Coach 9 - Official Work Thread

[Jason M Lamontagne]

There is a tentative arrangement to utilize the existing J&S trucks and build new, appropriate trucks for coach 9.  There's still some details to settle- so for now I'll post more details in the members only section.

See ya
Jason

[Brendan Barry]

The door post/trim on coach 3 sanded down to the original factory paint.

[Philip Marshall]

Very neat picture! The thin layer of Edaville yellow really stands out.

So was the original color really brown, or perhaps maroon "lake" ?

[Eric Schade]

we held up color chips to see what we were looking at. of the chips we had the "Kilz" color LM 100 (b3) "Incence Stick" looks really close -- think UPS truck Brown. which is "Pullman Brown" according to Google.

I also spent some time sifting through Jackson and Sharp images and found some good shots of similar cars.  This one shows the striping really well. http://delaware.contentdm.oclc.org/cdm/singleitem/collection/p15323coll6/id/3733/rec/1

[Bob Holmes]

So Eric, do you want to paint your new model coach in "WW&F Brown" as a test of what it would look like on the prototype?...

[Eric Schade]

Nope  but haw about Wiscasset and Quebec brown!

[Alex Harvilchuck]

[I would like more information regarding the Coach 9 cloning project] because I own an artisan woodworking/cabinetry shop.

Equipment-wise I seem to gravitate towards mid-century Rockwell and Delta, with a smattering of Acme, Poitras, Kuster Woodworks, Handy, Crouch, Sand-Rite Mfg., Wetzler, Beach Mfg., Boice Crane, Crescent, Newton, Dake-Johnson, Stanley, GE, Van Norman, and anything else I may have forgotten. I do only North American manufacturers unless I have no choice. I don't like plastic machines, only machines made of materials directly on, or alloyed from, elements on the periodic table.

• I can handle stock up to 20" wide and 6+" thick through my largest jointers and surface planers
• I can 2-pass finish sand up to 36" wide and 6" thick
• I can chain or chisel mortise
• My air-actuated Handy door clamping table is good up to 10' x 5'
• I can re-saw with either my 20" or 36" band saws

Let me know some details what you need for Coach 9 when you get a chance. Maybe I can help to fab up some sub-assemblies when there is some slack time in the shop as an in-kind donation.

[Harold Downey]

A short update on Coach 9 progress:

I finished the working drawing and bill of material for the base frame.    A copy is in the Percival house for review.

There are four castings needed for the base frame: 

Center pivot (2 required) - which mounts on the bottom of each bolster
Queen post casting (4 required) - for the two main truss rods where they cross the queen post beams
Bolster truss rod casting (4 required) - which terminate the bolster transverse truss rods
Body support casting (4 required) - these are the outboard supports at the bolster which keep the body from tilting.

And since the design needed to be completed in combination with the center pivot, the corresponding female center casting which mounts on the truck.

I have nearly completed all of the patterns for these.

Here are a few pictures of the center castings in progress, before and after the lathe turning steps:

[Harold Downey]

And the female counterpart:

[Dave Crow]

Very nice work, Harold!

[Harold Downey]

Here are the completed center castings, ready for finish.   

I thought I had them wrapped up yesterday, but I noticed that I managed to misread my own drawings and made the center hole 2" diameter instead of 1.5".   So, I made two plugs with the correct 2 degree taper on the lathe, epoxied them in each pattern, then drilled a new 1-3/8 hole with a forstner bit.   I then remounted each on the lathe, while carefully centering them up.  Since I had them on a backing plate, rather than in a chuck, it was a bit tricky.    Finally I recut the center hole to the correct 1.5" diameter with 2 degree draft. 

[Harold Downey]

Here are the completed body support casting pattern and the queen post casting pattern.

[Harold Downey]

.... and the last one - the bolster truss rod casting, with its three core boxes.  This pattern took more time than the other four put together.   But, it was kind of fun to make. 

[Wayne Laepple]

Outstanding work, Harold. I received a call yesterday from Cattail Foundry that they have completed the Jackson & Sharp truck castings, and I plan to bring them along to Maine when I bring the East Broad Top couplers, hopefully sooner rather than later.

[Ira Schreiber]

Great work, Harold and a supreme addition to our upcoming coach #9.