with many other museum projects, and all while running a railroad for our guests and visitors.

And despite our efforts to secure grants specifically for this project from several private foundations, all of the money raised in just nine months came exclusively from our friends, fans, and followers from throughout the world. At this rate, we could have both boilers paid for (and one constructed) by the end of 2017!

Please help us by spreading the word about this campaign. Please "like" the campaign on Facebook: https://www.facebook.com/wwandf21campaign/ and check in each Tuesday night for updates!


Sustaining Donors: Thank You
There are 13 individuals who have chosen to give monthly donations of $21 (or more) to the campaign. That is nearly $300 a month that we can count on for the materials and other costs associated with this undertaking. To these individuals, we offer our sincere gratitude.

To become a sustaining donor, simply send the museum a $21 donation each month. This can be done automatically using your bank, or by setting up a recurring PayPal donation.


Wishing You all the best in 2017,

- Ed Lecuyer, Jason Lamontagne, Stephen Piwowarski, and the rest of the 21 Campaign Team
Ed Lecuyer
Moderator, WW&F Forum

Mike Fox

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Re: 10 + 11 = 21: WW&F needs 2 New Boilers
« Reply #72 on: January 07, 2017, 09:01:44 PM »
The parts pictured in Eds photo were in the back of Jason's pickup and we unloaded them today. Jason was like a kid at Christmas. Anxious to show and explain the parts. Very impressive.
Mike
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Paul Uhland

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Re: 10 + 11 = 21: WW&F needs 2 New Boilers
« Reply #73 on: January 08, 2017, 02:35:26 AM »
Great summary of 21 Project progress so far.
Hope the UPS delivery truck doesn't tip over!  :D
Seriously, I'd expect a semi will deliver the steel in a few days, maybe in time for the Photo Weekends folks to catch. 
Paul Uhland

Brendan Barry

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Re: 10 + 11 = 21: WW&F needs 2 New Boilers
« Reply #74 on: January 25, 2017, 02:17:05 PM »
The rest of the boiler parts arrived from Syracuse, NY Tuesday morning.

On the New York Thruway Monday night before the nor'easter started up.



Sheepscot Tuesday morning.



Getting ready to transfer the load onto a flat car.



Parts loaded on the flat car.





« Last Edit: January 25, 2017, 02:27:34 PM by Brendan Barry »
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