W.W.&F. Discussion Forum
WW&F Railway Museum Discussion => Work and Events => Topic started by: Stephen Hussar on July 31, 2008, 06:19:41 AM
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All, Bernie Perch sent these new pictures of the just received castings for No 11's bell bracket -- which look fantastic...thanks Bernie!! I almost cropped the second picture showing Bernie's shoe, but I thought it was good for scale...so I left it in...shows how big this stuff really is!!
(http://img.villagephotos.com/p/2003-8/342468/bellcastingpcslayedoutsm.jpg)
(http://img.villagephotos.com/p/2003-8/342468/bellcastingpcstogethersm.jpg)
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I would like to thank Stephen for posting the photos because my computer skills in this area are non-existant. An extra special thanks to Wayne Laepple who encouraged me to become involved in this project and who shared the cost of making the castings--an expense which I didn't care to do completely myself. We are donating this to the #11 project. Foundry costs are esculating like everything else, and there is a lot of sticker shock involved with this project.
Wayne brought the bell down here from Sheepscot after a track weekend. It was an old, tired, and rough casting. I believe it was from an EMD diesel but a perfect size for our narrow gauge. It came with a collection to the museum. Having polished several rough bells, I knew what was underneath all that crud.
We decided to do a bell and bracket early on so that it could become a recognizable part of a display featuring the construction progress of #11. Most everyone has a good idea of what a bell is all about.
Finally thank you everyone for your positive comments. They are the fuel which keeps my desire going on this project. I'm sure that everyone up there who is working on all the projects looks forward to the compliments.
Bern
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Having seen the pictures of the great patterns that Bernie made, I really appreciate seeing the photos of the new bell hanger castings. It's great to find that you have a foundry that will do loose patterns and that will produce quality castings.
Dave Johnson
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Even though we took the patterns to the foundry "loose", and they were returned that way, there is evidence that they may have been mounted on boards. There was a $50 "one time set up fee" for each of the four patterns. Some foundries charge extra for core work.
When I sent "loose" patterns to Active Brass in Perkasie, PA. for Project 113, they mounted them on boards with all the gates, risers, etc. They were returned that way so that for the next trip, they were ready to go. Of course there was a charge for this.
Bernie
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Some folks may have noticed the four "feet" on the bell bracket casting. Bernie decided to add these so that the bell will be able to stand on a floor or shelf, and when it's time to mount this bell on no. 11's new boiler, the feet will be cut off. The actual base of the bracket is curved to match the radius of the boiler.
When Bernie and I went to Fairmount Foundry in Hamburg, Pa., the plant manager and shop foreman both expressed admiration for the craftsmanship and beauty of the patterns. They were quite amazed that Bernie, as an amateur, had done such a fine job. Those of you who saw the patterns for the spoked pilot wheel for no. 11 know what I'm talking about. Wait until you see the driver center pattern!
All of the above is to remind us how fortunate we are that Bernie Perch is willing and able to manufacture patterns for us. Thanks, Bernie.
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Hi all --
I have been corrected about my previous post by Bernie Perch. Two of the feet on the base will remain as is, while the others will be trimmed to match them. The feet will then serve to stand the base off no. 11's boiler. This serves two purposes. One is to lift the bell off the boiler and reduce the area of potential corrosion between the base and the boiler, and it will also lift the bell's base up to the depth of the lagging. The fore and aft feet were made longer on purpose, as I mentioned before, so the bell stands solidly on a floor or stand.
I learn something new every day.
Cheers -- Wayne
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No 11's finished bell arrived over the weekend! Thank you Bernie and Wayne!
(http://img.villagephotos.com/p/2003-8/342468/Finishedbell2.jpg)
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Ok everyone,
I have looked over this forum and even tried digging in the Old Forum....
What is No. 11??
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Hello, Vincent. No 11 will be a reproduction of WW&F No 7, to be built after No 9 is completed.
(http://img.villagephotos.com/p/2003-8/342468/WWF_7_elevationneg_sm.jpg)
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Here are some of my drawings for the project. These are not the best quality pictures. I took them with a camera phone.
Engineer's side,
(http://c1.ac-images.myspacecdn.com/images02/53/l_e8b3a3d54d6f42c5ab3a50f5757066f0.jpg)
Front,
(http://c1.ac-images.myspacecdn.com/images02/17/l_eff663928594407b9b4fbc5ec506c188.jpg)
Rear,
(http://c4.ac-images.myspacecdn.com/images02/57/l_e81f219d24c84f28a7004584ff381deb.jpg)
And technical mumbo jumbo,
(http://c3.ac-images.myspacecdn.com/images02/20/l_a836f1cc70b14cf49b3ea171b433bc6e.jpg)
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That's beautiful stuff Eric! Any chance I can convince you to take the original of the side view to a print shop with a full-size raster scanner?? (in between runs on the NJT of course!) ;)
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That is a photocopy of the original. I have three that I have been meaning to mail up north but work hasnt left much time. All of the pictures are on one paper.
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Can anyone tell me...
were the domes on #7 (or other engines) castings, or were they "pressed" into shape?
(Curious minds want to know. ;) )
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They're made up of several pieces. I would guess that the saddle and top are castings and the cylindrical part was rolled...but I suppose they could have been castings as well. Hard to tell even from photos. Here's a frame taken by Gus Pratt from his 16mm footage.
(http://img.villagephotos.com/p/2003-8/342468/GusNo7IDsm.jpg)
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The steam dome is generally formed over a die and them riveted to the boiler shell. The top of the steam dome (the dome cap) is bolted down. It's necessary to give access to the throttle valve inside. The sand dome is a rolled tube fitted to a base that will sit atop the boiler. The top of this base is usually an inverted V to provide gravity feed to the sand tubes. The rounded top is a formed piece. Fancy fluted domes sometimes seen on old-time locomotives are a series of rings fitted over the tube.
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Wow (!) I guess that answers that question. ;)
That still-shot from the old movie sure makes it easier to see of what you speak.
Now, to figure out how sand domes were formed on BIGGER locomotives...
(but that may yet be a question for annother forum. ;) )
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I don't Know where you saw domes made up with rings fitted over a tube. Most domes I've seen were made up of castings top and bottom with a rolled tube center this is for both fluted and rounded domes these are mostly for looks.The actual steam dome that is part of the boiler is as mention a formed bottom and top ring with a cap eighter riveted or welded to a rolled tube then mounted to the boiler shell by riveting or welding.
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Matt...
..that IS the idea! The 11 is to be a copy of the original 7 built up virtualy from scratch.
Who, exactly, is planing to build a replica of SR&RL 24? I know there's one version built in the UK from a previosly existing engine, and possibly annother built up almost from scratch. I belive one is on the Brecon Mountain line, not sure though.
Scroll down to the "Other Two Footers" topics and search there, or look up the older version of this forum (now archived in a "read only" status.)
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I know one place that would love to have one. Check this out.
http://www.frolin.net/mmgs/srcl/ (http://www.frolin.net/mmgs/srcl/)
http://www.srclry.com/ (http://www.srclry.com/)
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No one is building the 24 to my knowledge. BMR is building a replica of SR&RL #10 and SR&RL #23. Matt my drawings are not blue prints. They are just what the locomotive is going to look like. Baldwin destroyed most of the drawings for the #7 (#11 is going to be an exact replica of the #7 but the new locomotive will continue the original numbering pattern) therefore a few members of the museum (myself included) have been working on "reengineering" the 7's blueprints based on the information we have. Lots to do before this project comes off the back burner. Also Matt please do us all a favor and try and put all your replies in one post not five seperate posts.
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The 10 and 23 are being built in England not the US. You can find the blue prints easy. They were printed in a book at some point in time. Also I'm sure the WW&F wouldnt be interested in building the 23 being its a SR&RL locomotive. Also again with the multiple posts.
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Lots of incredible stuff going on "over there." I'm posting this absolutely gorgeous picture of Tornado, as it pertains to our building of reproductions, replicas, etc.,
with permission from photographer John Bowler. Thank you, John!
(http://img.villagephotos.com/p/2003-8/342468/A1_copyright_John_Bowler.jpg)
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A website address on a steam locomotive's tender looks...very different.
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I understand that the web address will be removed when the final paint is put on the locomotive. It is going to be painted in an authentic livery.
Now, how would Jason feel if we put "www.wwfry.org" on the tender of #9!!
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When will the #11 Reconstruction project will fully start? ??? :)
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There's no "re"construction about it - this is a brand new engine, from brand new parts.
We have many other higher priority projects right now (bathrooms, etc etc), and we won't need a new loco for a while. It will be a number of years before the project kicks into high gear.
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Matthew,
A considerable amount of "quiet background work" has been done on this locomotive and continues up to this point. I have seen a number of posts involving people who do a lot of wishful thinking about new or reconstructed locomotives who don't have a clue as to the amount of work it takes to build a locomotive from scratch. A considerable amount of engineering work and drawings have been made by Jason and others. Wayne and myself have spent many hours just discussing the cylinder castings with Jason and visiting a commercial foundry and another pattern maker who is more capable that myself to do this job.
Recently I saw photos of failed casting projects which were heartbreaking. This is why we are investigating getting this done commercially. Who takes the hit when a $75,000 casting fails to pour properly?
I have built several foundry patterns for this locomotive and have started the drive wheel patterns. Since I am involved in a local locomotive restoration project (CNJ 113), my WW&F stuff takes a back seat to this one and subsequently takes longer to get done.
Matthew, what you should do is start learning about patternmaking (there are many books available on the subject), and make one of the simple patterns for this project to see how much work is involved with each part. We will need more people to do this, especially young guys like yourself who will be carrying on this preservation stuff when we can't do it anymore.
One more thing I would like to mention is costs. The costs and tack ons at a commercial foundry will knock your socks off. I got sticker shock when I got the final vouchers for the bell bracket castings. The castings cost Wayne and myself just under $800. I have since learned the name of a smaller, cheaper foundry, but when getting some of the big castings done, we will have to go commercial because of the amount of metal being poured and just for the sheer experience of those who do this every day. Not all the work can be done by volunteers.
I have much more to say about this but I have to run.
Bernie
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hey bernie, need any help with those drawings? I just finished my CAD class and we spent over two months on drafting. I've got an E sized board and would be willing to put some of my spare time into this. (that is, while i'm not railhunting ;) )
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Vince,
As mentioned in the post above, Jason is doing the engineering and drawings--talk to him. I make the patterns from his drawings.
Bernie
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And what beautiful patterns they turn out to be.
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Mike,
Thank you, I appreciate it. I sent photos to Stephen to post of my latest project--spread out over many months. This was for CNJ 113. I hope you find it interesting--a three chime step top whistle bell.
Bernie
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Here are some of my drawings for the project. These are not the best quality pictures. I took them with a camera phone.
Nice drawning of the future WW&F #11! Do anyone have any photos of BS&R #7 dressed up in WW&F #11 lettering by using photo-shop?
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The B&SR 7 and WW&F 7 really arent very close matches. Outside valve gear, different cab, different tank, different domes, ect.
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I *think* Matt meant WW&F #7 photoshopped as #11.
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Yep thats what I said! :D ;) :D
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And, just for the record, B&SR no. 7 is nearly 7 tons heavier than WW&F no. 7.
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Also 4 feet longer.
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Does anyone have any Info on that? For what I do know that WW&F #11 is not as big as MNGM #7 & #8! ::) :) ;)
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It will be a replica of WW&F #7. If you can find any info for that, that will be the same as #11.
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Well technically the locomotive has no size because it does not exist.......yet. The locomotive when built will be built to as close to the original WW&F #7 as we can get. Therefore the measurements will be about the same as the 7. 7 had 33" drivers, roughly 40" diam boiler, 18' wheel base, was 30' 7" long, 10' fall and about 7' wide. It had 11x14 cylinders, weighed 56,000lbs, and had a tractive effort of 8300lbs.
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Well, the extant #'s 7 & 8 HAVE been labeled as MNGRR #'s 7&8, IIRC.
I know they've also been painted B&H durring thier time at MNGRR.
(So you guys are BOTH right. ;) )
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I hear ya on that.
But remember,... whatever the loco, it's present owners are PART of that history!
(Hence, WW&F # 10 is NOW an actual WW&F locomotive. ;) )
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Sorry I like to honor history more then the present.
That means you always refer to WW&F 9 as Sandy River #5? ;)
j/k..
I agree..nothing wrong with saying MNGRR 7 and 8..
that is their current status afterall..
Scot
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WW&F #11 weighs about 250 pounds at present, and could fill a (somewhat large) crate. That's because it's two pony truck wheels (no tires), a headlight, a bell bracket, and a number plate. Oh, and a few pounds of paper drawings, plus a bunch of files on people's computers (the files don't weigh anything measurable).
Much smaller than B&SR #7.
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The weight on #11 just went up. The tires for the pilot truck showed up. They had them made at the same time as the tires for the rail car.
(http://img.villagephotos.com/p/2006-11/1225939/100_1466.jpg)
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Are you going to use the traditional way of fitting the tires by a gas-fired ring to heat it up then install?
Rob
(http://farm3.static.flickr.com/2284/2178246251_c7165abed0_o.jpg)
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Maybe. The tires have to get up to 400 degrees to expand enough to be installed on the wheel. Any hotter and I guess it starts to have adverse effects on the hardened steel. I am sure someone will film our adventures, perhaps even me.
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You will press the wheels onto the axel before installing the tires won't you? That is the right way, there were some posts on RYPN about that, the tire tightens the wheel onto the axel even tighter than the press fit.
Mike Nix
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Are you going to use the traditional way of fitting the tires by a gas-fired ring to heat it up then install?
Why do they always set a fire the locomotive wheels in the shops? ??? ??? ???
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Matt, they are expanding the metal. This makes the inside diameter a little larger. The tire is installed on the wheel and when the tire cools down, it tightens onto the wheel.
Mike Choo choo, that is my understanding. Jason figures it will be easier to contol the wheel if there was an axle attached to it.
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Hi,
When I worked at a shipyard, we put the coupling end on one of the shaft sections. We had electric heaters that were shaped to fit the outside of the coupling. The shaft coupling was heated to around 450 degrees, if I remember correctly and then pressed on using large threaded bolts. We only had one chance to get it right. The electric heaters were easy to use and control the temperature so it didn't overheat. Maybe we could get a similar type of heater.
Erik
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Hello all,
We will be using a gas ring, fired with propane mixed with compressed air. The ring has already been made by Vern Shaw and Jonathan St Mary. We've been focusing heavy on the railcar lately- and hope to put tires on those wheels early next month. I'll make an announcement here as I figure some might enjoy seeing this process.
Of course now we'll have 30 people there and something will go wrong.... sightons (spelling, John M.?) Not much really can go wrong- usually only takes about 8 minutes to heat, then a couple seconds to drop on.
Don't know when we'll do no 11's lead wheel- No 9 is so screaming for attention that No 11's first complete wheel probably ought to wait a bit.
see ya
Jason
see ya
Jason
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sightons (spelling, John M.?)
from: http://tmrc.mit.edu/dictionary.html
Psiton
elementary particle carrying the sinister force. These particles emerge from the eyes of spectators, and even remote and future viewers (therefore, the number of psitons out of a video camera can be huge!). Since psitons carry the sinister force, then:
The probability of success of an action/demonstration is inversely proportional to the number of psitons falling on it.
-John
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sightons (spelling, John M.?)
from: http://tmrc.mit.edu/dictionary.html
Psiton
elementary particle carrying the sinister force. These particles emerge from the eyes of spectators, and even remote and future viewers (therefore, the number of psitons out of a video camera can be huge!). Since psitons carry the sinister force, then:
The probability of success of an action/demonstration is inversely proportional to the number of psitons falling on it.
-John
Hmmm, somewhere Murphy and Smoot are smiling...
::)
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Yup, Murphy said if something can go wrong, it will and at the worst possible time. I think that was his first and best known saying.
Duncan
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Jason and all,
I am looking at the appendix in the back of the Moody book and it says that:
WW&F 7 was built by Baldwin as their C/N 40864 in 9-1907. the total engine weight was 56,000 or 23 tons; heaviest locomotive to run on the WW&F. She was a 2-4-4RT locomotive.
I think the locomotive was burned in the engine house fire and sat out the last years of operation.
You are announcing quite a project there! only a handful of steam locomotives have been built from scratch in the United States. The most famous are the two opeerating 4-4-0s at Promontary National Historic Site in Utah. Of course being standard gauge they are somewhat larger.
But the British proved that they can do a new locomotive for main line operation. The Toronado has just entered service. She is a standard gauge Pacific!
But if you build enough parts you will end up some day with a steam locomotive! More power to you!
When the #9 is in steam I will even send you a donation for the new locomotive project!
Ted Miles
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7 was not the largest. The 6 was which was a 2-6-2. Also the 7 was 28 tons and yes it along with the 6 were caught in the engine house fire at Wiscasset.
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Was #6 larger the SR&RL 2-6-2 #23 & #24? ??? ::) :)
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It was for sure not bigger then the 23. 23 was the largest two foot gauge locomotive built for use in the USA. My guess is that the 24 may also be larger as well.
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I'm not sure if this is the proper place to post this, Feel free Mr Moderator to move it if necessary.
I have been making some parts for the #11 under the management of Jason. It was decided that since the axles for the #9 are servicable (I will let Jason give you the details) that the material for the #9 axles have been turned into some key parts for the #11. Here are some of the parts.
This is the axle for the lead truck It has been rough turned one end at a time. Next it will be turned between centers to get everything exactly concentric.
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Next,
A main crank pin takes shape. To make these, I cut the material to the length of 2 pins. I then hold onto the rough material to make one pin, flip the material around and hold onto the finished end to make the second pin. When both ends are finished, I cut the two pins apart and finish up the saw cut ends.
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These are the main crank pins and the lead crank pins before parting. Once they are parted, the second end will be semi finished and they will be turned between centers to make them true. The main crank pins will be threaded at this time to accept the jamb nuts that hold the rod retainer rings on.
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Finally, after a full days work, all of the parts have been rough turned, parted, and the rod retaining caps have been cut.
If you have any questions, feel free to ask.
Bruce Mowbray
Springville, PA
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Wow, those are beautiful. Thanks for the update.
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Awesome, Bruce!! Beautiful work...thanks for posting!
Stephen
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Bruce,
Absolutely beautiful work! I have been looking for something to get me fired up in the pattern making department for this locomotive. My Project CNJ 113 whistle project got completely out of hand but I should be finished with it shortly and get back to the driving wheel center patterns. Your posts got my #11 adrenalin moving again. I figured all energy was being directed to completing #9, so there wasn't much of a rush. Now it is time to attack the pattern again. I generally move faster when I see a need and some sort of deadline and you have set some things in place for me. Also when I see others working on parts, I visualize the completed locomotive. Up to this point I haven't been able to do this.
Is there anyone else out there working on parts for #11?
If I Googled Springville correctly, you live about 1 1/4 hours north of me here in White Haven. Maybe we could get together and fire each other's enthusiasm.
Bernie
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A question to you Bernie. Since you are going to make the pattern for the driver centers are they just spoked or do they have counter weights included?
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Well, While not necessarilly parts, I have been doing fair amount of drafting. Each one takes me about ten hours. As nice as the drawings look, I don't think thats the kind of excitement your looking for.
I do agree seing parts is verry exciting!!!! With that front axle done we could press on wheels and shrink on tires! Now THATS worth getting fired up over!!
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Paul,
The lead drivers are spoked only. There is enough weight in the crank to balance the rod. I haven't looked at the drawings for a while, but there may be hollow areas in the crank(s) to accept lead.
The main drivers have counter weights. I am going to make one pattern for both sets. The pattern will come through with the counterweight attached, be rammed up in the foundry, and then the counterweight will be removed and the plain spoked drive wheel center will be rammed up.
Vince,
All parts of this project are important, the drawings being the first step without which we couldn't do all our work. I have spent considerable amounts of time just studying the drawings I have. Being a retired art teacher I appreciate the drawings very much. They are the start of the dream!
Since this project seems to be taking off we should communicate more with each other to know what is currently happening.
Bern
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Here's what Bernie's been working on...
(http://build11.org/images/480_drive_wheel_center_pattern_sm.jpg)
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I assume this is an outside frame locomotive with counterweights on seperate cranks outside the frames?
Keith
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It's buried somewhere in this forum, but No 11 is a planned reconstruction of WW&F No 7, an outside frame 2-4-4 Baldwin of 28 tons. We've been working on design and drawing for this project for many years- using the original erecting card, a smattering of BLW component drawings (not many), BLW standard practice books and numerous other locomotive and general design resources. Bernie has been doing a spectacular job on pattern-making for several years now- completing a number plate, bell bracket, lead truck wheel center and now drive wheel centers. Bernie also made the pattern, and had cast, No 10's number plate. Eric Bolton, Vincent LeRow, Steve Smith and I have been doing finish drawings, all by hand on size C paper, as fast as I can kick out design sketches. About 2/3 the drawings are complete, and the locomotive is completely designed (i.e. structurally and dimensionally figured out and sketched) except for boiler and brake rigging. Lately I've been spending some time trying to figure the best way to manufacture equalizers.
No 11 is an enormously fun project to work on, at least for me and I suspect the other guys involved. The board is fully behind it- but no one makes any pretense about the project's priority. No 9 is the priority right now- as promised to the membership for many years. We hope that our infrastructure grows at the rate that the No 11 project progresses, such that 3 locomotives will be appropriate for our desired (typical) 2 train operation someday. Our goals with No 11 at this time, as No 9 progresses, is to keep the project alive and progressing such that when No 9 is done, we're prepared to jump on some exciting parts of the project, which should in turn help with getting folks excited for fundraising. For now that means getting the design and drawings wrapped up, getting some important patterns made (drive wheels and driving cranks), and getting a few juicy tidbits actually built (bell, lead truck wheel, etc).
We're trying to be particularly careful with the project in regards to No 9- we are fully committed and excited about No 9 and don't want No 11 to overshadow those facts. So for now it's a quiet but determined effort- it's not a secret but we're not shouting out loud (yet).
Jason
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Will the bearing(s) be brass or roller? If they are brass, what are, if any, ways of lubricating the brass? I am thinking like grooves and such?
Rob
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AFIK The bearings are going to be brass. they are lubricated with a purple grease that is sqeazed down from a grease cup over the bearing. Underneath the bearing is a grease cellar which helps lubricate the axle as well by catching the gease that rolls out of the bearing. It's essentially the same way the rods get thier grease, with the little cup on top that you turn untill the grease oozes out the side oof the brearing. At least thats the way #4 works.
Jason will know better and probably explain it better as well. I suggest PM'ing him for more and better information.
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Rob,
I have no idea what type of bearings are planned for No. 11...but standard practise for locomotives with plain friction bearings was to use bronze, not brass and the bronze was almost always lined with Babbitt metal. The Babbitt metal was hand scraped to fit the axle closely, and did have grooves chipped in to expedite oil flow.
Roller bearings present some problems, notably they are difficult to replace in the event of a failure. To change a roller bearing you have to remove the wheels from the axles. With Babbitt metal lined plain bearings you just drop the cellar, which is an oil reservoir at the bottom of the driving box, and you can then lift the bearing away from the axle without removing the wheels.
Keith
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AFIK The bearings are going to be brass. they are lubricated with a purple grease that is sqeazed down from a grease cup over the bearing. Underneath the bearing is a grease cellar which helps lubricate the axle as well by catching the gease that rolls out of the bearing. It's essentially the same way the rods get thier grease, with the little cup on top that you turn untill the grease oozes out the side oof the brearing. At least thats the way #4 works.
No. 10's rods are lubricated with oil, not grease. The rod oilers are replicas of Lunkenheimer cups that have an oil reservoir topped by a hemispherical chamber. As the locomotive moves down the tracks, oil splashes up into the hemisphere and some drops down into a feed tube that supplys the bearings.
Keith
Attached is a picture of the rod oilers when they were being made.
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A question to Jason. Will the Main frame rails be fabed,cut, or cast. The origianal would have been cast. Now however with modern shop pratices either fabracation or cutting are prefured.
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Another question to Bernie from the picture it looks like the counter weights are to be detachable additions to the main pattern. Is this correct? Also will you or someone else be making a pattern for the outside counter weight or will these be cut and machined from platte steel?
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Paul,
You are correct, the counterweignts will be removable from the patterns. I mentioned ramming up the main drivers first, because I assume there may be some damage to the counterweights when they are removed. It is also possible that some filler will have to be removed at the foundry and sanding done before the lead driver centers are cast. If we were making many castings, then it would be wise to have two separate sets of patterns.
I have the drawings for the cranks and a while ago had some discussion with Jason about them. It is my intent to make these patterns too, but as I do most of these by hand, I would like to say that I would like to get the driver center patterns done first and then go from there. The cranks are distinctly different and two separate patterns will be made for them.
Bernie
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We're currently planning on waterjet cutting the frames from 3" plate- though it's still some time away. Crank/counterweights will be cast of steel.
Jason
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Although he's been just a tad busy with a certain CNJ 0-6-0 restoration in Minersville, PA... Bernie has continued to plug away on the wheel center patterns for the No 11 project. I may be getting ahead of myself, but it's going to be absolutely thrilling sweating tires onto the castings born from these!
(http://img.villagephotos.com/p/2003-8/342468/WWFRR_11Drivercenterpatternsprogress002sm.jpg)
(http://img.villagephotos.com/p/2003-8/342468/WWFRR_11Drivercenterpatternsprogress001sm.jpg)
(http://img.villagephotos.com/p/2003-8/342468/WWFRR_11Drivercenterpatternsprogress003sm.jpg)
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All,
Thanx Stephen for posting the photos. I had to put this project on the back burner because I have too many projects going, and the ones that have a certain completion time must be done first. I am now back to the #11 project and it would be nice if the plain spoked pattern would be done in time for the work weekend. I was originally planning to make just one pattern with removable counterweights, but decided it was only a little more work just to make two patterns. I used the various plies of the plain pattern to lay out the counterweighted one and it should take less time. It would be nice to see all these patterns being used for more than one locomotive.
One project that took mountains of time was the CNJ whistle project. The plan was to make only two whistle bells. In the end we cast 11 and I finished ten up to 220 grit finish. I mirror finished mine.
For anyone interested, we should be putting a fire in CNJ 113's boiler in a month or so. I have been looking forward to that for a long time (over 10 years).
Bernie
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Are the patterns adjusted for shrinkage? Just curious as I would think that since they will be machined the measurements don't have to be as precise?
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Robert,
Yes, they are adjusted for shrinkage. Jason and I discussed the outside diameter to allow for shrinkage. All the surfaces that are to be machined are also thicker. I tend to leave more metal available for these two circumstances than most patternmakers would. My philosophy is that it is easy to take metal away from a casting than to add it on. Since these are not for any production runs where time is a factor, I don't concern myself for how long it takes to machine the parts (the machinist may feel differently and years ago, one reminded me that there was way too much metal to be taken off).
I would note that I am not a commercial patternmaker. I am "self taught" and learned by trial and error and asking questions at the foundry, the school where I worked and alot of reading. Also each foundry has its own ideas and I try to adjust to what they want. I could go on and on about this, but way back in this forum I wrote much about this.
If the #11 project is to be finished in a timely fashion, we are going to need more patternmakers and machinists and, of course, wheelbarrows of money. This is why the display is in the freight house--to show that we are serious about this project and will really attack it when #9 is finished.
Bernie
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Bernie
Since the machineing will most likely be done by Jason if he is ok with the amount of materal that needs to be removed then what is the problem? By the way great looking work!!!!!!!
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Are the centers pressed on to the axle or keyed? I would love to learn how to make patterns and castings. Has lost-foam casting ever been talked about?
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I think we used lost-foam for the casting for #9's new frame piece. The first place didn't do so great a job. The second place did better, but unless the place knows what their doing I don't think lost-foam is a great solution.
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B E A utiful Bernie. Keep up the great work.
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All,
To answer a few questiions:
I believe the axles will be keyed and pressed on. I stand corrected on that one.
As for too much metal to machine, that will have to be directed to Jason. It really isn't really THAT MUCH metal. The only thing he commented was that he wanted the axle holes cored out on the driver centers to save time. I did not do that on the leading truck/railcar wheel centers because they were to be machined to two sizes. I could have probably cored it for the smaller size. I also ask myself which takes more time--making the core box or drilling and finishing a solid casting. If favors the coring process as the number of castings increases.
As for learning how to make patterns: read one of the many books out there, make a simple pattern, get it cast and go from there. For what we are doing, it is not rocket science. The pattern that will be a real headache will be for the cylinders if we finally decide to cast them. We still haven't figured out that one, but that is a ways off.
Bernie
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Indeed beautiful work, Bernie.
Bernie is great at communicating the needs of the project well before making things final, and we had solid conversations on shrinkage and machining allowance. Everything he has pointed out is right on-- if we were making engine block castings for 10,000 model T's, there'd be less machine allowance- but we're designing this pattern for one 4-drivered locomotive, so an extra 1/4" to shave off here and there is well worth making sure the castings will end up being right (after casting flaws, etc). If they're used for more locomotives- great, I'd love to see that too, but any subsequent project will need to fit around the patterns made for this, the main project.
James is right about lost foam-- the first casting wasn't acceptable. The second casting was made from a conventional mold packed around a styrofoam pattern- the pattern was removed before the pour. I wasn't real pleased with this either as it was obvious that the pattern took a beating during the molding as some of the geometry was lost. I actually think lost foam, with a foundry familiar with proper venting, is better as the geometry would be better maintained. Bernie's wood patterns do two things that foam doesn't: it's a great representation of how they did it- we firmly believe that just having a steam locomotive in the end is not good enough, we want a machine that represents the era of the original, as much as we can anyway. and 2- it's permenant value; these patterns will be available for another project- which hopefully will serve as the excuse for another project someday.
Bernie has said it right- we are focused on, and need to follow through on No 9- then we're going to tackle this. One step at a time- great to see Bernie's steps in action!
Jason
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Where are the crankpin bosses? Is number 11 inside or outside framed? I forget...........
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Robert, Since Engine 11 will built along the same lines as the original WW&F number 7 it will be an outside frame locomotive.
Stewart
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Since you brought them up ;D ...here's a shot of No 11's crankpins, which were expertly machined by Bruce Mowbray.
(http://img.villagephotos.com/p/2003-8/342468/No11cranksbyBruce_photoSJHsm.jpg)
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Nice work. What type of steel was used for the pins?
Speaking of metals, will #9 and #11 use modern types of steel rather than historical types? I know cast iron is not a great metal to use anymore due to the fragile temperment it has. Ahhhh, educating myself on these topics is great mind excercise!!
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I beleive the crank pins were made from stock originally obtained for but not used for the axles on the wheelsets that ate now complete. Someone please correct me if I'm wrong.
I agree with you that educating oneself about these things is a challenging yet worthwhile pursuit.
I also agree that the focus should be where it is, on completing #9 first. That said, I cannot help but feel renewed anxiousness for #9 to be completed every time I see new parts show up for #11. Once she's finished, that is going to be one heckova' engine! ;D
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Material choice is a deep subject with no consise answer. The broadest brush is that a variety of materials are required in a steam locomotive based on the specific purpose- from gray cast iron to cast steel, mild steel both cold and hot rolled, bronze, and plenty more. A more indepth look shows that each of these "kinds" of material are generic descriptions at best- there are specific alloys and manufacture techniques for any of these metals. Depending on the purpose of the component- we are either not concerned with the specifics (simply stating 'gray cast iron' is good enough for a bell bracket), or very concerned with the specifics (we are using AISI 4140 Hot-Rolled Annealed for axles and crank pins). Critical components not only get their material very carefully specified but a record of the material's manufacture, including its actual chemical makeup and record of mechanical testing done, is retained by us to be part of a final construction package (someday).
Cast iron can be brittle and is far weaker in tension than in compression- for this reason it was never used for components subject to these stresses. It is still the only logical choice for many components. We have considered using ductile cast iron in place of cast steel for some components- with a monetary advantage but the disadvantage of not being weldable in case of a defect. Jury's still out- we may do some this way but keep the critical pieces in steel.
Generally speaking, we'd like No 11 to be built similar to the way it was done- using castings where castings were used, forgings where forgings were used. Some restrictions will force us to bend on some of that- but we'll be as true as we can.
Enough rambling...
Jason
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Pete, who expressed concern about #11's parts slowing up #9's progress and others with the same opinion.
I, Wayne, and Bruce live down here in Pennsylvania and have little ability to physically work on #9 and most of her parts are made. For myself, I have little desire to work on #9 either. I like to make new parts and for most of my hobby life have been making foundry patterns for the organizations I have been involved with. I have also found that people who work away from the base of operations and are working in their own shops are invisible most of the time (like myself) and are not appreciated by some of the people doing the every day grunt work. This attitude caused me to leave an organization and running steam and I pray that it doesn't rear its ugly head at the WW&F.
As far as I can ascertain, the only physical work done on site to #11 was the machining of the wheel center, pressing on the axles and shrinking on the tires and this was done in conjunction with the railcar and took up little time from #9.
The rest of the work was probably done off site and this includes all the drawings, all of the bell work, the builders and number plates and finish, the leading wheel center pattern, the driver patterns and the axle and pins. I don't think any of this in any way interferred with #9's progress.
If all this work wasn't done on #11, what would it be--just someone's distant dream which I hear other people ramble about on other forums about their dream locomotives?
Bernie
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Bernie,
I think you read me backwards. I am anxious (as everybody else) for #9 to get finished, but I also believe that #11 is just as important. Not just to the museum, but to the future of steam operations in the US, and perhaps elsewhere.
The products forged from your patterns are TOP NOTCH quality work and your dedication to them and the steam/RR community is beyond admirable.
My anxiousness is for us to hurry up and finish the work on #9 which is holding up #11!
I know that these things will all come in time, but in no way did I mean to infer that your work on #11 was in any way holding up necessary work on #9. I realize the major parts necessary for #9 are already on-site and, knowing how far CT is from Maine, I can understand why you continue your work in PA, even farther away from Maine.
That being said, it was a pleasure to have met you earlier this spring and to have seen the whistle casting that I had only previously seen in pictures.
Again, Bernie, your work is both important and outstanding.
Keep up the good work!
Pete
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It's been a while since I posted here and here is a good place to get back into the swing now that summer is over.
As Jason mentioned, the material used for the pins was chosen for it's characteristics. It just so happens that it's the same material used for axles. Also, it was about the same diameter for both parts. Originally, I was to make all of the the axles for #11. It was later decided to make the crank pins. So I just used the chosen material to make the crank pins instead.
Great work on the patterns Bernie. Am I sensing another circular "backshop" style BBQ in the spring?. Right now I am making parts for the big lathe at the WW&F shops so that future projects, like #11's wheelsets, will go smoother. I will be coming up this fall to get that machine back in running order. My buddy Ed G. and I plan to spend some time on the machine improving some of it's less than desirable traits.
Removing 1/4 to 1/2" of material from parts as big as wheel centers is not a big deal. When not in mass production, it's better to have more than enough material to machine off rather than not enough. This eliminates some of the "we shoulda' left more meat on in that area" discussions. It's far easier to take material off than to add some on.
As far as taking time away from the #9. Like someone said, it's easier to make parts from afar to engineered drawings for a new locomotive that will be built from scratch where known fits can be predetermined. I live in PA and to travel to Maine for more than a couple of weekends a year is difficult for me. I have a desire to help the WW&F museum achieve it's goal by offering my machining experience. I can do that by making parts here in PA and bringing them up when I can or shipping them with someone who will be Maine bound. The #9 is up there in Maine and many of the parts are already there awaiting rehab. This rehab requires having the mating part(s) on hand to check for fit and operation along with decisions being made on whether to make new parts or reuse the old ones.
Also, to have a big part of the #11 on hand is good incentive for some to keep the project moving forward. It shows that the museum is serious about building the #11. In the not for profit museum world, this is a good "seed" for getting the funding needed to keep the project moving forward. When benefactors and granters see their donations become something tangible, they feel good about donating again.
Time to go off to the shop and make some chips.
Looking forward to my next visit.
Bruce Mowbray
Springville, PA
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Hi Bruce, I'm a vendor at the AACA Fall Meet in Hershey, Pa. and will be running a motor home from Maine to PA by way of I-84 to Scranton and then down I-81 on Oct. 5. Then on Oct. 9 we run I-78 over to NJ for a quick visit on the way back to Maine. My motorhome is equipped to haul a trailer with a Reese Hitch, and the large plug in for brakes. I can't find Springville, PA in my Atlas, but if I can help in any way, let me know by email: glenns@tdstelme.net Glenn Byron, Smithfield, ME. (Belgrade Lakes area) There are several other Maine old auto nuts who also make this annual pilgrimage for the holy days of Hershey,the largest car show in the world. Anything that can save the museum a buck will help a little.
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Glenn,
Thanks for the offer. I may just take you up on it. I will be done with the parts for the bog lathe in the next day or so. If I find it may be a while before I can get up to Maine, I may have you bring the parts. My friend Ed may be visiting me sometime this fall, and I could send the parts with him. I may even get up there sometime this month. Either way, I'll keep you in mind.
Bruce
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Is #11's restoration going to kick into full swing after #9 is restored? Just wondering? ???
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We anticipate ramping the project up considerably after No 9 is complete- both with a lot more work at Sheepscot Station and with direct fundraising efforts. The current effort is establishing the project as real and definite- so when we really start asking for money- we'll already be well ahead of a dream on paper.
As with all projects at the railroad- No 11 will fit in with other museum priorities- and won't 'bump' everything out of the way. A direct effort will ensue, however.
Jason
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#11 isn't a restoration. It is the construction of an all new locomotive, pattened after the original WW&F #7. This was a 2-4-4T outside frame Baldwin, weighing 28 Tons. Slightly Smaller than B&SR 7 and 8.
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All, here is the latest from Bernie's pattern shop...the email simply read, "ready for Maine" -I had to smile at the simplicity of the message -given how complex this pattern is, and how much work obviously went into it. Simply gorgeous, Bernie! Thank you!
(http://img.villagephotos.com/p/2003-8/342468/WWFRR_11Drivercenterpatternsprogress012sm.jpg)
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Hey Bernie,
I spend as much time as I can spare doing grunt work at Sheepscot and I stand in awe of your work and that of Bruce, and the many other extremely talented artists "from away" who are doing yeoman's work for the WW&F. I am grateful for the contributions from you and your pattern work, Wayne L. and all of the "stuff" he locates and donates to the museum, to Stewart when he lived away, to the Mass contingent, to Steve H. our master of the photographic canvas, and to all of the members from far away who give 100% of the time they can spare either at home or on site, to make our mutual dream come true. The thing I like most about all of you/us is that we seem to hold that common dream of restoring a Maine two footer and we don't lose sight of the dream even with all of the personalities and egos involved (and we all have one of each!). We seem to have a real band of kindred spirits in this organization. As one whose talents are limited to pounding spikes and shoveling ballast and a bit of dabbling in a few other areas, I count us lucky to have each and every one of you and I take off my virtual hat to all of you and say: Thanks a million for helping make MY dream come true with all of your fantastic work! No one takes you for granted.
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Bernie,
The only thing I'd like to see more than your pattern rolling across a floor is seeing the actual wheels turning on #11. Looks beautiful. We are going to have to display all these great patterns when the loco is complete. Thanks for all the work you put into them.
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Dana,
I really appreciate your comments. Whenever you post something like this, it represents a lot of deep perception and insight into the volunteer situation at the WW&F. Whenever I came there for the work weekends I have felt perfectly at home and right from the first visit became involved with #11/railcar projects. I don't know if the work weekend sessions are unique to the WW&F or not, but I do not see any references to any others on the few forums I read. I hope the situation stays the same. By unique I mean that everybody is welcome to work, not just members. I am familiar with the sessions at the EBT and the C&TS.
I know that display space is extremely limited, but it would be nice if ALL the patterns and parts for #11 could be currently displayed. It would be a little more impressive and show that there is a deep commitment to the project already. I know that the WW&F is not pushing getting money for this project yet, but if there are any of those people out there who keep talking about building new locomotives would contribute a little toward getting turning stock, Bruce could be "turning" out many more parts. I have personally supplied all the plywood, materials and tools for my patterns and Wayne and I paid for the bell bracket, and Stephen purchased the plates, and this has added up to many hundreds of dollars toward the project already (I don't keep a record as it would probably scare me).
Bernie
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Bernie, these patterns belong in an Art Gallery, not buried in a sand box.
As a suggestion, how about setting up a site where photos of all the patterns and parts could be displayed as they are completed.
We certainly don't have enough space to display them properly on the property at the present time. That may be an enducement to some to contribute to a #11 fund although this shouldn't draw funds away from the current hot projects but obviously money is being funnelled to #11 by those in the know and those who are interested.
Win Nowell
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Here's another picture (with Bernie in it!) that shows the scale of this pattern!!
(http://img.villagephotos.com/p/2003-8/342468/WWFRR_11Drivercenterpatternsprogress011sm.jpg)
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Incredible!
I have to seriously reign in my own excitement when I see photos like the above, otherwise I'd be all "giggly and jiggly" like a schoolgirl! ;)
That being said, I don't think it's possible to overstate the importance of this project to the world of preservation at large, railroading or otherwise. The implication is that not only can we build a locomotive from the railhead up, we could, if necessary, duplicate any part necessary (ie: a cracked drive-wheel core) to keep the existing ones running.
I understand that the museum and it's BOD have chosen to handle the #11 project with discretion at this time and I understand why, but that only makes me look forward that much more to the day when WW&FRR makes "The Big Announcement" to the world about #11. I can only imagine the jaw-dropping and eye bugging that will occur later.
To date, there have only been three "from scratch" steam locomotives built in recent history (that have gotten any serious attention, at least.) The A-1 "Peppercorn," the "CPRR Leviathan," and the 3' ga. 2-4-4 (whose name is on the tip of my tongue right now.) There may have been others (possibly Welsh 2'?) and I do not mean to take away from them as such, but I think we all can agree that such projects are indeed rare.
The possibilities of what projects could follow this one are even more staggering! Weather from or for WW&F or another such group, the idea that a 2' locomotive can be built from scratch invites us to beleive it possible for us to someday see SR&RL engines like #10 or #24 one-day roam the backwoods again.
Who knows what will follow? Nobody can ever say for certain, but those of us who dream of such things can now feel a certain sense of validation for our dreaming.
I will go as far as saying that I'm willing to be the first to contribute to a #11 fund if and when it is established, even so far as to earmark a donation as such in order to make it so. I may even attempt to do so this weekend.
In the meantime, I look forward to seeing the results of Bernie's fine work gracing the shop-floor in person, hopefully before this time next year.
Thank you Bernie and Bruce for giving life to our dreams.
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Absolutely beautiful -completed counterweight drive wheel center patterns from Bernie's shop... I've got some stills and video of Bernie working on these, which I hope to edit and post soon! Thanks, Bernie!!
(http://img.villagephotos.com/p/2003-8/342468/WWFCounterweightdrivewheelcenter003sm.jpg)
(http://img.villagephotos.com/p/2003-8/342468/WWFCounterweightdrivewheelcernter004sm.jpg)
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Thanx Stephen for posting these photos. The work on these actually started before the plain spoked driver center patterns were finished, so it has been a long haul. What I look forward to is seeing #9 finished and running and getting the #11 project off the back burner. There are several of us just chomping at the bit to get this project moving along. I am working on the core box for these patterns, and the next are the cranks. I hope they can be cast in 2012 and the machining can start.
Bernie
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Is the core box used to make the counterweight portion hollow?
Will the journal boxes be cast?
Your patterns all look too pretty to use!
Dave Crow
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Dave,
The counterweights on the driver center will be cast solid. The faces on the counterweights are thicker on the pattern and the castings will be machine faced to adjust somewhat the balancing forces. I haven't fully discussed the cranks with Jason, but at least the ones on the main drivers will be cored hollow to pour in lead to adjust the counterbalancing. I do not know if the cranks on the lead drivers will be hollow or cast solid at this time. If you saw the pattern for the lead driver centers, there was no counterbalance on them at all. I will be starting the patterns for the cranks in a month or so.
The core box I am making now is for the axle holes. The core print is the nub in the center of the pattern. This is usually painted yellow or orange to indicate a core. For display purposes I chose not to do this to keep the patterns "pretty". It will probably be painted by someone up there before it goes to the foundry, along with the inside of the core box. I did paint the core prints and core box for the bell bracket.
Jason will have to answer the journal question. At the Strasburg RR shops, they have made journal boxes out of solid slabs. The crown brass is machined from hollow round stock rather than from a casting. I visited the shops recently and saw some blanks for the crown brasses on the floor. This eliminates hitting air pockets in a casting.
Bernie
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Behind the scenes, a couple of months ago in Bernie's shop...
(http://img.villagephotos.com/p/2003-8/342468/Berniebandsaw_sm.jpg)
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(http://img.villagephotos.com/p/2003-8/342468/BPwheelvertdremel_sm.jpg)
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Journal boxes in the 2 foot gauge size could easily be made from bar stock. If they were going to be cast, I would make them of cast steel. This gives the shop folks the opportunity easily to weld them up if they break or get worn. Even wheel centers and truck frame parts should be made from steel castings for the same reason - ease of repair and rebuild when necessary. In the journal boxes I repaired for the 0-6-0 I am working on, I chose to use continuous cast bronze tube for the crown brasses. With the aid of a CAD drawing, I figure out the ID and OD of the material so that I can get 2 brasses out of a round tube. This cuts the material cost by 1/3 since the brasses go a little more than 1/2 way around the axle.
Bruce
Bernie, Beautiful pattern work!! It was nice to see you up at ST. Wish I had more time to chat with you. Maybe next time.
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All, more phenomenal pattern work by Bernie Perch. Bernie brought this one up last month, but I think everyone was so blown away by "the whistle" 8) that this gorgeous pattern slipped under most people's radar. Since this one's got the counterweight, I decided to bring it into the shop and set it next to No 9's drivers. And with No 9 coming back together, we're actually getting close to casting these!
(http://stephenhussar.smugmug.com/photos/i-zSknw24/0/L/i-zSknw24-L.jpg)
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Stephen,
Thanx for posting the picture of the comparison of the drivers. Except for when we blew the whistle for the first time, I generally kept a low profile even though most of the time of the work weekend I was walking a foot off the ground. The wood for the cranks arrived and I plan to start them shortly. I am looking forward to when the #11 project physically starts. It's been a long wait for me (since Oct. 2006) when I first talked to Jason about the project, and longer for those who were working on the drawings.
To start enticing those who may be supporting the project moneywise, maybe you should show a photo of all the patterns (3 wheel centers, bell bracket) and all the parts which have been made (lead truck wheels and axle, machine work by Bruce, bell and cradle, and plates) or accumulated (headlight and ?) to show that we are really serious about this project.
Bernie
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Thanks, Bernie -I'll try and put something like that together. Here are a few pics taken in Bernie's shop during the creation of this pattern...
(http://stephenhussar.smugmug.com/photos/i-3mdtwg8/1/L/i-3mdtwg8-L.jpg)
(http://stephenhussar.smugmug.com/photos/i-MxtcwHd/1/L/i-MxtcwHd-L.jpg)
(http://stephenhussar.smugmug.com/photos/i-tTtchmc/1/L/i-tTtchmc-L.jpg)
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I did a short search of the group and didn't find a really description of the Design of the No.11 which pattern, Locomotive builder is being copied? Are there any complete CAD or illustration of the project? Have you considered releasing the drawings to the modeling world to create interest and excitement, people could buy copies of the drawings with receipts going to the project and then when No.11 becomes public then people can show up with their models to pose...
Stephan please keep posting more pictures of the No.9 rebuild they are great quality and show cool details that you would never see like how the frame has extra bolt in piece for the cylinder saddle, not baldwin practice...
cheers
Thor
www.thorsteamworld.com
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Thor, Loco 11 is a copy of the WW&F's locomotive #7, a Baldwin-built engine. #7 was a "modified Forney" - a 2-4-4 RT. We have a set of plans which would have come from the Baldwin archives (which I believe is located at RR Museum of Pennsylvania). The archive owners would have the exclusive rights to reprint the plans, not us. Nice thought, though.
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James et al, I believe the DeGolyer Library at SMU has most of the Baldwin steam archives...
http://smu.edu/cul/degolyer/collections2.htm
Stephen
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I believe that what the RR Museum of the State of Pennsylvania has, is the Broadbelt collection of glass plate negatives of Baldwin builder's photographs. A good place to get a copy of the builder's photo...as the museum sells copies. Those old glass plate negatives give you remarkable detail.
Keith
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Stephen....Hussar, that is: Some years back you posted a photo of WW&F No. 7 in which you had changed the number on the cab from 7 to 11, I guess with Photoshop. As I recall, it was a nice picture. Would you perhaps still have that image? I was thinking it might be interesting to Thor, and to others to have started visiting the Forum since that time.
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Ooops! I forgot that the picture is already in the Build No. 11 section of the WW&F website. Sorry 'bout that.
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(http://stephenhussar.smugmug.com/photos/i-NKW6hM2/0/M/i-NKW6hM2-M.jpg)
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Hi Guys,
Thanks for the feed back, just found the specs for No.7 and 2-6-2 No.6 in the Baldwin order books. If anybody doesn't have these let me know I will gladly send you the zoomed and cropped pdfs that I secretly prepare at work... ::)
So for future projects and documentation of our locomotives in Brazil, I'd like to ask the group if anyone knows of drawings or detail pictures of the Eames vacuum brake equipment that was delivered on a lot of the Maine 2fters? We found the original patent documents which have pretty good illustrations but not the same as drawings or of scalable pictures.
I have seen reference to Sandy River & Rangeley Lakes Railroad and Predecessors, Equipment and Manufacturers, Vol. I or II by Jerry DeVos. which said something about Eames but at $60 and oversees shipping it is alot on a gamble. Can someone recommend a source, book or confirm that there is enough info to worth it?
I am scouring the Baldwin records for other 2ft/60cm engines and there are some interesting ones coming to light in Mexico and other South American customers, searching for them would be hard since most were bought through brokers so I find just going through the records page by page is best. If anyone is interest I will share.
Two more questions, anybody have experience ordering pictures and alike from Pennsy Museum Broadbelt collection? I can't seem to find an indication of typical prices, delivery times and payment options.
Last question, anybody have an idea which 2-4-4 Bachmann used as the prototype for their outside frame models or is it a cross between inside/outside locos?
Thanks
Thor
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Thor,
If you are able to access Google, I found some great drawings by searching for "Eames Vacuum Air Brakes" and "Eames Vacuum Air Brake Ejector". Take a look at this link:
http://books.google.com/books?id=Ah1PAAAAYAAJ&pg=PA141&dq=Eames+Vacuum+Air+Brake+Ejector&hl=en#v=onepage&q=Eames%20Vacuum%20Air%20Brake%20Ejector&f=false
Dave Crow
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I know that various parts are being produced for the planned WW&F locomotive #11. Has a dedicated building fund been created to set money aside so that when work begins in earnest there will be funds on hand? I'm sure many members and friends are eagerly awaiting the completion of #9 so that the new locomotive project can move into the shop. And I'm equally sure they'd be willing to toss in some money up front.
May donations be made specifically for that purpose and so noted, or will that add too much to the bookkeeping? I think that it's never too early to get a jump on what probably will be a long project, and get some funding in the bank. What say you all?
Richard
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Dick, it is an official project, and there is a "dedicated column" in the books for No 11 funding -so donations toward No 11 are happily accepted! Good timing for your posting as we're almost ready to start fundraising in earnest!
Stephen
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Well that's good news. At the same time, we don't want to shortchange other ongoing projects which may need a final boost over the top.
If every member were to donate just 11% (#11, get it?) of their tax refund when it comes back in April, I'll bet we could put a nice tidy sum in that column of the bookkeeper's ledger. What do you think? I'd be up for it. How many others can we get to make a similar pledge?
Richard
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During the annual fund raiser, I requested that mine go to the #11 project and my thank you note stated that it did go into that fund.
Bernie
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How much is in that fund at present?
Richard
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As much as I'd like to agree, if we all gave to #11, the rest of the major projects would become underfunded. We have #9 to finish, bathrooms to construct and a parking lot to build before #11 will show up. And that list could also include a Roundhouse and Turntable to keep the Locomotives in. It is great to keep some funding going for this project, so it continues to progress, but will be quite a while before I earmark any of my donations for it.
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How much is in that fund at present?
We have $50 in the #11 fund right now.
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FIFTY? That's it? If we did the 11% bit just ONCE, we could then let it rest and go back to funding the other projects Mike mentions. We're not prioritizing it. But let's at least give the #11 Fund a running start. It would not have any further effect on the ongoing project funding. Just a one time kick in the pants.
Come on, who's up for it? There must be someone else out there.
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Dick, Mike is correct, and this is why I wrote "we're almost ready" in my initial reply. The plan is for everything concerning the No 11 project to "ramp up" once No 9 is finished. Several members (on their own) have already donated funds, time, patterns, drawings, etc., so the $50. James mentions is merely "today's" balance.
I'm sending you a PM with more details...
Stephen
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I guess everyone knows how much I contributed in my above mentioned post. I know we need lots of money for this project, but many other things can be done. We are going to need more pattern makers and machinists to get this locomotive done. The more that is contributed by volunteers, the lower the overall cost of the locomotive will be. Outside labor costs are extremely high. We have a machinist with access to a big shop here in Pennsylvania who is just waiting for raw material.
I have been involved with this project since October 2006 when I was introduced to Jason by Wayne. Over the years, I have made several involved patterns and have from 500 to 1000 total hours in them. I am currently working on the cranks which should come up in Arpil. I have paid for all the materials myself and along with Wayne paid to have the bell bracket cast which is now on display in the freight station. I wish I had known about the foundry in Auburn, as it would have been much cheaper than the big foundry we had them cast in down here. We both have $1000-$2000 in castings, wood, supplies and tools which we have donated. I'm sure the commercial prices for the patterns I have made would range from $10,000 to $25,000.
What I am saying is, if you want to see this locomotive get done, get involved! The reason I am so involved is that since I live down here in PA, there isn't much I can do up in Maine on the physical property of the WW&F. I would also like to state that I am not a commercial pattern maker. I learned the hard way when we needed them at the WK&S and later at Project CNJ 113. Just because you don't know how to do something doesn't mean you can't learn. The whole railroad at Sheepscot was built that way.
Bernie
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There's about $6000 in the project so far, not counting the value of Bernie's patterns. The $50 is just what we have in cash dedicated to the project.
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A good bit of funds (that were donated for #11 over the last few years) were used on the construction of the pony truck wheelset. Monies were used for the axle, cast wheels and tires. The lead truck wheelset is the largest part of #11 to be built so far.
Stewart
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I have been admiring Bernie's pattern work for some time. There is one thing that bothers me 'tho on the latest picture of the driver for #11. There is no provision for the crankpin! A drive wheel is not of much use without a crank!
I know that this project is being somewhat kept under wraps for the time being for financial reasons but it would be nice to know who are the leaders of the project. We know Bernie is the pattern maker and I assume Jason is probably the project manager but he is already overloaded with rebuilding #10. I have heard rumors that someone is doing the drafting and castings have been ordered for the front truck so someone must be doing some machining.
I am not being picky, just curious. Although I don't get up as often as I would like I am still interested.
Win Nowell
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Hi Win,
The difference in wheel centers is because #9 is an inside frame locomotive with crankpins on the wheels and #7 (which #11 is based on) was an outside frame engine. The crankpins on an outside frame loco go on the counter weights outside the frame so there's no crankpin on the wheel center.
Stewart
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Bernie is working on the crankpins/counter weight patten. He sent me a picture - great looking pattern. Massive looking too, much like #6/#7.
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OK - Thank you both for straightening me out! Now I've got to find some photos to wrap my head around that one!
Win Nowell
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Take a look at the locomotive photographs in the original railway section of the museums website. There is a photo of #7 showing the cranks and counterweights.
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(http://stephenhussar.smugmug.com/photos/i-DfpVTP8/0/O/i-DfpVTP8.jpg)
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Stephen,
Thanx for posting the picture of the crank pattern. What is shown are the two halves of the main crank. I am working on the lead crank and when the construction of that one is done, I will paint on the finish of both and then photograph them together for everyone to see. There are also 5 core boxes to make. The lead crank has a smaller counterweight and will not be cored for a lead filled pocket as will the main one.
All this talk about #11 keeps my juices flowing and keeps me focused on the project. Remember if there are any more people out there who can make patterns, we can use more. All of mine are donated, including materials. Remember that it is going to take alotta money to make this locomotive and for all those who are talking about building new locomotives, here is your chance to help in some way. I have explained my position in many previous posts.
Bernie
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How about posting this on RyPN with a much larger readership?
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James Patten
James if you would like to put me in touch with Bernie or whomever - I would like to volunteer to do some pattern work as Bernie requested.
Win Nowell
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Win, I've sent you Bernie's email - but you should also be in contact with Jason Lamontagne, as he is Master of Ceremonies for this project.
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The work that you guys have been doing on #11 and #9 is really incredible. The WW&F has stuck in my mind since my short visit in July of 2009, and I've been reading the forums on and off since then, being quite inspired by you guys the whole time. I live in Texas, making the trip to come and volunteer on-site a bit difficult, but as a woodworker, I would love to try and learn how to make patterns to contribute how I can, or anything else possible with the distance for that matter. I know I'm new around here, but how can I help?
-Alan
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Alan,
First, please join the Museum as a member, if you aren't already one! Financial support is just as important as volunteer support.
Second, reach out to Bernie and Jason (you can send them a message via the Members link on the toolbar at the top of the page).
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I'd hate to say it, but I don't see the museum being ready to really start working on #11 till 2015 at the earliest. I'd rather see the money be used for extending the railroad, either main lines, or yard tracks, and maintain what we currently have track wise and locomotive wise, including the #10, and soon to be #9, build the bathrooms, etc. To build such an engine will cost, I'm going to guess $500,000. Shouldn't that kind of money be used to make the museum better? Granted a new steam engine, especially a 2-4-4 would be amazing, but shouldn't we focus on our current goals?
Although, the rate that things have been going on working on #11 now in my mind is great, because then when the railroad is ready, we will be that much further ahead.
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I am wondering if Joe's post is just his opinion or does it represent a general attitude of others concerning the #11 project? I know that what he said is reality and the cost of this project is really mind boggling. Jason seems very positive about it and has been keeping us in plans, and I am nearly finished with the crank patterns and all their attendant core boxes. Two others have stepped into the pattern making phase of this project and I hope we are not wasting our time. I am planning to purchase the wood to make the pattern for the casting between the the front and rear frames. I would like to know the opinions of those in power whether or not I should take on this pattern. Are there people up there who would just like to see the project disappear as too expensive and too impractical?
My goal in going ahead with the patterns was to get the project from the drawing phase to a physical phase. Will it instead proove that this is not the way to go? I am 66 years olde and if this project is not going to start before 2015, I can spend my hobby time elsewhere.
Up until now my posts concerning this project have been very upbeat, but Joe's post has sent me thinking otherwise.
Bernie
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Bernie, I meant nothing bad by what I said, and by all means, I am really glad that you have taken the time, and the effort to work on #11. And I am not a member of the board either, so nothing I say should be taken so, absolute. I only gave 2015 as a rough figure in my mind. That gives the museum time to raise money for it, etc. But like I also said, the projects you have been working on from the start a few years ago, will make the project progress that much more quickly when it does happen. Sorry to have seemed so negative towards the project, because I am a huge supporter of seeing a #11 for many reasons.
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Speaking as a board member - the board has not changed its mind regarding #11. This is a long term project and will take a while to complete. While it may take $500K to finish building the engine, we don't have to have all money in hand to start. We didn't with #9. And like everything we do, we'll run the #11 project simultaneously with other projects.
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Since it was my idea to have folks send a donation of 11% of their 2011 income tax refund as a special "set-aside" for the #11 project, I fully intend to do just that as soon as my tax refund appears in my bank account. Various people put down the idea from the moment it left my computer keyboard, saying it would take money away from other ongoing projects. That was not the idea. The idea was to raise some totally new funding for a special project in an imaginative way. You know, thinking outside of the box.
If anyone would like to follow my lead with a similar donation to the #11 fund, I would encourage them to do so. I will continue to make my regular donations to the annual appeal, so the other projects will not be "short changed" by my specific funding of the #11 project. I suspect others will do the same.
Richard Symmes
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Hi all,
(Me speaking personally as I am not a BOD member, nor a member of the steam crew.)
I don't think anyone (BOD included) is trying to discourage volunteers to step forward with their donations of time or funds toward the construction of #11. I think we all agree that #11 is a long-term project, and it will be many years before a fire is lit in her belly.
Now, if someone came forward with a check for $500,000 specifically for #11, I don't think the BOD would put that aside either.
Honestly, I think the current approach is correct. Work slowly, but steadily on #11, in conjunction with the other important projects (rest rooms, ROW extension, parking, turntable, car storage, etc.) If we all do our part, we'll see #11 under steam soon enough.
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Bernie, thank you for keeping the No 11 project moving forward!!!
(http://farm8.staticflickr.com/7036/6976976983_3f1eb9107a_b.jpg)
(http://farm8.staticflickr.com/7204/6976977069_d50bc0496b_b.jpg)
(http://farm8.staticflickr.com/7179/6830850004_2bbabeaacc_b.jpg)
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Gee....those look like Lehigh Valley RR tracks in the background.....
Keith
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How much did the counter weights weigh? Those look great. Can't wait to see the actual castings.
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I guess we have to stir up this #11 pot every once in a while even though it is on the back burner. Getting it done is going to be a big challenge, but I plan to truge along making more patterns. The slowness of the pace can be helpful because then we are not rushed to get any of the patterns and parts done quickly. I am still adjusting my mind as to what "back burner" really means to the whole project. Whenever I get a pattern done, I like to see castings made and of course, this isn't going to happen for a while. I have to develop more patience with the pace of the project and once in a while my emotions and impatience will show. The next pattern will be the large casting between the front and rear frames. Since the pace is slow, I probably won't have it finished until next April unless the pace picks up for some reason. Two others have volunteered to join the pattern making and they are free to respond to all this discussion too. I just want to see this locomotive run while I am still alive.
No, I did not enter this discussion to get my picture in the forum again. It does add scale to the size of the cranks and they are quite large. They will come up for the April Work Weekend. The smaller core boxes for the pins and axles are almost done. I will then take a break for other projects.
Mike, I have been following your Rowmow project with great interest if without comment until this time. I love seeing someone take a lot of "stuff" and make something useful out of it. The railroad needs more mechanical maintenance items even if the original WW&F did not have them. Have you thought of what your next project will be?
Keith, that is the olde Lehigh Valley RR in the background. The eastbound main and team track are both gone, and way in the background the olde CNJ yard and main line have been replaced with a shopping center and parking lot for the Lehigh Gorge State Park and trail. I deliberately took the photo there. The tracks are adjacent to my property and I am serinaded by trains day and night. The CP and NS keep things humming and the R&N sends a local through. I was told by a railfan that if he lived there he would set up a camera with an electric eye. In reality I like watching and listening but have taken few photos. Once in a while R&N 425 pulls a steam powered excursion through.
Bernie
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I have a thought Bernie: Would it be possible on one of the larger events that the museum holds to have a small "casting pour" demo? I think it could tie in what is being done to make the parts for #11 on a smaller scale and educate people on how the process is done. For myself I would love to learn how to draw, engineer and make patterns and molds.
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Insert Quote
I have a thought Bernie: Would it be possible on one of the larger events that the museum holds to have a small "casting pour" demo? I think it could tie in what is being done to make the parts for #11 on a smaller scale and educate people on how the process is done. For myself I would love to learn how to draw, engineer and make patterns and molds.
There is a gentleman currently pouring some bronze pieces for me who might be willing to do just such a demonstration - I know he has held a few seminars and can pour cast Iron. He is also developing a product line for the Live Steam folks. If your interested PM me and I will send you his contact info.
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Can't wait to see those in person Bernie. Your work still amazes me. The pattern work you are doing now will save us a lot of time when we finally get going on this. This project, as well as many others, are the reason the museum is so sucessfull. There are some that may doubt that this locomotive will ever be built, but I have no doubt. And I don't care when it gets going if it takes 2 years or 10 to build, the work being done now is essential to the completion of the project.
No idea what is next for me. Probably an upgrade to Big Joe if I can get some shop space next winter.
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I'm one of two other people who have started to help out with the pattern making for #11, whom Bernie mentioned. I concur with the general sentiment that work and efforts on #11 should not detract from the ongoing work on #9, and the site improvements. It is impossible for me to help out with the projects on site, but I can make patterns and send them to up to Maine. I must say that it definitely keeps things low-stress without a full-tilt build going on yet. And as its been said, three years isn't too terribly long. But three years is definitely a significant chunk of time for a head start to be built up while other important work is going on. And any time saved by doing preliminary work now, will reduce the amount of work left to do once things kick off.
The work that Bernie has done so far is absolutely incredible. I have even more respect and appreciation for the skill which his work shows. I too will be very excited to see the metallic results of his work, I very much look forward to seeing the wheel centers turn a dull grey.
I have not been working for very long on this project, but to add to the status update; To get my feet wet, I have completed the assembly of the cross head guide yoke bracket patterns, and will now start on the smoothing and finishing. Next I'll be working on the two types of brackets which hold the pilot to the beam, as well as a pillow block. Hopefully, with everybody's efforts, we'll have a nice dent in the pattern making once attention is turned fully towards #11.
I wish I could say so in person, but thank you to everybody working from near or afar, for your time and energy spent on the museum. The work being done leaves me humbled, and very grateful that this project can be taken on.
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There are so many important items that can, should or must be cast in order to complete such a project.
These items (that I can think of off the top of my head) would be:
1) Firebox door
2) cylinders
3) smokestack and petticoat pipes,
4) the exhaust pipes that connect the cylinders to the smokebox,
5) driver boxes (if included in the design)
6) brake shoes, hangers etc.
Can anyone else think of any others I may have forgotten?
At the current pace, with 3 pattern makers working, I'd expect there'll be quite the pile of parts waiting in 3 years.
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Steam and sand domes. I believe the outer shell of both are cast.
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Steam and sand domes. I believe the outer shell of both are cast.
YES! Ty Joe.
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A complete list of parts (including castings) can be seen at build11.org on the "Parts List" page.
Stephen
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As I had promised in an earlier posting, I have today made out a check in the amount of 11% of my 2011 income tax refund, as a donation to the Locomotive #11 Building Fund. It goes in the mail tomorrow. If anyone else would like to do the same, I would urge them to do so, without using it as a substitution for your Annual Appeal contribution.
I also will be donating to the Annual Appeal next fall so that ongoing projects will continue to receive support. This #11 donation is a one-time idea, and I have fulfilled my part of the bargain.
Richard
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I do like the percentage idea. I think it's time to build a car 100 so we can get 100% of your refund next year. ;)
Seriously though, working on #9, from forming the back head to the rivets to puting the frame and boiler together has really got me thinking of #11. Can't wait to be at the same stage as we are now with #9. Just takes time and money.
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All very true, and that's why it's good that we are assembling parts and putting aside monies for the project so that when the time comes to shift attention from #9, we'll have a nice beginning to draw on.
At the same time, no one should expect this to take away from ongoing projects. This is like putting aside something for a "rainy day", only this is for something special which has nothing to do with "rain".
Hopefully others will jump on board and add their little bit to the "kitty".
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Folks, here are a couple of pics of new patterns for No 11, created by Alan Downey...VERY nice, Alan!!
(http://farm8.staticflickr.com/7117/7129124503_16136c0bf9_z.jpg)
(http://farm8.staticflickr.com/7269/7129124609_b5236c4b1a_z.jpg)
(http://farm8.staticflickr.com/7218/7129124729_c3e532e32f_z.jpg)
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What are the patterns supposed to be? Looks like the larger one may be the bracket that goes from the frame to the tank. They do look nice.
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Pilot brackets, I believe.
Stephen
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Stephen,
Thank you for posting photos of Alan's patterns. Alan and I have been corresponding during his initial pattern making efforts and I find him to be an extremely competent, intelligent and hard working young man. His emails are impeccable in their clarity and grammar. It is good to get young people involved in this project. The more who become involved, the more it can move forward even though we can't really attack until number 9 is up, running, and bug-free.
One thing which the photos don't show is the extremely glassy smooth surface of the patterns. In this regard, he has taught me some new methods I can use on my patterns and I will use them in my next efforts. One is never too olde to learn.
It was a super weekend with many important projects being worked on. I look forward to seeing the Turner Centre car at its display site and the resultant response by the tourists and hopefully, more of the locals.
Sunday morning during the weekend, I spent many hours with Rick Sission discussing pattern making. He is going to make working CAD drawings to the exact specifications of the patterns which will make our work easier. I look forward to making my next pattern from his drawings.
I am already thinking about October.
Bernie
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Stephen, Mike, and Bernie, thank you so much for the really flattering compliments. The closer these patterns came to being done, the more worried I was about making sure I got everything right, so it was a huge relief to get the thumbs up from Bernie on Thursday, and from you today!
I have to admit, I thought that patterns wouldn't be "that" difficult to make, but they really were a bit of a mind-bender at times! I would not have been successful had it not been for Bernie's truly excellent tutelage. My respect for the work that Bernie has done on #11 (and 113!) has grown exponentially after just barely getting my feet wet. I also have to tip my hat to Jason, and Vincent LeRow for providing some really excellent drawings that were a pleasure to work from, and to Rick Sission for his current work on the electronic versions of the drawings.
Stephen, your pictures made my patterns look a heck of a lot better than I thought they did. Thank you so much for posting the pictures, it was really great to see them in Maine. And yes, the larger of the two patterns is a bracket to hold the pilot to the beam. You can see it's silhouette in the builder's photo on the other page of this thread. The smaller pattern is the "cross head guide yoke bracket", and is a bit more hidden away on the engine. I am still working on a second smaller pilot bracket that can be called a pole pocket, as well as a pillow block for the tumbling link.
I have to fit my pattern making in between my studies and work, so my time spent making sawdust is never as much as I would like. But, I very much look forward to getting the other two patterns I have going wrapped up after my increasingly hectic semester ends, and starting the next set. I'll see if I can get a picture of the other bracket and pillow block posted here in soon. Again, thank you for the kind words, and stunning photographs. It's truly a pleasure to be a part of the project, and I hope to get a chance to meet some of you one day.
-Alan
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(http://www.philwieland.com/postcard/r/d6164.jpg)
Is this what #11 will end up looking like?
http://www.youtube.com/watch?v=otULlBTIYdk
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#11 is a 2-4-4T and is a copy of the railroads original # 7.
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This does not look like the proposed #11, but it would make a nice #12. Do they deliver? Just kidding. Very nice looking locomotive.
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Hi Robert,
As Brendan posted, WW&F #11 will resemble the original #7 which was a Baldwin 2-4-4T. Brecon Mtn Railway's #2 that you posted a photo of is a 4-6-2 built by Baldwin in 1930. It's a beautiful locomotive, I think it looks like Sandy River & Rangeley Lakes #24 which was a 2-6-2. There are a few parts of the future #11 at Sheepscot. The pony truck wheels, headlight and bell with bracket (to name a few) are on display.
Stewart
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Yeah I could not remember what #11 was going to look like, but I thought you guys would like that pics of the Baldwin. On a side note (power wise), two questions: Did Heisler produce any 24" gauge locomotives and did they ever build that three truck 4-cylinder version? I have all the patent drawings but cannot find much info about them (outside the larger ones).
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To answer my own question after doing some more research, a 4cylinder version of the Heilser was never built, and the smallest one built was a 36" 14ton loco. Nothing was built in 24", but I am still trying to find the Heilser catalogs from that time period.
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While I can't help you with a two-foot gauge Heisler, here's a photo of a sweet two-foot gauge 12-ton Shay.
While there never was a four cylinder Heisler, the British firm Simplex built at least one V-4 steam loco for sugar plantation service in the Pacific. I've seen a photo but can't seem to locate it right now.
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While I can't help you with a two-foot gauge Heisler, here's a photo of a sweet two-foot gauge 12-ton Shay.
While there never was a four cylinder Heisler, the British firm Simplex built at least one V-4 steam loco for sugar plantation service in the Pacific. I've seen a photo but can't seem to locate it right now.
It would be neat if the owner of that little Shay would follow the example set by the owner of Eureka, and brought that engine here to Maine to play!
Keith
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The only Heisler built for 24" gauge was shop number 1336 for the Laguna Corporation at Campeche, Mexico. It weighed 22 tons and had disc cranks with outside frame trucks. A rather nifty looking locomotive. This information is from the Heisler Locomotive book by Ben Kline.
Bernie
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Regarding the BMR #2 - maybe there would have been at least one of them here if the FS&K had been built and there was a good passenger market on the Farmington - Wiscasset route.
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I know this is way ahead of its time, but is there any plans for a replica of #6 (2-6-2) that would be the #12?
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John,
Jason and I briefly discussed this and this is the reason we are making patterns for #11. Many of these could be used for a replica of #12 but since some are smaller (cranks and cylinders), it would be a slightly less powerful locomotive (unless the pressure was raised from the original). Something like this could only be considered after #11 was finished. I figure about 2035 would be a good target date. The cost at that time would probably be about 2 1/2+ million dollars. By that time the large passenger consists from our wild popularity and through service from Wiscasset will demand such a locomotive.
Bernie
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Bernie's mention of 2035 is probably a good one. It is important that the WW&F Railway Museum grow right-of-way, support facilities, customer facilities, rolling stock, and locomotives in a uniform and orderly fashion. Needless to say, financial and manpower resources would have to grow at a similar pace. A fourth steam locomotive would have to fit into that overall growth pattern.
-John
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The only Heisler built for 24" gauge was shop number 1336 for the Laguna Corporation at Campeche, Mexico. It weighed 22 tons and had disc cranks with outside frame trucks. A rather nifty looking locomotive. This information is from the Heisler Locomotive book by Ben Kline.
Bernie
Thanks Bernie. I would love to get the drawings for the locomotive and see how they solved the truck gearbox with such a narrow axle.
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Just thinking out loud at the moment, but how would No. 11 size up against, say, one of the Henschel 0-4-0s at Boothbay?
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Probably 2.5 to 3 Henschels would equal (lengthwise anyway) one #11, from coupler to coupler
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Number 11 is a reconstruction of WW&F 7, so lolling up those specs can tell you a lot. 28 tons, 11.5 by 14 inch cylinders, 33" drivers. We are designing and drawing based on the original Baldwin spec sheet and erecting card for WW&F 7.
See ya
Jason
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So... No chance of finding one and re-purposing some parts for No. 11. Well, unless you find one that's far larger then one of the Henschel 0-4-0s that could provide some components to work with (motion parts, wheels, side rods, etc.)...
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So... No chance of finding one and re-purposing some parts for No. 11. Well, unless you find one that's far larger then one of the Henschel 0-4-0s that could provide some components to work with (motion parts, wheels, side rods, etc.)...
Dylan, the technology between the German Industrial locomotives (which are basically pieces of contractor's equipment similar to a bull dozer) and American mainline narrow gauge locomotives is just too great. The little German locomotives have plate frames as opposed to the much heavier American bar frames. The German locomotives have cylinders bolted to the frames, where the American locomotives use a split cylinder/smoke box saddle unit casting.
Basically to compare in modern railroad terms it would be like trying to build an EMD SD-45 by using parts from a Plymouth. :)
Keith
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Dylan,
In case it hasn't been mentioned fairly recently in this thread, take a look at Stephen Hussar's web site for the locomotive project:
http://www.build11.org/ (http://www.build11.org/)
I'm not sure if Stephen has updated his awesome photos of Bernie's (and others') patterns on the site or not, but most of that (recent) progress is documented on the pages of this thread. In addition, some of us continue to provide drawings for various parts.
Dave Crow
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Are their also plans on making a replica of WW&F #7's number plate, so when ever this locomotive is built and running in the distant future, so that we can make #11 look like #7 for historical re-enactments.
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All, one of the Bolster patterns for No 11 underway in Bernie's shop. Looks great, Bernie...thanks for the picture!!
SH
(http://farm9.staticflickr.com/8367/8420185886_ef76301ec0_b.jpg)
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Thanx Stephen for posting this. Any more pattern makers out there? We need a lot more to make and to get the #11 project moving along as soon at #9 is finished and we can all see that approaching.
Bernie
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Has anyone thought of enlisting local high school wood shops to make patterns of the more "simple" parts? Maybe something that should be considered and also as a way to generate interest in the RR with a younger generation.
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I second that idea. Is this a dying art?
Richard
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I don't think most High Schools even have a wood shop anymore...
SH
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Stephen,
That seems to be true. I know my high school dismantled one of two remaining tech classrooms (of the original 4 from when the schools was built) to add more space for other programs. I worked with my asst. principal (whose model of a Southern Ry. PS-4 on his desk attested to his interest in railways) to acquire some of the machinery from the shop for a local railway museum. Unfortunately, it did not work out.
While substitute teaching, I was witness to some absolutely scandalous things in tech classrooms. One day while subbing, we went through and identified the name and purpose of the different parts of the internal combustion cutaway they had in their room. They described it as "the most fun the ever had in tech" and were mystified as to why a music teacher knew stuff about a car engine.
Steve
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While I've never made patterns such as Bernie is quite skilled at, I am a fairly skilled woodworker and would be willing to help produce a pattern or patterns for this project. When next a pattern is needed, feel free to contact me and advise what I can do to help.
Duncan
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Duncan,
The drawing in the photo of my patterns was made by Rick Sisson and has compensated for shrinkage and machining. All you have to do is follow the exact dimentions and you will have the perfect pattern. If you start one and have any questions, just email me. I don't know exactly what Rick is working on now, but his work make ours much easier. Talk to Jason about what he wants next. Actually the one in the photo would have been a perfect beginners project.
Bernie
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Has anyone thought of enlisting local high school wood shops to make patterns of the more "simple" parts?
I could had done that 2 years ago while I was still in high school because I my school did had a wood shop and I was in that class for 2 years and I could had easily done you guys a favor but that was two years ago and my Grandpa's wood shop does not have the correct tools to make parts you need. :o :( :-\
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Bernie,
I have time and tools. I will have to keep in touch about making a pattern.
Duncan
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Has anyone thought of using a 3D Printer to make patterns? One advantage would be making a "model" of the pattern from a scaled down drawing to see it before going full size. 3D Printers are limited in size by their work area size, however patterns are typically made from a number of parts, so not a problem. Once a drawing is converted to 3D it can be sectioned to fit. 3D Printers are falling in price and now start a low as $500. They produce a product from ABS or PLA plastic and can be accurate to 100 microns. The software is freeware (for the most part) and thus could be shared between a number of "draftsmen". Also drawings can be saved on a memory card library for reuse or sharing. The final drawings can be e-mailed for production at a single site. Drawings would be something to do on cold, winter nights.
Surf YouTube to see the how's and what's of 3D Printing. Sample http://www.youtube.com/watch?v=LRv4jp-hhBE
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Yes, we've been talking about 3D printing for quite a while now.
Stephen
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how about patterns for parts to make #11 (7), in HOn2, O and G scale and then sell them as "custom" units.
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All, more beautiful patterns for No 11 from Bernie Perch...this is the Outer Bolster pattern. Thank you, Bernie!
Stephen
(http://farm9.staticflickr.com/8527/8551883582_200c44eb60_b.jpg)
(http://farm9.staticflickr.com/8385/8551884518_a55da1462d_b.jpg)
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Stephen,
Again, thanx for posting this. I have already started the next one which should be ready to bring up for the work weekend. Alan just finished some and the pile of patterns for #11 is accumulating. I am looking forward to seening parts on the erection floor.
Bernie
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This image is from Alan Downey and shows patterns for the Pilot poling Bracket, Pillow Block Core Box, and Pillow Block. Thanks, Alan...nice work!
(http://farm9.staticflickr.com/8093/8550784025_ef5987aef7_b.jpg)
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Wow - nice patterns by Bernie and Alan. Youz guys do beautiful work!
Stewart
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Nice work. I do have a question. What is the yellow for? Is it marking a location or are you making a pin for that?
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Thanks for putting the pictures up Stephen, and thank you all! I'm looking forward to bringing the patterns up to the museum this May, and getting the chance to meet and work with everyone.
Mike, the piece in the middle is a "core box". It's used to ram up the sand to form up two halves of a cylinder to create a core, which is used to create holes in the castings. I would imagine sometimes core boxes are a final dimension, but in this case, it's to aid the machinist in boring out a larger hole for the bearing in the pillow block. The painted yellow sections tell the foundry that there is to be a core placed in those locations once the halves of the mold are rammed up, and the patterns removed. The core box is painted yellow so that they know that it's a core box, and not something else. Bernie has made many more core boxes as well, including for the counterweights, he can also correct me if I've misstated anything, or not made sense!
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Gentleman,
Really beautiful work. I remember a while back when I was reading Dave Gingery's series on building a machine shop from scrap, he mentioned using auto body filler to create a fillet on castings. I see this on your pattern Bernie and was wondering what you use.
Take care,
Steve
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Alan,
Your description of the coring process and how the foundry recognizes it is correct.
Stephen,
I use homemade wood quarter round for most of my fillets. I used some plastic wood in some of the shallow and tight spots. Chances are it wouldn't hold up if the pattern was being used continuously. I should have also used wood in those areas. I never thought of using auto body filler although I have used quite a bit of it when my brother had an auto body shop. Alan uses a homemade mixture which I haven't been able to duplicate.
Also, the paper I promised to email to you about whistles during the last work weekend, I couldn't find it.
Mike,
If you wish to see more complicated cores, go to page 11 of this thread to see the one for the crank. The axle and crank holes are marked for cores, but the core boxes are not in the photos.
Bernie
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I've used "Bondo' in the past on patterns at the museum....specifically for coupler pocket and headlight castings. I'm sure it's been used on many other patterns too...
Stephen
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Alan,
Thanks for the excellent explanation.
Bernie,
Short term memory, and if I was to look back, probably the same question was asked then too. Perhaps even by me.
Excellent work by both of you guys. I can't wait to the these pieces come together.
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Dear Narrow Minded Gentlemen,
I am pretty interested in building or repairing 2ft gauge locomotives using modern methods and one question I wanted to pose is if there are full drawings and or 3D Cad drawings why not considering having the patterns machined out of wood or plastic for the complex shapes which are much easier on CNC machines. Surely some shop out there in east of US would be willing to donate some time if a 3D CAD model is available in a standard DXF or STEP file format?
The next idea I wanted to through out is if patterns are really only need once for one locomotive then it is not necessary that the patterns are re-usable or that they survive to collect dust on the shelf...
During my 2 years of working for BMW in 6 Cylinder engine development in Munich I watched all the technology of the current engines out of aluminum or magnesium and the cores these days are all injection molded closed cell foam where several pieces of very complex passageways for all the water and oil cooling and these are put together like a 3D jig saw puzzle, automatically and robotized assembly naturally. And these cores are then packed in sand and the molten aluminum then melts the Styrofoam into a noxious gas during poring. Theoretically just like lost wax casting.
For patterns in the size that we narrow minded people are creating we can imagine starting with big blocks of foam and cutting with hot wire, saws, filing and sanding, will make a mess but requires low-tech tools and you can use fillers, paints and puddy to fill things and create sealed smooth surfaces which would be of great advantage for surface finish in steam passages for a free breathing locomotive...
So just throwing my thoughts out, hopefully it will encourage someone to experiment. I hope to visit the No.9 & No.11 in the next years, have to wait for my 2 year old son gets alittle older before flying the 8 hrs from Germany to Maine.
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Thor,
Even though I have and will make more wooden patterns in the traditional manner for #11, I can agree with you overall and if I were in charge of building a new locomotive, I would use the most modern methods available but I am not in charge of this #11 project. Also most modern methods could mean more dollars.
The reason we are using the "Olde tyme" methods is that the powers to be wish to duplicate as many of the olde processes used when the original #7 (which we are duplicating) was built. There will be notable exceptions such as a welded boiler and some flame (or similar process) cut parts. I am encouraging them to use the "lost foam" process for the central frame section which would be a complicated wooden pattern.
Another reason we are using the wooden patterns is that the cost for the railroad is $0. All the patterns that Alan and I have made have been paid for by us and donated to the cause. There is a chance that when this project is started, others may want to build a locomotive and parts can be made by or for them with the patterns. Way down the road, other locomotives may be built by the railroad when the traffic demands it. This last statement may seem like dreaming, but who thought fifteen years ago that there would be the complex at Sheepscot that currently exists.
Getting back to what Thor stated, I will stick to the way they want it done at Sheepscot. If I were making #11, the tender truck wheel centers would be spoked like the lead truck with a tire (the pattern already exists and would get more use), it would have outside valve gear, and the cylinders among other things would be weldments.
I also agree that once a wooden pattern is used and finished, it is rarely used again except for grates or plates. I am a part of Project CNJ 113 and the pile of patterns we used on the locomotive, both commercial and mine are rather carelessly stored in a trailer, exposed to hot, cold, and dampness, and in a few years they will be worthless. We used "lost foam" patterns for the stack and base.
Bernie
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With the utmost respect for both the work that Bernie has done and his valuable opinion, my take on replicating WW&F 7 comes from a slightly different perspective. I feel that it is extremely important to recognize that the original machine was a product if its time, and if not for the technology from which it came, it would not have looked like it did or exist at all. By replicating such a machine, we are not only providing a tribute to that engine but to that era.
Now the counterpart to all that fluffy idealism is practicality; building it has to be within our means. We have moved almost entirely to CAD drawing and, in some cases computer modeling, despite my early reluctance. Some foam patterns are being considered. Our goal is an end product which is both an accurate reconstruction of the original and is a respectable tribute to the technological era of 1907.
Regards
Jason
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I think that replicating #7 is kind of along the same lines as the railroads' crank telephone system. The phones and ringer boxes are all 1920's era while most of the wiring is new. The visitor sees the historic instrument and how it works providing the experience of how railroads used phones in the 1920's. The parts that are not seen such as feed cables and lightning protection are newer technology which provide safety and better operation for the crew. The phone on the station wall is a nod to the folks who designed and installed such equipment 80-90 years ago and how it helped railroads operate more efficiently. Jason makes a good point, building #11 is a wonderful project which will open yet another window on the past for our guests.
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"Lost styrofoam" smokestack patterns from CNJ 113. It's super interesting to see this stuff, thanks, Bernie!
(http://farm9.staticflickr.com/8521/8562888149_07a7a7d9a0_b.jpg)
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Stephen,
Again thanx, many times over for posting my photos.
I have been wanting these photos to be posted for quite a while, but was waiting for the proper time and Thor's post had me dig them out. These patterns were made by the Behler Pattern Works in Deer Lake, PA. They also made several complicated wooden patterns that were beyond my means and especially, time. The worn out and broken stack and base were taken to the works and they made the patterns directly from the originals without drawings. I am used to heavy wooden patterns and when we visited the pattern works, I went to pick up what my subconscious mind was saying 50+ pounds of pattern. The problem was that this "huge" pattern weighed about two pounds and I almost threw it off the table. There is no doubt in my mind that this is the way to go with "one-offs" Behler took the patterns to the foundry and worked with them so that the casting process went well. I have no idea what the whole process cost, but it was well worth it.
Bernie
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Hey guy check on this thread from the Facebook of the "Lyon". The boiler work and casting of the Smokebox door is amazing.
http://www.facebook.com/pages/V-T-Lyon/269396092936?id=269396092936&sk=photos_stream (http://www.facebook.com/pages/V-T-Lyon/269396092936?id=269396092936&sk=photos_stream)
cheers
Thor
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Stephen,
Again thanx, many times over for posting my photos.
Bernie
Hi Bernie, how did the surface finish come on the lost foam castings? I would think it would be very close to a lost wax process and so give a fine grained surface. What I am curious about is how they ram up the molds. I wouldn't think they could use a hydraulic ram as that amount of pressure would crush the foam.
Keith
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I was wondering about that also, Keith. I never thought to ask Jason about that, in connection with the first pattern for the frame transition casting. I'm pretty sure he told me the pattern for the first casting--now Ichabod crane car counterweight--was foam. I wonder if there's maybe some sort of vibratory process used to compact sand that doesn't rely as much on pressure.
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I believe they use the chemical-set sand. It is vibrated into to mold and self sets in several hours. Enterprise Foundry in Lewiston does this; that's where I learned about it.
No 9's first frame casting was lost foam. The pattern, made by the foundry, cost more than the casting; total cost around $5000. I wasn't pleased with porosity in places, but what condemned it was dimensional in nature... It never made it to the radiograph we were requiring, so we don't know how extensive that porosity really was. We didn't pay anything for that casting.
The one we're using cost around $6k. It was also a foam pattern, but not lost foam. It was made, packed and withdrawn like a wood pattern. It appears that this foundry did not use self-setting sand because the corners are not crisp but rather rounded over and beaten looking.
See ya
Jason
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In my above post I mentioned that a representative from Behler took the pattern to the foundry and oversaw how it was placed in the sand. I have no idea concerning the process. I talked to Bob Kimmel about the costs and these are 10 years ago prices. The patterns cost a little over $5,000. The rough castings were about $600 and machining the castings was about $1500. The castings were not perfectly smooth and I don't think they were checked for porosity because they are not in a high stress area. The metal was a special alloy mix to tolerate the heat in this area.
Bernie.
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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:
(http://i1065.photobucket.com/albums/u385/ricksisson/wwfry%2011/Cylinderstudy2Bcores.jpg)
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:
(http://i1065.photobucket.com/albums/u385/ricksisson/wwfry%2011/Cylinderstudy2Bcasting.jpg)
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!
(http://i1065.photobucket.com/albums/u385/ricksisson/wwfry%2011/Shapeways.jpg)
My design is on the Shapeways web site and you can see the model here:
http://www.shapeways.com/model/952269/cylinder-study-2be.html?li=my-models&key=15c6a8ee31134438744f6510c95a0906 (http://www.shapeways.com/model/952269/cylinder-study-2be.html?li=my-models&key=15c6a8ee31134438744f6510c95a0906)
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.
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Thank so much, Rick, and congratulations. That is impressive, in all respects! That it is difficult and time consuming to comprehend, even with the aid of such wonderful technology as Turbo Cad, shows so well what a complicated casting it is. The old time pattern makers and other foundry people sure had to be good at visualization, along with a bunch of other skills.
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Rick,
Super job. Next we need to figure out how the cores are going to lock into place and how we pull the whole thing out of the sand. This is going to be a fun pattern to make.
Bernie
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Stunning work, Rick. This is another great step forward for the project. Bernie's right, this is going to be a really cool pattern. Having never really studied the inside of a cylinder saddle before, I've never been able to visualize how all the ports fit together, so thank you for letting us see how it all fits together. Just out of curiosity, what scale did you have the 3D printed parts produced at?
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Rick...this is excellent!!
Stephen
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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.
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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.
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Over the past year, I had known that SMU had the Baldwin Locomotive Works archives, including some information regarding #6 and #7. I had tried a few times to no avail to access those documents digitally until a few days ago. I'm sure many of you have already seen these, and or have been working from them. But in case there were other folks like me who hadn't seen these, I wanted to pass them along.
The two sheets appear to be the design specifications for the two engines, providing the framework to design the engine around. I had no idea the original order was for an "olive green and aluminum" paint scheme. Was that how #7 spent it's time on the line? Interesting as well, is the note on #6's tender for it to be "as short as possible"- presumably trying to fit the turntables?
It's a PDF of scanned microfiche which enlarges beautifully- but is thus quite large (447MB). #7 is on page 40, and #6 on page 41 of volume 31, which can be downloaded at this link: http://digitalcollections.smu.edu/all/extra/degolyer/rwy/BaldwinManuscripts/mss0061_02_31_opt.pdf (http://digitalcollections.smu.edu/all/extra/degolyer/rwy/BaldwinManuscripts/mss0061_02_31_opt.pdf)
The other volumes of the BLW archive can be found on this page:
http://digitalcollections.smu.edu/cdm/ref/collection/rwy/id/32 (http://digitalcollections.smu.edu/cdm/ref/collection/rwy/id/32)
Enjoy!
Rick, that's both funny and painful to hear. Too bad "economy of scale" doesn't apply in that way. I'm glad the 1/16th scaling was pretty economical for you to have produced though- it sounds like it was a real help. From my own experience doing 3D-modelling, there was no way to really be certain of everything until I could handle a prototype.
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Hey Guys,
I've been busy working through all the Baldwin locomotive specifications searching for Brazilian and all locomotives 2ft6in gauge and so far I have found all Baldwin Maine Two Footers and 98% of the Brazilian 60cm engines and alot of other interesting engines.
Since I don't know how to upload pdf files to this forum I have uploaded them to the files section of the Maine 2fter Modelers Forum, you have to join the Yahoo Group first but no big deal but for that you can get the 30 single files from pages for all the engines. If you find one that I missed let me know and I will dig it up. I'm getting good at that.
http://groups.yahoo.com/group/Maine-Two-Foot-Modelers-Forum/files/LocomotiveSpecifications/ (http://groups.yahoo.com/group/Maine-Two-Foot-Modelers-Forum/files/LocomotiveSpecifications/)
Hope this says some people some work and think on the book author Rich Dunn that funded the posting of the micro fish as digital scans. It is in the spirit to volunteer information instead of hoarding it your private files until you die....
Thor
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Fantastic work on the CAD model congratulation to all, I have a question about the Baldwin drawings link, We at Statfold in the UK have just taken delivery of 2 Baldwins from India. They are the WW 1 4-6-0 type but they are in poor condition, the Indians have had the best out of them. Does anyone know if the drawings exist which I can see that there is a huge data base of drawings could any one point us in the right direction thanks
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I noticed that this thread is the first one to pass 30,000 views. It's probably an indication of the level of interest for building #11.
Stewart
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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:
(http://i1065.photobucket.com/albums/u385/ricksisson/wwfry%2011/Cylinderstudy2Bcores.jpg)
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.
Rick, I'm sure I am missing soemthing. But when I look at your models it appears that the rear port on the top of the cylinder is connected to the front of the cylinder. Am I looking at it funny or does the engine have crossed ports?
Keith
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Keith,
I believe the picture only depicts one half of one steam chest; there would be a mirror image portion forward (farther into the page) that would be the front half of the casting. What is shown appears to be the back half of the engineer's (right-side) casting, and I think that's why it was referred to as only one-quadrant of the entire cylinder saddle assembly.
Dave Crow
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Keith,
I believe the picture only depicts one half of one steam chest; there would be a mirror image portion forward (farther into the page) that would be the front half of the casting. What is shown appears to be the back half of the engineer's (right-side) casting, and I think that's why it was referred to as only one-quadrant of the entire cylinder saddle assembly.
Dave Crow
Dave.....ah, now all is clear! I knew I was missing something vital!
Keith
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Hi Keith -
Dave is correct - here's a picture of the half-saddle cores:
(http://i1065.photobucket.com/albums/u385/ricksisson/wwfry%2011/Cylinderstudy2Bmirror.jpg)
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Am I correct in assuming that light green is "Steam In From Boiler (via wishbone)," blue is "Steam Into Cylinders," and red is "Exhaust Steam?"
-John
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You are correct John - blue is "Steam Into Cylinders" and "Steam Out Of Cylinders"
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
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Hey guys its been a while. I was wondering if anyone could share info on the number plate for #11. Where was it cast and what was the cost? Reason I ask is because I am currently looking into getting a plate made for a project in New Jersey I'm involved with.
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Eric,
I had the plate cast at the Zawol Foundry in Wilkes-Barre, Pa. for Steven Hussar. I no longer have the patterns, nor do I know if Zawol is still in business. That could have been over 6 years or more ago. I don't remember the cost.
Check with Wayne James in the Gettysburg Pa. area. He has all sorts of plate patterns almost ready to go. He can cast them in aluminum in his own foundry in his shop or have a foundry cast them in brass or bronze. His work is super and there are a lot of his plates out there.
Bernie
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Thank for the reply. I sent you a PM Bernie.
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Eric,
Zawol Foundry is still in business. 44 Gilligan St. Wilkes-Barre, PA 18702 (570) 823-7522 Only a very short distance from the old Vulcan Ironworks where our #10 originated.
They also have a Facebook page.
Would your NJ "project" happen to be for a 2-8-0 under restoration at Pine Creek?
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I doubt it is for a 2-8-0 at Allaire....the Quincy and Torch Lake engine went back to Michigan some time ago......
But then....you never know.
Keith
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Its a Porter 2-6-0 that ran in Panama. #46
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Eric,
I answered your PM.
Bernie
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While I was up in Maine and Pennsylvania, I finally got the chance to sit down with Jason and Bernie. Between the two of them, I got a slew of pattern projects to chew on, and some great insights to improve my pattern making as things go forward. I had to take some time after I got back from Maine to work on a few personal projects, but I'm able to devote the bulk of my free time for the last month of my summer to pattern projects.
I spent half a day making a pair of sleds to cut the draft for my patterns by machine planer in minutes, instead of hours with hand planes as I did with my first round of patterns. This obviously sped things up quite a bit, so within the first week and a half of work, I've been able to complete the fabrication of the pilot truck oil cellar, get pretty far along with the lead truck frame, and prepare most of the parts for the driving box oil cellar.
The sled on the right gets used first, and cuts a 2 degree taper along the length of (formerly) square stock until the taper extends the full width of the board. If the pattern requires, I flip the piece and place it on the 4 degree sled to cut the draft on the opposing face. I know Bernie and I use different construction methodologies, but if anybody ever can find this useful now or in the future, I hope it can save you some time.
(http://farm3.staticflickr.com/2818/9395479004_336974697a_c.jpg) (http://www.flickr.com/photos/95801104@N07/9395479004/)
Here's the pilot oil cellar. I'll actually assemble it over the coming academic year, since I can do the smoothing/finishing in an apartment.
(http://farm4.staticflickr.com/3747/9392708749_4c915f4cc7_c.jpg) (http://www.flickr.com/photos/95801104@N07/9392708749/)
The lead truck frame arches don't sit flush with the plane of the casting. The big upright sections are frame arches, while the shallower and wider pieces are the core prints which will be used to create the air space in the casting underneath the arches. The piece in the background is the core box shaping up. I still need to make some small pieces to add to the sides of the arches for the swing link bosses, and attach everything together. But this pattern is *nearing* completion- at least fabrication wise. Thats a 24" rule on the side, and a 12" up front for reference.
(http://farm4.staticflickr.com/3813/9392708325_7e9fc00af1_c.jpg) (http://www.flickr.com/photos/95801104@N07/9392708325/)
For all my patterns following the lead truck frame, I've switched to a marine grade plywood hoping it would be a lot easier to work with hand tools for the finer work than the cabinet grade stuff I used first. It has turned out to be a lot more consistent, but it sure is ugly!
In addition to wrapping up fabrication on the lead truck frame, I'm hoping to start work on the pilot truck journal box proper, finish the driver oil cellar, and perhaps start on the drive box. It is unlikely at best that I will make it to the drive boxes in the next couple weeks, but it gives me a nice goal.
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Wow! Great work, Alan. We need more guys like you in the program!
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Wow, Alan, great work, and fast! Thanks so much!
Jason
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Very impressive, Alan and thank you.
Ira Schreiber
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Alan,
Your work is fantastic. As you know, all the patterns have to do is make good castings, not look pretty. The less time spent on them, the better. My shop has few machine tools, so I do things by hand and they subsequently take longer. At this point in my life, I will not get any more, so I believe that you will overtake me in production and that is a good thing. Keep it up.
Bernie
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Thanks guys! I'll try not to get too distraught over ugly plywood, and keep chugging away.
Once we start to have whole assemblies of patterns complete, it might be an interesting picture to see everything lined up and placed in a way that gives some skeleton to the locomotive. Sort of like how crash wreckage gets "re assembled", but in a much less morbid context.
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All, the latest from Bernie's shop. These are the patterns for No 11's Center Body Bolster & Core Box. Thanks, Bernie!!
(http://farm3.staticflickr.com/2876/9677611419_106c9a0acf_o.jpg)
(http://farm3.staticflickr.com/2827/9677609413_4e5f0db29a_o.jpg)
(http://farm3.staticflickr.com/2864/9677607769_ff02152a24_o.jpg)
(http://farm4.staticflickr.com/3748/9677605907_6f4fc04d13_o.jpg)
(http://farm4.staticflickr.com/3809/9677603929_ed3d676518_o.jpg)
(http://farm8.staticflickr.com/7352/9680837892_d79264d844_o.jpg)
(http://farm8.staticflickr.com/7303/9680835568_03292668b3_o.jpg)
(http://farm6.staticflickr.com/5488/9677597247_461a4066c5_o.jpg)
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Bernie, nice work - as always! Does this set of patterns make two different parts? The body-mounted bolster as well as its mate on the truck?
Dave Crow
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Stephen,
For the unteenth time, thank you for posting my photos. This would be an impossible task for me. I look for the day in the not too distant future when we start seeing castings.
Dave,
This is only for the frame center body bolster. The outer tapered parts are machined flat to fit between the frame pieces. The larger diameter round section is machined to fit onto the truck bolster pad which I assume is similar to the one we put on the TCDA trucks a few work sessions ago. My next group of patterns tentatively will be all the castings for the trailing truck. First, I have to do the intermediate body bolster casting pattern, but it is not as complicated as this one and shouldn't take as long. I told Jason to forward the truck pattern drawings to me when they are ready.
Bernie
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Happy to help, Bernie! This "official" No 11 thread has had over 35,000 views! I'd say people are VERY interested
in this project! :)
Stephen
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Hi Bernie,
I made drawings for most of the castings required for the rear truck including the center casting (the pieces out at the end of the bolster that has a circular hole in it) and the the pivot casting. Because I had drawn the parts to scale, I believe Jason was planning to mark them up by the percentage required to account for shrinkage as the casting cools.
I look forward to seeing the patterns for the bolster parts; with enough donations, the flat stock and angle steel required for the rear frame and truck could be purchased. Wouldn't it be neat to see the rear portion of #11 sitting in one of the roundhouse stalls? Dream even bigger and have the tank made and mounted on the frame!
Dave
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You know what might not be a bad idea? See if WPI or one of the other technical schools in the region would be willing to make some mini replicas of No. 11's number plates on their CNC machine... Sell them to raise funds for the project and give out some flyers describing the endeavor with them...
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Dave,
Is there any possibility of sending me the scale drawings? I could start getting my mind prepared, I also can generally guess at the shrinkage rate which wouldn't be that much. Also I could compare yours and Jason's. When I was working on the bolster patterns, it would have been nice to see the scale drawings.
Bernie
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Bernie, I'm at a conference in San Antonio this week, but I will look on my desk at work next Monday to see if I still have copies of the individual parts. I believe I showed you copies of them last fall when I first drew them up. I have since sent Jason a second set, and I'm not sure if I kept copies of all the drawings or not.
I do have PDFs of Baldwin's rear frame and rear truck drawings; I can send them to you. You wouold have to enlarge them when you print them out. Or I can bring you an 11x17 of each at the Fall work weekend.
I think the shrinkage is about 3%, or is that the draft angle? I'm not exactly sure how much steel shrinks when cast...
Dave
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Dave,
It will be two to three months before I finish the intermediate body bolster pattern, so there is no rush to get the plans to me. If it is necessary, I will ask Jason for them. I believe the locomotive should be built from the rails up. It would be great to see the trailing truck finished early. We have to convince Jason to use the spoked wheel center pattern which we already have.
It would be fine for you to give me the drawings during the work weekend if you can get them ready.
The shrinkage is about 1/8" per foot. The draft angle is 3 degrees. I would have to check. I put more than enough on a pattern to allow for shrinkage and machining.
Bernie
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Enjoy the weather while you're down in my neck of the woods, Dave! We turned the heat down a notch for September.
I am as excited as the next person to start seeing parts cast and assemblies come together for #11. But I think that there would be real value in us producing a pattern for solid wheels for the rear truck. The historical appearance is certainly a big part of that. But also, as we look into the future of the museum, it's operation, and equipment upkeep and possible construction, we only have so many sets of 2ft wheels. While there is a real and appreciable cost to getting wheels cast, and axles purchased/machined, it would be good for us to have that option, than be held strictly to the wheels we have on hand. A wheel pattern could end up being one which the museum (and maybe even others) would get a lot of use out of. I'd be curious to hear others' thoughts.
Now that I am up at school, I'm working on patterns less, but I'm laying the groundwork so that I can finish a couple of core boxes, and produce 3-6 more patterns over the winter break. I've started working on the eccentrics, but haven't fully committed to any others yet. The eccentric straps, cylinder heads, and pistons were all candidates on my list pending communication with Jason, but I'd be happy to take a swing at the rear wheels if that would be of help. We might could even make the core for the axle the same as for the pilot wheels to save time in that department.
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Hi Alan,
I agree with the desire to have a pattern for a non-spoked wheel. The pattern could be used for more than #11, as wheelsets tended to be shuffled between freight cars, passenger cars, and tender trucks - most of the railroads swapped axle sets between equipment to save money.
We certainly have a need for wheels. I can think of 20 wheels needed within the 5-year time frame or sooner: 8 wheels for a set of freight car trucks, 8 wheels for rebuilding the spare set of passenger car trucks, and 4 wheels for #11. Shucks, if we wanted better (namely, round) wheels under the creamery car, there would be another 8...
I did get a price quote from a well-known (and friendly to the preservation industry) manufacturer in Pennsylvania; if we were to purchase 20 wheels, the cost would be $2000 per wheel. The price went up to about $2200 for smaller quantities. Monetary donations are welcome from the readers out there in internet land.
Jason, I believe, would like to have a pattern created for the Portland Co. freight car wheel; he was going to look through the museum archives for a copy of the wheel drawing. Give him a shout, or we'll see if he sees this thread and responds! And, yes, it would be great if the core for the axle could be re-used to save time.
Dave Crow
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Things have still been chugging away in the #11 patterns department. I don't know what the tally is for certain, I think we have about 20 or so patterns completed, or underway. I'm finding it really exciting to see whole component groups of patterns be completed, such as the set of bolsters that Bernie has been working on. Here's an idea of where things have come since the last update from Bernie and myself.
Bernie just sent these to me a week ago- this being the last of the three bolster patterns which were to be made. He always reminds me that patterns don't need to look nice, and that aesthetics are not generally a concern of his except for eye-catching patterns like the wheel centers-yet his work always looks really sweet. My hat's off to you, Bernie. I'll be looking forward to seeing your next project.
(https://lh4.googleusercontent.com/-OViZHFzBxik/Um2ceLxubDI/AAAAAAAAAFo/6IA_qCJu97M/s912/WW%2526FRR%2520%252311%2520Intermediate%2520Bolster%2520Pattern%2520Progress%2520005.JPG)
(https://lh5.googleusercontent.com/-Jt4Lwmr488E/Um2ceCUXXGI/AAAAAAAAAFs/8suN5LF7CLY/s912/WW%2526FRR%2520%252311%2520Intermediate%2520Bolster%2520Pattern%2520Progress%2520008.JPG)
(https://lh4.googleusercontent.com/-oz5uefdYYDE/Um2gQidcKcI/AAAAAAAAAGI/wa7447yb_iA/s912/WW%2526FRR%2520%252311%2520Intermediate%2520Bolster%2520Pattern%2520Progress%2520009.JPG)
Since my last photographic update, I've gotten quite a bit done. The journal boxes and for the lead truck, and the main wheels have been mostly finished. From left to right- first there is the journal box and oil cellar for the drive axles. Then there is the frame for the lead truck leaning against the wall, and the trough-like box in front of it is the core box to produce the negative space beneath the arches. Next is the front and back halves of the eccentrics. Finally, closest to the camera is the lead truck journal box and oil cellar.
(https://lh6.googleusercontent.com/-EykhWBO7lsA/Um2IvajTUiI/AAAAAAAAAE8/7kWLdxbUpX4/s912/DSC_8362.JPG)
(https://lh5.googleusercontent.com/-A4_ghknxRYc/Um2IykWFQ9I/AAAAAAAAAFE/ry643OHG8yc/s912/DSC_8374.JPG)
(https://lh4.googleusercontent.com/-IMIPUX3Ayik/Um2IupEYYZI/AAAAAAAAAE4/KAZ_TFp_ADE/s912/DSC_8369.JPG)
(https://lh5.googleusercontent.com/-IOEnarPOfAA/Um2I-TfCCBI/AAAAAAAAAFM/dM_mnGR87mc/s912/DSC_8376.JPG)
None of these patterns are done yet. They all still need some filleting, each journal box needs a core, and the lead truck frame needs some dimensional tweaking. The larger eccentric half is still very rough on the interior. I'm trying to get some machine shop experience at school by producing a template for my router to follow with an endmill. This should get everything dimensioned and smooth. Ill then add draft by hand.
Over the winter break between semesters, I hope to finish all the fabrication work left for the patterns I've started, and also add some combination of the pistons, cross head, or valve chest to the list. We're holding off on a wheel for now, to allow for some more research. One step at a time.
Alan
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Four cheer for Alan and Bernie! So exciting to see the work coming along this well.
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Wow!
-John
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Absolutely amazing.
'nuff said.
Ira
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Alan,
Thanx for posting the photos. You have to email me the steps for posting photos so I can add that to my limited computer skills. I always try to keep in mind how the patterns will be stored so that they can remain relatively intact for future use should another locomotive be constructed. You saw how carelessly the patterns have been stored for CNJ 113 and I found that disheartening. I enjoy comparing our different styles of construction. I am waiting for the next set of plans.
Bernie
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I for one would like to see these displayed, exhibit style if you will, when the room becomes available. I don't mean in the station, but when the house gets revamped there is talk of having a whole floor as a museum. These would be great pieces to display there, not only to show how it was done, but how it is still done. You guys are doing fabulous.
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I think that by the time we're all done with all the patterns, we'll need a whole building just to display patterns!!!! Not that I would complain in the least bit ;D
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Thanks everyone for the very kind words.
Mike, I completely agree with you. Part of the value in us building #11 as close to how it was originally done as is reasonably and practicably possible, is in providing a way for the public to see how how it was done. If/when space becomes available for more interpretive exhibits, I think it would be really cool if there were displays regarding processes/features like the Russia Iron, patterns and castings, or any of the many things that go on at the museum which are really unique, but that the public might not see on a regular weekend visit. For now, I'm glad that we have the forum to use as a record and a view into how so many of the projects at the museum are made possible.
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Hi Alan,
I'd like to propose that someone write a couple of articles for the WW&F Newsletter about some of these things. That would also be a record and a view into how so many of the projects at the museum are made possible. The newsletter has over 1100 readers, so between the forum and the newsletter, this information would reach a lot of people (admittedly with some duplication).
Who might that "someone" be? My crystal ball is cloudy, but I think I see a first letter "A" and maybe a first ;letter "D." ;)
-John
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The Winter #11 Update
Since my post in October, I had the chance to spend a few holidays at home, including a nice lengthy stay over the Christmas break. No new patterns (for #11) have been made, but each one that I had started still had a lot of finishing work to do.
One of the biggest hurdles was producing the core boxes and prints for the two journal boxes. In order to reduce the machinist workload as much as possible while maintaining good margins, I had to try out a different core box construction method. For both of the journals, the core box for the bottom half comes apart on all sides, negating the need for draft in the core box itself. Bernie's feedback regarding my ideas was indispensable- I wouldn't have been confident in attempting it without it. The cores were a bit of a brainbender to figure out how they would go together, while maintaining accuracy and repeatability but I am very happy with the results, and will be keeping this construction method in mind for future patterns.
(http://farm8.staticflickr.com/7330/12897969433_ee157e9906_b.jpg)
The core box assembled:
(http://farm3.staticflickr.com/2808/12897978123_ec372b89e9_b.jpg)
And apart:
(http://farm3.staticflickr.com/2839/12897984793_e0eaf2f786_b.jpg)
The lead truck journal is nearly a carbon copy in terms of pattern construction
(http://farm8.staticflickr.com/7330/12898320014_3b86989290_b.jpg)
The eccentrics have had a fair bit of work done. At last post, they had been roughed out, and were awaiting cleanup. In order to produce, I used a template and a follower along with a very long, 1/2" end mill to clean up the excess. At full extension, the end mill had a fair bit of chatter, reinforcing the reasoning behind using big end mills when you have to have a lot of extension. Too bad they won't fit in the router table! Nevertheless, it worked pretty dang well. I will also be keeping this in my back pocket in case it comes in handy for more complex interior shapes.
The eccentric, and it's template
(http://farm4.staticflickr.com/3775/12897855455_310d3c0c77_b.jpg)
On the router table. I only raised the end mill 3/16" per pass, but wanted to show how everything worked together.
(http://farm3.staticflickr.com/2863/12897861875_5fc801a213_z.jpg)
At this point, the retaining ring rattled off, and the template guide got caught up in the end mill. It was terribly exciting. Fortunately, the template guide was the only casualty, but I had to stop at this point until a new guide could arrive.
(http://farm8.staticflickr.com/7359/12897959143_900642cbe6_b.jpg)
While I wasn't able to make the three more patterns I'd hoped for #11, I did spend some time making a few new patterns for another project that's in the works. All of the other patterns received a lot of clean up work and attention. Applying the fillets takes a fair bit of time, and with everything all batched together, there were many days just spent filleting, and cleaning them up. All of the patterns (save one) are now either being finished, or are being prepped for finishing. As much as I loathe the finishing process, it's great to see things wrapping up. I had been worried that I bit off more than I could chew this year, and I think everything should come together just in time for a trip Down East this summer. I'll be glad to free up my bench space, but the car is going to be pretty full this year!
(http://farm3.staticflickr.com/2815/12961445253_ce670aee13_b.jpg)
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Alan,
WOW!!!!!!!!!!!!! As soon as my frigid cellar gets warmer, I will continue to add to the pile. This has been a brutal winter among other things which have slowed me down. You are an inspiration. We need more youth like you.
Bernie
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Alan,
Great work on all of those patterns!
Dave Crow
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Alan, I second Dave's, Great Work! And Bernie's, WOW!!!
Stephen
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Looks fabulous, Alan, thank you!
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Alan…no question about it, we need to invent some new superlatives to describe your work. Thank you so much!
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Fabulous work, Alan, just fabulous.
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A wonderful addition by a talented volunteer.
Thank you.
Ira Schreiber
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Hi Alan,
Those patterns are some NICE work! Thanks for posting the photos, can't wait to see them in person. Any idea when you may be coming to Maine?
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Thank you all so much for all of the very kind, and wonderful compliments. It's an honor to be working with this museum. I can't wait to see the pile of #11 patterns grow some more!
Stewart, I'm happy to say that my father and I hope to make it back up around the end of May this year, and we're really looking forward to it.
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Nice job Alan! I look forward to seeing you at Sheepscot.
Dave
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Just noticed that this thread has passed 40,000 views, the first one (by far) to do so. Not bad for a locomotive that doesn't even exist yet.
Start
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Some inspiration from Australia:
http://www.abc.net.au/news/2014-08-01/amazing-backyard-build/5642732
-Philip Marshall
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I am nearly finished with my first pattern for #11 - the lead truck center casting. It is pretty complex -- there are three cores, one of which is very large.
First a sketch in isometric view of the casting as it should look when finished.
Then two views of the main pattern with the two small core boxes. Orange in this case indicates where cores go on the pattern (called core prints), and the core boxes, which are similarly color coded.
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Finally the nearly finished core box for the main core. Since it is so big and complex, I tried something new: I made a positive of the core (shown to the left of the core box), and used that to make a plaster mold. The plaster mold is the core box. It took nearly 50 pounds of plaster, and I had to do some repair work after making the casting to fill voids. Then I sealed it with a few coats of polyurethane. Finally it will get a nice shiny coat of orange as well.
Thanks go to Alan for helping me figure out how to do this, and also all his helpful jigs and fixtures for making 2 degree draft features, and many other tricks and shortcuts.
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Wow! That is some great work, Harold. I've seen a full-size version of the lead truck casting, and it is a pretty involved piece. Glad you were able to figure it out. I look forward to meeting you and Alan some day soon to express my appreciation of your work in person.
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Wow- what great fun to see that piece become reality!
Credit to Steve (Smudgy) Smith for that isometric view!
Alan reports that 35/89 patterns required for no 11 are completed or in progress- that's great!
See Ya
Jason
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The stuff that is coming from Texas is nothing short of stunning.
Bernie
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Alan and Harold and all of those working on #11,
Your work is wonderful and so important in moving this project forward. Thanks for applying your enthusiasm, dedication, and skill to this project and the railway!
I think the board may want to look into adding a teleportation device to the next long-term plan to aid in traveling between away (wherever that might be) and Maine. ;)
Steve
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Nearly everything Gene Roddenberry envisioned has become reality...teleportation can't be too far off :)
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There's even a warp bubble theory in the works out there. So much for transportation by rail...
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I am going to start a short series of posts on the pattern for the rear frame extension casting. This is the second largest pattern for the locomotive. Overall it is 56 1/2" wide by 15" tall and 20 3/4" long. Estimated weight of the finished steel casting is 521 lbs.
The function of this casting is to connect the forward frame to the rear frame just in front of the firebox. If you recall for #9, it needed a similar casting when it was rebuilt.
The first thing I did was take the CAD drawing and add machining allowance and draft. Then I scaled it by the expected shrinkage of 1/4" per foot.
The plan that Alan and I worked out for this casting is to break it into three parts, and to back it up with what is called a 'follow board'. This allows the pattern to serve as its own core box (to form a core), and to be able to extract the pattern from the sand mold. This will become more clear as the build progresses. Just follow along and see.
I started with the largest piece, a rectangular piece of plywood, laminated up to 1 1/64" thick, 2 degrees draft on all sides, and three 8" holes. The holes are reinforced by a 3/4" wide ring, which also gets 2 degrees draft on both sides.
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Then I added two thickeners on the ends, as well as the top and bottom flanges. These flanges are laminated up, then tapered with the appropriate draft. I glued these on, and put in some screws from the back to make sure they stay on.
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I started this on Saturday, laminating up most of the material for this part of the pattern. Today I got this far: I added the two large wings that stick up vertically, and the small horizontal connectors between the rings around the holes. The two large wings are glued, but also backed up by some 2 1/2" screws to reinforce the joints. I will have to plug the holes from the screws. Eventually all the outside corners need to be rounded over, and inside corners need fillets.
Stay tuned, more updates to follow.
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We should find a few outside, relevant discussion forums to link this to. Pattern making, industrial preservation, etc. This project can really have wide appeal...
Thanks so much for chronicling your work, Harold!
Jason
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Harold,
Again, super work. A while back Jason sent me the plans for this part and I am studying how you are making it and how it will be pulled from the sand. Are you going to core in the washout holes or just figure that will be drilled in after the fact?
Bernie
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Jason,
When we came up for the work weekend, you mentioned you were going to talk to the foundry about getting some castings made for #11. Has anything transpired since then?
Bernie
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Here is an image of the solid model that Alan did in Solidworks. It gives a pretty good idea of the complexities of this casting. There are washout holes in the corners that are at 40 degrees -- how can this be pulled from the sand if these are to be cast in?
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To answer Bernie's question, I will explain how we decided to make this pattern.
If you look at the picture, we are creating a split line on the pattern along the dashed line B-B, so that the sides with the washout holes are separate, and can be withdrawn from the sand at the angle of the washout holes. Then the back portion comes out perpendicular to its plane. That way we get all the holes without cores, and the amount of draft required is minimized.
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Howard,
WOW!!!!!!!!! I love how you solved some of the complexities of this casting.
Bernie
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If you look at the picture, we are creating a split line on the pattern along the dashed line B-B, so that the sides with the washout holes are separate, and can be withdrawn from the sand at the angle of the washout holes. Then the back portion comes out perpendicular to its plane. That way we get all the holes without cores, and the amount of draft required is minimized.
I've looked at this a couple of times and I can't say that I understand. Since there are "wings" on both forward and rear, that means the whole casting has be to pretty deeply in the sand, and there has to be sand (or maybe its a core, not sure of terminology) around it to make the wings. So how do you remove the wing with the washout hole without messing the rest of the casting? Do the wings fold back so you can then remove the main part?
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James, the back side of the pattern will be filled completely at first with a wooden construct called a follow board. It will be flush with the back surface, where the mold will split, and extends out top and bottom a few inches. After sand is rammed up over the outside of the whole thing, the follow board is removed, the sand is dusted with parting compound, and more sand is rammed up in place of the follow board, forming a core. The core comes out; then the pattern is removed in three pieces, then the mold is put back together for pouring.
See Alan's sketch below; the follow board is the red part:
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Daily progress update:
I glued up material for the top and bottom flanges of the side wings. I cut the 40 degree separation line where the back will join to the sides, and also made the flanges that stay with the back portion, and glued them on.
The 40 degree cut was interesting, since I could only achieve 45 degrees on my table saw with the pattern laying flat. I then used a hand plane to bring it down to the line.
The flange sections started as glued up plywood to the thickness I needed, then planed to get a 2 degree draft on both sides (using the planing jigs that Alan came up with). I printed out full size patterns for their shape, glued it on the surface, cut them out on a bandsaw, and used my hand plane to flatten the mating/gluing surface. Note the dovetail feature which will interlock with the corresponding flanges on the sides (once I make them).
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I didn't have too much time to spend today, but I got a start on the top and bottom flanges of the two side wings. I printed out the drawing full size (it took four pieces of paper to fit), glued it on the wood stack for both the left and right flanges, then cut it on a band saw.
The second photo shows how it fits on the main back portion of the pattern.
Each of these I will need to taper to get the required 2 degrees of draft. I can't think of a way to do it with power tools, so I will mark the finished width along the outer edge, and use a hand plane to taper it from the inside down to the final outside thickness. Since there are four of them, it will take a while.
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Amazing!!
Stephen
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Rear extension casting pattern:
Sorry, no pictures today. Progress is not quite so visible. All four of the flanges for the two sides were cut out, cleaned up to their lines, then tapered by hand on both sides to achieve the required draft. I then made a full size template for the inside of the "U" to use to fine tune the fit of the flanges to the back portion of the pattern. They are now all tuned up and ready to go.
Next I need to make the vertical portion, the web the connects the top flange to the bottom flange. I am going to stack laminate them from plywood, so each layer has the shape of the cross section. I am preparing two templates to use for these, since I will need to cut out and stack 16 pieces of 3/4" thick plywood for each side. It is really amazing how much plywood a pattern can eat up. Just the four flanges took almost a 1/4 sheet of 3/4 ply.
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Pattern progress:
This pattern seemed to go really fast at first. The back portion was large but relatively straight forward, so it went together fast. The two side wings are taking a lot of time.
Over the last couple of days, I have cut out all the pieces to stack laminate the two sides. There were a total of 36 pieces required. In the picture below, you can see where I have glued up two stacks, which will make up one side. In the foreground are the two templates that I used to generate them. After I glue up the pieces for the other side, I need to do a lot of hand work to fill the voids exposed in the plywood, smooth the surfaces, then cut to final height. I am debating whether to cut out the large oval holes for the clean out plug access before final glue up, or do it in each individual piece first.
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Today's pattern update:
I finally got one side all glued up, as you can see in the picture. There was a lot of tedious hand tweaking to get it to fit properly. You can see that I cut most of the oval hole before assembly, except for the center web -- which I will cut out later. The problem with stack laminations, is that they can skew during glue-up, and then nothing is square because it parallelograms. I am probably looking at two more days of work to do the other side. Despite spending more time on the stack glue ups, they are worse than the first set.
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Harold on the laminations, could you put in a couple of holes in a set location on each layer and then use a dowel as a register pin to ensure that all of the layers line up perfectly?
Keith
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The slipping laminations reminds me of my mother making a fancy dessert for her bridge club. It involved slicing an angel food cake into about five layers, putting a filling between the layers, reassembling the whole thing, frosting it, and then chilling it in the refrigerator. She had failed to make the slices absolutely parallel, and the chilling process somehow made the filling more slippery. No number of toothpicks (similar to Keith's dowels) could stop the impending sideways collapse. The result was too ugly to serve to the bridge club, but my father and I found the taste was unaffected by the disaster. ;D
-John
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Keith,
I can't speak for my dad, but while dowels would be an effective way to assure the pieces stayed aligned for a glue up, brad nails also work stupendously. as long as you're sure that you won't need to cut anything later. But my dad and I have differing philosophies on the use of brads.
I was at home last weekend, so I grabbed a couple pictures of the pattern while Harold was working on it. They give a much better sense of scale for the whole thing- it's really huge. I've been working with the drawings and 3D model for the casting for the last few months, and I still was taken aback when I saw it in person. And it's even larger now that the wings are going on.
It was a nice 70 degree day, so we rolled up the door and enjoyed the fresh air!
(https://farm8.staticflickr.com/7546/15725591883_53ecbf1f7f_c.jpg)
(https://farm9.staticflickr.com/8602/16343780471_e2336762da_c.jpg)
Filleting has been the biggest time suck for the pattern making process. If we could speed up that portion of our work, I believe that we could really increase our pattern output. Thus, we've decided that the Rear Frame Extension would be a great test bed for us to use commercially available wax fillets. So we ordered some loose ball bearings, and I've spent part of the week making ball end fillet tools. I've got a little Sherline lathe in my apartment that makes short work of little projects like these. We're looking forward to finding out how they work. Hopefully well!
(https://farm8.staticflickr.com/7462/16344874112_7ff7669131_c.jpg)
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Harold, Alan,
I am an advocate of the brad method and when making core boxes, I use wallboard screws to keep everything in place.
Bernie
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I was thinking dowels that were long enough to extend the entire height of the stack.
It would not only align the laminations, but would give strength vertically to the stack.
Also dowels work great for cross nutting when you have to screw into end grain.
Alan....it's a shame your dad has to work in such cramped quarters! ;D
Keith
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Alan....it's a shame your dad has to work in such cramped quarters! ;D
He can always take a break on one of those 70-degree days and take a quick trip in that nice strip canoe in the background! 8)
-John
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Pattern progress:
First, thanks for everyone's suggestions. I agree that dowels would have improved things a lot, and even brad nails have their place. so, maybe next time... In the end, what I ended up with was not as bad as I feared. I tweaked the bottom surface to make it more square to the new (skewed) sides, then took out the rest with judicious hand planing. In the end, I had enough fat in my rough cut out to fix it without having to add any material.
As you can imagine there was a lot of time spent squaring up and flattening the subsections. Then I glued up the RH wing. After that cured, I spent even more time cleaning up each wing, since the alignment of each of the five pieces that make up each wing is not perfect. I mainly used hand planes for leveling the surfaces, but some hand sanding and even a belt sander were also used.
I was not real happy with the fit of the joint between the wings and the middle section. To improve that, I put waxed paper on the joint surfaces of the middle section, buttered up the mating surfaces of the wings with thickened epoxy and squashed them together. A few clamps to hold them over night, and after some clean up today, they mate really nicely. Recall that these wings remain separate pieces, so that they can be removed from the sand mold before the middle section.
The latest picture shows all pieces together. The dark spots are areas that have epoxy fill to take care of low spots, voids in the plywood and self induced errors (did I mention that belt sanders can do damage really quickly?). I have 62 hours in this to date.
The remaining tasks are: additional fill, smoothing, edge rounding, filleting and finishing. I will also be starting on the follow board.
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WOW Harold, really a nice looking pattern.
Tom C.
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Nice work, Harold!
Dave Crow
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And a tip of the Kentucky Derby to you for all your efforts
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I started on the follow board for the pattern. It needs to fit inside the U of the casting pattern, and project outside about 2 inches. It also needs a generous draft on the top and bottom surfaces - I used five degrees. It should fit tightly against the insides of the 5 big holes, to back up the sand that gets packed around the pattern.
The first parts I made were the inside radiused corners. These I made by cutting six pieces with 7.5 degree angled sides (15 degrees included angle) which when glued together makes a 90 degree segment. Initially it had facets, but after a minimal amount of planing and sanding, it became a nice smooth arc. I used western red cedar, which is very easy to work.
I adjusted their shape as much as I could to mate with the inside of the pattern, but the pattern had more errors than I could accommodate. My sanding of the inside radii of the pattern got a little too wild. So time to break out the epoxy! I wrapped the radius segments in waxed paper; filled the low spots on the pattern with the filled epoxy and pressed in the follow board corner segments. When I removed them the next day, it looked pretty close to what it needed to be. Just a little sanding and I had a fantastic fit to the follow board, and the pattern is the correct shape now. This is the part of pattern making that is so different from furniture -- it doesn't matter how it looks, only that it has the shape and dimensions you need.
As you can see in the picture, I have connected the two corner bits with a flat section in the middle, and two wing sections as well. There is not much more to do on these, just the top and bottom faces, then some reinforcement here and there. I should be able to post a picture tomorrow with the pattern and follow board assembled together.
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I said I would post some pictures of the (nearly) completed follow board inside the pattern. The first two photos are a couple views of the follow board and pattern together. Then the follow board by itself, and finally the pattern by itself. This is the orientation that it will be in as the sand is rammed up around it to make the mold.
I won't have much to show from this point to the completed pattern, since it is merely a lot of time spent filleting, sanding, filling, sanding, finishing, sanding... Although I got some wax fillets to try, so I will do a post that shows how they are applied.
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Next photo
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Last one
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Nice work, Harold. So, how does a follow board work when the pattern is at the foundry? Is the bottom portion of the packed sand formed to the shape of the follow board, with the top/removable half of the mold formed around the pattern itself?
Dave Crow
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Dave, pardon me if my expanation is not so clear, but I will try.
Imagine the pattern and follow board together, as in the first picture, on a flat surface. The bottom flask is placed around the assembly, and sand is rammed up in the flask.
Then the flask is inverted and the follow board removed. The exposed sand is dusted with a parting compound. The second flask is placed on it now, and sand is rammed up in it. This second flask and its sand is lifted vertically, and it has the shape of the inside of the casting sticking out from its face.
Now the pattern is removed in three pieces - the two side wings first, drawn out at the angle of the washout holes, then the main portion is removed vertically.
Now lower the top flask onto the bottom, and the net shape will be the shape we want. No cores needed, and all five holes are formed in the mold.
There is an additional complication due to the fact that a C-shaped casting will want to bow out when it solidifies, so we need to form a couple of sacrificial tie bars across the back. This can be done with foam inserts or by shaping grooves in the sand by hand.
I hope this is clear. Alan and I worked out this scheme after much discussion. Jason alerted us to the issue of the casting deforming, since it happened on the first casting done for #9. We hope not to be making any more crane counterweights :)
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Hi Harold,
Okay, now it all makes sense. Thanks for your explanation.
Dave Crow
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Where/how did you learn how to do this?
-John
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Well, the short answer is, Alan taught me everything I know. :) Also, I read three old patternmaking books that google book search had complete scans of. I also am a mechanical engineer, and spent some years designing stuff to be manufactured, so I have some feel for this kind of thing.
For reference, the books are:
Pattern Making and Foundry Practice, L.H. Land, 1912
Pattern-Making, G.H. Willard, 1910
Practical Pattern Making, Frank Wilson Barrows, 2nd Ed.,, 1913
Alan also figured out a lot of techniques that help make the whole patternmaking process pretty streamlined. And Bernie got Alan started with much help and discussion.
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One of the reasons why I enjoy pattern making so much, is that you often have to come up with unconventional ways to deal with unconventional shapes. For the most part, our efforts for #11's patterns are guided in two ways- completing major component groups, and starting from the ground up. Since it doesn't make sense to start a locomotive from the sand dome, this has lead to the fabrication of component groups such as the drive wheels and counterweights (finished), the front truck (finished), rear truck (in progress), frame components (finished), and valve gear(in progress). But every once in awhile, the difficulty of undertaking a pattern starts to feel like something of Baldwin trying to challenge our capabilities. The smokestack was exactly one of those sorts of patterns. When I get caught by a bug like that, the easiest way to deal with it is just lean in and see where it goes.
About a year ago, I started wondering how we as a group would make such a large turning. The stack pattern itself is 40.5" tall (without core prints), and 15" in diameter at it's largest. No available pro-sumer wood lathes are large enough to accommodate such length, and our heavily modified Harbor Freight lathe couldn't handle the swing over it's bed even if it wanted to. Secondly, making the pattern out of solid wood would eat up a massive amount of material, and be highly unwieldy at best. I've had this post sitting on the back burner for a few months, but here's how it all happened.
The second problem wasn't too hard to solve. I've had the fortune of watching two cedar stripped boats be put together, and I've seen barrels. So I figured that if I could make a barrel out of cedar planks, it would be economical to make, and light enough to be easily maneuverable once it was assembled. I got started on this whole process within a week of getting back from Maine, last summer. Firstly, I made three hexodecagon stations, designed to come apart in the middle. The hole at the center of each station was dual purpose...
(https://farm6.staticflickr.com/5605/15473838952_5e7f6fe4b5_c.jpg)
It took a few tries to get my jig to work correctly...
(https://farm6.staticflickr.com/5609/15287552598_81438d7420_c.jpg)
In order to get some clean staves that would turn easily, I rummaged through a stack of cedar at Home Depot with my Dad, to find 9 perfectly clear 2x4's, which was surprisingly easy. I cut them down, and planed them to about 1.25", and cut the first bevel on each piece.
(https://farm4.staticflickr.com/3941/15287475650_22e35c18b0_c.jpg)
The stack tapers outward towards the top, by 1 degree. So I had to make a second jig to cut the taper, and the bevel simultaneously.
(https://farm6.staticflickr.com/5602/15287605477_b5217dc3c1_c.jpg)
After multiple test fittings, I glued everything up with epoxy, and cargo straps.
(https://farm4.staticflickr.com/3937/15287466400_a0c56b6bbe_c.jpg)
And later added on the stock for the upper lip of the stack.
While the swing over the bed of our lathe is only 10", we can rotate the head stock 90 degrees, and turn "outboard". Usually, this is used to make very large diameter, but "flat" sorts of objects. The eccentric patterns were turned as a unit in this way. Turning something as long as the stack requires that it be supported on both ends. To do this, I decided to run a pipe through the length of the pattern, to be picked up by a pillow block mounted to the workbench. The pipe was fitted into the head stock face plate which had been bored out to fit, pass through the holes in the plywood stations, and make a tight fit with a wooden face plate on the other end, before fitting into the pillow block.
(https://farm4.staticflickr.com/3927/15474153315_c569fcbf00_c.jpg)
Also shown, is the tool rest that I rigged up. I would need at least one tripod to support a standard tool rest. But I had anticipated that the turning would take a day or more, and I didn't want to be limited to turning 12" at a time before having to move the rest around. So I made a second tripod to support a 40" tool rest. It turned out that I only needed turning tools on the body of the stack for a couple hours. The vast majority of the time was spent bringing everything to final diameter with 60 grit sandpaper. I had the dust collector running big time to keep things manageable. I filled the pockets and imperfections with epoxy after the first day.
(https://farm4.staticflickr.com/3933/15474132735_721fc8c78f_c.jpg)
And turned the lip the following morning.
(https://farm6.staticflickr.com/5599/15287426950_2366423c24_c.jpg)
And gave everything a coat of epoxy to seal the outside.
(https://farm9.staticflickr.com/8701/16320393294_1f1b075d17_c.jpg)
Since August, (when work on #9's whistle started), the stack has sat mostly idle. It still needs core prints, and a giant core box. I also worked on the valve chest and cap, and spent so much time filleting them that I came to despise them. And compared to the stack, they are pretty tame. While I originally hoped to bring the stack up in the back of a car- once the core prints are added, it will be exceedingly difficult to transport. So the stack will probably stay in Texas until the cylinder saddle duties have been divided up and completed- then bring all of the giant patterns up in a truck load.
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Alan,
You guys are totally unbelievable!!!!!!!!!
Bernie
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Fantastic work Alan, the stack pattern is a work of art. Thanks for the update.
Start
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I am just absolutely gobsmacked at the ingenuity you and your dad use to solve problems, Alan. You two make it all look so simple!
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Nice work
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Alan;
I am in awe! Your work should be in a museum! Oh, wait, it will be...
We are so fortunate to have you as members. I look forward to seeing you and your father in Sheepscot again.
Dave
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Awesome piece of work! You guys have been so clever in figuring out how to make the patterns; the castings should be much easier!
Dave Crow
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Really nice. The photo of the unturned barrel looks like a gatling gun.
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Phenomenal!! Really enjoying seeing these different items take shape, thank you!!
SH
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Absolutely awesome.
I could not assemble a balsa wood airplane without the wings falling off !
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Wow, I'm impressed! Absolutely beautiful work, Alan.
By the way, coopering a set of staves and then turning the hexadecagon/octagon/whatever down to a tapered cylinder on a big lathe is exactly how wooden masts are made for tall ships. Your intuition led you to the right answer!
-Philip Marshall
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Thank you for the compliments! I hope these posts that we do aren't too wordy. Some of my favorite posts to read on the forum are the ones about the creative solutions people come up with for the wide variety of problems that come up at the museum. I also just like to show that as weird as pattern making seems to be- it's not magic. And I hope that seeing some of the problem solving might encourage others to give it a try.
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Alan...absolutely amazingly first-rate design and work, the usual for you, and your dad.
IMHO you can explain and show your processes all you want.
Bravo! :D
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Is this where I suggest that a full size outline of #11 be
erected painted somewhere and the
beautiful patterns mounted in their proper locations?
It should be where it can be seen by the public and the huge amount of work appreciated.
(Buy a piece of a pattern?)
If the pattern is to be used more than once it will have to be in a climate controlled environment?
This may be something down the road but I think it would make money if it does not cost too
much to set up.
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Perhaps an air tank could be put in side the pattern locomotive Carl is speaking of so it could be powered by compressed air. It could then shuffle around the yard. Just a whimsical thought. The patterns you and your dad make are true works of art. I enjoying looking at them and marvel at your accomplishments.
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Perhaps an air tank could be put in side the pattern locomotive Carl is speaking of so it could be powered by compressed air. It could then shuffle around the yard. Just a whimsical thought. The patterns you and your dad make are true works of art. I enjoying looking at them and marvel at your accomplishments.
Bill...that would be impractical. Basically you don't need to make the same number of patterns as the number of parts. As an example, you only need one drive wheel pattern as you can use the one pattern four times.
Keith
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I have been in the foundry business off and on for many years, and now I am restoring a 23" gauge Porter 0-4-0T, Jones & Laughlin Steel No. 58. Three weeks ago I brought both of those interests together when I cast a new set of grates for the locomotive at an iron pour that we held at the Carrie Furnaces National Historic Landmark in Rankin, PA, just outside of Pittsburgh. We are ramping up a metal arts program at the site and over the winter will begin construction of a foundry building. By next summer we will have the ability to cast grey iron and ductile iron up to about 7,000 lbs. We will also be able to cast bronze. Much of our work will be art pieces, but my interest is in creating a location where castings for historic restoration projects could also be made. We will be producing all of the castings that we need for our railroad, including the wheels.
I am confident that we could produce all of the grey iron, ductile iron and bronze castings for the WW&F 11 project, do it at a cost substantially less than what a commercial foundry would charge and with the same quality. I have worked at foundries producing iron castings from 100 tons down to a couple of pounds using both no bake and greensand. I've also operated my own iron foundry business making reproduction parts for gas engine and tractor enthusiasts.
Carrie Furnaces NHL is a former US Steel blast furnace plant, once the major iron producing facility for the now demolished Homestead Steel Works. The furnaces could each produce over 1,000 tons of molten iron per day that was converted into steel and rolled into I beams, channels, plates and armor plate. It is now a major tourist attraction in the Pittsburgh area. We are restoring the J&L 58 in the blowing engine house and have intentions of constructing several hundred feet of track on which to operate the locomotive when it is finished.
Just something to think about as you plan your WW&F 11 build. Click on the below link and advance through the photos of the making of the grates as well as builders plates. I made one plate out of bronze and four more out of iron, working from an aluminum reproduction plate that I changed the construction number on. The grate pattern is about 100 years old and part of the collection at the WA Young Foundry & Machine Shop, a complete turn of the century lineshaft driven machine shop that is also under our care.
https://www.flickr.com/photos/33523379@N03/21477577788/in/dateposted-public/ (https://www.flickr.com/photos/33523379@N03/21477577788/in/dateposted-public/)
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Hi Rick,
I'd definitely like to chat with you privately if we could. I'm busy at the moment but hope to establish an email conversation soon. Thanks for reaching out,
Jason
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I have been following your work on other sites. Alan Downey and I have been making patterns for the #11 project for years and they have been shown on this site. I would love to see some of these castings made so the actual construction of the locomotive could begin. I am also working on a whistle project where I will need the parts cast in a high pressure steam bronze. Will you have that capability? Would you also be able to cast a complex three chime flat top whistle bell in a horizontal plane?
Bernie Perch
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Bernie, I've always enjoyed making the more complex castings, as it take a bit of patience and some out of the box thinking to get the cores to stay where they need to be and get the gating and risering right. I can try anything, and if it doesn't come out just throw it back into the furnace and try again. As long as the alloy is available in ingots we should be able to melt it in the crucible furnace.
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I am going to PM my email to you to discuss this fully.
Bernie
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An organization that I am involved with, Rivers of Steel Heritage Corp., owns a 1900 era lineshaft driven machine shop located in a small town along the Monongahela River about 60 miles up the river from Pittsburgh, PA. It is the WA Young Foundry & Machine Shop, and most of the machines inside are operational. With the desire to build No. 11 using techniques that were available around the turn of the last century, we would be able to offer the use of WA Young for the production of some of the components needed for No. 11.
The shop is equipped with a varied assortment of machine tools, including a lathe that can turn 30" (or maybe larger), a 30" x 6' planer, drills, milling machines, smaller lathes, and a 200 ton horizontal wheel press. All are flat belt driven and are original to the shop. In the adjacent room is an iron foundry with a 22" cupola furnace and a coal fired crucible furnace for making brass castings. I spoke with Jason today about WA Young and the possibility of doing some work here. One of the goals of Rivers of Steel is to make WA Young useful again. I have been doing some limited machine work down there and reactivating machine tools as I go.
The Historic American Engineering Record documented the facility and this is their survey:
http://www.loc.gov/pictures/collection/hh/item/pa2222/
I also have an album of photos of Young here: https://www.flickr.com/photos/33523379@N03/albums/72157648586082640
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Rick,
That's a nice shop with lots of good equipment. We like the old flapping belt shops and have all the parts to build a shingle mill with the lineshaft system. Thanks for posting the links.
Start
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Hi Rick,
What a beautiful shop! Thank you for posting these pictures.
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I had a great chat with Rick yesterday, and believe partnering with his many efforts in PA will hold tremendous benefit for our projects- and hopefully meet some of his needs as well.
Jason
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And- what a FABULOUS shop at Young; I hope to see the No 11 project blended there and here, and that some of our members might show up there to help when the time comes. Great possibilities...
Jason
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The Young facility puts me in mind of the East Broad Top's shops, as well as the old shop at Cass, which burned in 1972. The EBT's facility included its own iron and brass foundry as well. I can't recall if Cass had an in-house foundry. I'll looking forward to a visit to Young sometime.
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I was down at WA Young today. While I was there I took a short video of the shop, basically showing the extent of the machine tools and other equipment that are there. The radial drill has not drilled a hole in many years, but today we used it to drill a couple of 3/4" holes in two smokebox door dogs that I had to make for J&L 58.
We were also looking at the coal fired crucible furnace that is in the floor. We plan to test fire it sometime over the winter, and hope to have it ready to melt bronze in preparation to some casting work to do in the spring.
The planer has a 32" x 10' bed, and the big lathe has a 40" swing with a maximum workpiece length of 16 feet. There are various jib cranes located in the building to move heavy workpieces off and onto the machines.
Anyways, here is the video: https://youtu.be/9cSW9KQWIoY (https://youtu.be/9cSW9KQWIoY)
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A co-op arrangement with the Young shop looks like the exact element now needed to get the 11 build started.
And I'm sure Rick has a few experienced hands from the Youngstown/Pittsburgh area, along with WW&F guys, who could help.
Looking forward to a fascinating journey toward 11's steamup.
Imagine...WW&F a three-loco road in the near future. ;)
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Wow! What a cool shop. And still all there which is so rare these days. It would be great to see parts of #11 being created but I think there might be a just as pressing need to make some more passenger car and freight car trucks for existing and future equipment. With #9 coming back online and now with our ability to accommodate tour buses we're going to need more WW&F (reproduction) passenger cars.
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Building trucks might be a good way to "get our feet wet" so to speak over at WA Young. Most of the machines haven't made chips in decades, so starting out with a simple project such as truck building may be the ideal project to work the bugs out of the machines and lineshafting. Pressing wheelsets together on the 300 ton wheel press is going to be interesting to say the least.
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In an attempt to reassure everyone that there's some logic and reason behind our aspirations, ill mention here that we have active plans to build a replica coach, along with a historically appropriate WW&F open excursion car. We have passenger trucks and couplers for the coach already. We also have most of the in house capability to perform these projects. Both, and many others, will be started and completed long before no 11 steams.
No 11 is a big project that will serve as a rallying point for members, volunteers and donors. It's meant to be ambitious, though I assure you there is tremendous thought and planning that will allow the project to proceed smoothly. Rick's offer of help from WA Young is the perfect outside kick to allow this project to really get off the ground- and we want to use that offer as thoughtfully as possible. Getting a start on a big, long term project that stretches our own shop's capability seems like a great down payment on the no 11 project, while rebuilding the passenger trucks we have and building a coach is all attainable right in Sheepscot and is a near term goal (2017- after the turntable).
I guess what I'm trying to say is: these projects can proceed simultaneously- each at their own rate. No 11 will take so long- it will need to overlap with numerous other projects. Rest assured- our priorities are straight- we know we have to build 12 coaches so no 11 has something to hall :)
See ya
Jason
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12 coaches(?) or coach # 12?
Ira
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12 coaches, numbers to be determined...
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Thanks.
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I recall being told that one (or more) of our passenger consist currently resides on freight trucks, plus I believe that #65 sits on what would be considered shop trucks. Hence my previous comments. Jason's comments only confirms that we will need trucks, however long it will take. Has anyone started on patterns for the required castings?
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Jason,
I assume that we will attempt to recreate replicas of the original WW&F passenger fleet first, (if we have drawings, etc). If not, is the plan to reproduce copies of #3? Long term it would be really cool to create our own version of the Rangley. (wishful thinking)
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Ok guys- hold on-- 12 coaches was a joke. I certainly hope we are big enough to need that many someday- but my comment was completely meant as fun. One replica coach is currently planned- with long term thoughts of another (perhaps combine).
65 has proper freight trucks, though new wheels are in order.
Coach 8 is doing ok on the trucks it has.
See ya
Jason
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OK you got me good !!!!!!!! I think I'm entitled to a free pass on the April gags...........
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Does no. 11 need a NOS Metropolitan?
http://www.enginads.com/classifieds/showproduct.php/product/122718/cat/7
Probably TOO small for an engine that size but it might suffice.
Can't be too many of these left in the original box...
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Since only one passenger car will be built next year ;), what is on the schedule to start Sheepscot's last big addition, the turntable? Is the roundhouse part of the project? How about the coal bin, to now feed two busy steamers?
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Turntable work will start this winter (with castings and machining), followed by excavation in spring assuming that the Kubota is healthy.
Roundhouse is not yet scheduled in.
Coal bin was one of the projects in this year's fund drive but it's unlikely to be funded this time around.
As for passenger cars - yes we want to build one but it won't happen in 2016. A lot of work goes into one of those. My guess is that would be a two year project at least.
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Thanks for the update.
Good luck with running the best Victorian Christmas yet!
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Plans for no. 11's boiler.
(http://i148.photobucket.com/albums/s5/bbarry74/bbarry74008/IMG_5927.jpg)
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Jason's pictures.
No. 11's barrel sheet after being cut on the water jet table.
(http://i148.photobucket.com/albums/s5/bbarry74/bbarry74003/IMG_9778.jpg)
11's barrel sheet being lined up with the rolling mill.
(http://i148.photobucket.com/albums/s5/bbarry74/bbarry74003/IMG_9775.jpg)
11's barrel after rolling.
(http://i148.photobucket.com/albums/s5/bbarry74/bbarry74003/IMG_9776.jpg)
Part of 11's fire box and outer wrapper sheet. In the picture is Jim Hueber, 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.
(http://i148.photobucket.com/albums/s5/bbarry74/bbarry74003/IMG_9774.jpg)
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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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Political message.
It is amazing what can be accomplished when the Government does not oversee the project.
(Tongue in cheek)
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Well done, all.
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Well said Ira.
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Very exciting to see the pieces start to take shape. Looks like we have some serious riveting ahead.
Did I miss the rolling of the sheets for #10's boiler? Or are they next in line?
Oh, and please, let's leave the political comments out. There's plenty of opinionating everywhere else, and getting away from all that is one of the great things about the WW&F.
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2 comments:
1. The components for #10 and #11 are being rolled simultaneously. The order they come out at the fabricators is based on their preferences in getting the entire job done as efficiently as possible. If all went according to plan, all the parts should now be completed.
2. I considered Ira's comment more of a joke/humorous stab than a political statement. Any further debate on political matters will be subject to moderation.
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I'll post about the sheet rolling under general discussion, 21 campaign.
Jaso
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It's the cadre of donors that makes it all possible. All the plans in the world mean little if the money isn't there to back it up. Thanks to all those who regularly give a little something each month to this project!
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Just curious. Is the horizontal seam in the barrel going to be welded or riveted? If it's riveted what style of joint will be used?
Thanks, Mike Nix
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I know this thread is old and I know that major work on #11 is a few years away however I thought I would post this link. http://dakotafoundry.com/capabilities/ Dakota Foundry is owned by Cory Anderson, who built the 150 hp Case traction engine replica. Having some of the more complex casting like the cylinders done by them would be something to consider as they understand steam engines. I'm not suggesting they would be the cheapest place but they might be ones the best and I would hope that they would at least be consulted before decisions on who will do major castings are made.
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Over the past couple of months, there has been a lot of discussion back and forth among members and friends concerning the possible sale of No. 10 with the idea that its sale would help fund the construction of a new locomotive, No. 11. Building No. 11 has become necessary by the new Mountain Extension, with its challenging grades and curves.
The negotiations for the sale of the locomotive have ended, so No. 10 will remain at Sheepscot for the foreseeable future. That said, a new plan has been developed that will return No. 10 to service while at the same time work will begin to build No. 11. The first phase of the plan calls for work to construct the boilers for both locomotives simultaneously. There are major benefits to doing this, not the least of which is cost savings that will be realized in performing some procedures at the same time for both boilers.
At the same time, a small team of WW&F members will start construction of No. 11. In fact, some parts have already been ordered from outside vendors. While this approach may slow No. 10's return to service, it will accelerate the construction of No. 11. No. 10 should be ready to should be ready for use in 24-30 months, and the timeline for No. 11 is 4-1/2 to 5 years.
To support the project, the museum has opened a FundRazr crowd-funding site. The goal for the first round of fund-raising is $17,000, which will boost the funding for the first year of the project to $50,000. Anyone is welcome to donate to the project at http://build11.wwfry.org
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Bringing this thread back.
The "Build 11" project is ramping up. Funding for 2020 has been secured, and money needed to move forward in 2021 is being raised at:
build11.wwfry.org (http://build11.wwfry.org)
If all goes according to plan, #11 will be under steam in 2025.
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Coverage of Build 11 in the online Railnews of Railfan and Railroad:
http://railfan.com/maine-museum-building-new-steam-locomotive-gets-big-boost/ (http://railfan.com/maine-museum-building-new-steam-locomotive-gets-big-boost/)
Article by WW&F Member and former Mainer, Justin Franz.
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I was wondering what configuration of #7 was planned for #11 to be based on, I've looked through both this thread, and the fundrazr page and come up with nothing. I previously had assumed as built due touched up builders photo being passed around, but nothing was ever confirmed directly.
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There have been some discussions among the engineering team about what No. 11 will look like when it's finished. The reality is that's still a long way off, and there is plenty of time to discuss it before anything concrete must be done. The locomotive had three distinct "looks" during its 26 years on the WW&F. The as-built look is probably the least likely for a number of reasons, so it's safe to say it will look like it did toward the end of its career, one way or the other.
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I hope the tender gets the large lettering (I think all our locos should have the large lettering).
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it's safe to say it will look like it did toward the end of its career, one way or the other.
Toasted wooden cab and all? Joking of course, I was just curious if it was going to end up in olive green green.
I hope the tender gets the large lettering (I think all our locos should have the large lettering).
#9 and #10 both have the small lettering correct?
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Yes, both 9 and 10 have the small lettering. For a couple of years 2002-2003 #10 had large lettering, but after the rebuild it went back to small.
I'm a proponent of using the railroad's large lettering on tenders. That comes from a time when the railroad was (relatively) prosperous. The small lettering I tend to think of as a declining fortunes money-saving device. I think we don't want to portray that we're a down-on-our-luck railroad. #9, alas, has a stipulation in the lease that requires it to retain its 1933 appearance, so that letting size must remain.
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Historically #9 wouldn't have worn the large lettering right? It would seem odd to me at least to have them mixed and matched era wise, especially with #9 not having worn it or really been around it (if that is the case). If it is accurate with the final configuration outcome using the larger letting for specials, that or just interchanging them from time to time add a neat mix and some extra representation.
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The "Heritage Rail Alliance" is the industry group that encompasses all heritage railroading (tourist trains, museums, etc.) in North America.
In a recent listing of ongoing projects, their editor called out the Build 11 project with the following description:
"Never underestimate this museum, which has assembled a lot of manpower and has a long list of recent accomplishments."
https://heritagerail.org/2020/12/active-restorations-steam-locomotives/ (https://heritagerail.org/2020/12/active-restorations-steam-locomotives/)
Tune in on Friday for the latest update on the Build 11 project...
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BUILD 11 Update!
There is some great news about the Build No. 11 Project this month. First and foremost, our FundRazr has reached and surpassed its goal of $17,000, thanks many donations from members and friends far and near. Nevertheless, if you want to contribute, you still have about three weeks to do so. We’ll be announcing a new FundRazr campaign for 2021 on January 11.
The quotations for casting the cylinder half-saddles, driver centers, cranks and various other parts were received, and the team is evaluating them. The expectation is that an award will be announced by the end of 2020.
In other good news, Mountain Machine Works of Auburn, Maine will be machining 10 new axles for the WW&F Railway Museum, including the axles for the rear truck under No. 11. The others are for coach No. 9, a-building now in the Sheepscot shop, and B&SR boxcar No. 56, also in the shop. The really great news is that Mountain Machine is doing this work at half the usual cost, as a donation to our museum. This donation has been described as “a tremendous time savings” for the museum since we don’t have to manufacture the axles ourselves.
The new pattern for the WW&F No. 7 builder’s plate replicas was completed recently and delivered to the foundry on Dec. 7. The first 10 plates will be cast and sent to those who donated $1,100 to the Build 11 Project soon. If you want one of these beautiful bronze plates, just donate a lump sum of $1,100 (or more) to the project.
The engineering team continues to make purchases of materials, which will be stored in a designated container (which arrived at Sheepscot last week) until needed. Actual progress on Phase I of the construction of No. 11 will of necessity be slowed until the restrictions on travel imposed by COVID-19 are lifted sometime next year, we hope.
(http://wordpress.wwfry.org/wp-content/uploads/2020/12/driver.jpg)
Here is a 3-D rendering of one of the drivers for No. 11, which is among components that will be cast in the new year.
(http://wordpress.wwfry.org/wp-content/uploads/2020/12/repplate-e1607649158159.jpeg)
The pattern, made by Preservation Pattern of Lewiston, Maine, for the Baldwin builder's plate replicas was delivered to Cattail Foundry on Dec. 7.
(http://wordpress.wwfry.org/wp-content/uploads/2020/12/IMG_2857.jpg)
This container will be used to store components manufactured for No. 11 until they are needed in the shop for finishing and assembly. It will be painted next year to match the first container.
Donations for the project and more information can be found at build11.wwfry.org (http://build11.wwfry.org).
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January Build 11 Update!
The 2020 fund-raising campaign has wound down. The goal of $17,000 was reached and surpassed by nearly $8,000. To all who donated, a hearty thank you.
Starting today, we’re opening another fund-raising effort. For the year 2021, we’re hoping to raise $50,000. That sounds scary, and it is a lot, but we remain confident that our friends and members will support the ultimate goal, the construction of a new locomotive!
Several members and friends have committed to monthly donations of either $11 or $22. That may not sound like much, but it all adds up. We hope some others will join in that sort of effort.
We will also continue to offer the reproduction Baldwin builder’s plate of WW&F No. 7 for one-time contributions of $1,100 or more. More "perks" are still being planned. Donate early and often at: build11.wwfry.org (http://build11.wwfry.org)
(https://static.fundrazr.com/story/697b37b45bce4b83a4266166f2d2522e.jpg)
In other No. 11 news, the hydraulic power unit for the flanger has been relocated outside the shop to reduce the noise and exhaust fumes.
Gordon Cook built a “doghouse” to protect the unit from the elements. The hydraulic hoses have been fed through two holes in the wall of the shop. Flanging work is expected to get started sometime this month, first completing the last few components for No. 10 and then going right into parts for No. 11.
(https://static.fundrazr.com/story/25ba1fe326b84dcfb7fd507941d41725.jpg)
A start has been made moving various parts of No. 10 and No. 11 into the container, where they will be stored until needed for assembly of the locomotives. This helps clear out needed work space in the shop. The two main frame sections are among the parts moved, and Gordon Cook has built cradles to stand up the main frame sections. Other parts will be stored on pallets, and a pallet jack has been acquired to move the pallets about in the container.
(https://static.fundrazr.com/story/64f8b898b0bc496ca02ece7fc3686059.jpg)
Meanwhile, at Preservation Pattern, the rear frame extension is receiving tie bars at the top to make the entire piece a continuous “loop” to retain its shape through casting and heat treatment, after which the tie bars will be cut off. Some minor modifications were necessary to the rear bolster patterns due to design changes in the original Baldwin design to improve the locomotive’s lateral stability.
(https://static.fundrazr.com/story/d94547cb34cf4cb990aac3b58f89d45b.jpg)
The water-jet parts completed in Syracuse, NY will be shipped to Sheepscot soon. Most of those will also go into the container. In addition, we plan to order steel stock from two vendors shortly. One vendor will custom cut stock to length, while the second vendor provides full-length stock for use in a variety of applications on the locomotive.
(https://static.fundrazr.com/story/c46566693f104ca09fcaec375a50eb96.jpg)
Finally, we expect delivery of the new to us large lathe later this week. It may be dropped off at Ken Boudin’s Machinery Service Co. for a couple of weeks of storage until everything is ready to install it in the shop.
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Let's see what was under the plastic..
(https://i.postimg.cc/QxvBth5Y/0112211424.jpg)
(https://i.postimg.cc/ncXjpCsQ/0112211424a.jpg)
(https://i.postimg.cc/pVGhwDdH/0112211424c.jpg)
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Wow, those frames are amazing...and obviously the fundamental core of the 11 build!
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No. 11's frames are all tucked in. Picture from Jason...
(https://i.ibb.co/TRPqvC9/IMG-3252.jpg)
I think that that the horizontal legs can be trimmed quite a bit now that they're in place.
Hopefully it won't be that long before we'll retrieve them to start assembling No. 11. That will be truly exciting.
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It's exciting to know that this is will be the first Maine two-foot steamer built from the ground up since Baldwin rolled B&SR/B&H #8 out in 1924.
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and the last steam locomotive built in the state of Maine since Portland Co. built B&SR #5 in 1906!
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and the last steam locomotive built in the state of Maine since Portland Co. built B&SR #5 in 1906!
Steve, I think you meant the FIRST one since B&SR #5 in 1906. Just me nitpickin'....everybody knows whatcha meant. :D
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I wonder whether the use of fitted bolts is intended for the assembly of the frames (rather than welding)?
JBS
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Bolts where designed, and I think some rivets in there too.
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Those frames would have been originally put together using bolts that were individually turned to size and driven into reamed holes before being finally tightened. The result is very secure.
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Never fear, we are aware of the necessity to use fitted bolts in the frames, and we have the capability to manufacture them in our shop.
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When you use the term "fitted bolts", do you mean "tapered bolts"? If so, are you going with the traditional railroad taper of 1/16" per foot or Morse Taper. The original railroad taper reamers are hard to find and cost makes them difficult to recreate.
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Someone more qualified that I will have to answer that question.
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The bolts aren't tapered.
This method of attachment is used for assemblies that will undergo repetitive stresses that could loosen a bolted joint.
The parts are clamped together in their final location, then the bolt holes are reamed be be the same diameter and in perfect alignment, and the non-threaded portion of the bolt is turned to be a light interference fit in the hole. The bolt is then driven in and retained by a nut.
This ensures that there cannot be relative movement between the assembled parts and the integrity of the joint is not dependent on the friction between the parts and the tightness of the bolt.
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I was not aware of that method. It was common practice to use tapered bolts to connect locomotive frame members in the first half of the 20th Century. The only difference from your planned method is the use of tapered bolts (after reaming the holes) instead of straight bolts. As it was explained to me by a master machinist, as the bolts are tightened they stretch and elongate and the interference is reduced or eliminated. Tapered bolts reduce or eliminate that issue and that is why they were most often used instead of straight bolts.
One cannot draw them out the wrong way by cutting off the heads though.
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Gordon has explained matters correctly, where fitted bolts are concerned
Tapered dowels are used for the accurate relative location of mating parts which are separated clamped together by bolting. There is a separation of functions. Effectively, a fitted bolt combines the functions of location and securement.
Locomotive frames are subject to great fluctuating stresses and, accordingly, they have a tendency to crack. In general, susceptibility to cracking may be associated with welded construction. My main purpose in raising the subject of frame bolting was to ensure that there would be no danger of frame cracking from welding.
During a locomotive restoration project, now many years ago, I had the experience of partly dismantling bolted bar frames and the efficacy of the fitted bolts impressed me greatly. The bolts were tough to remove but, have no fear, they were eventually carefully replaced as the project proceeded to a successful conclusion.
In general, welding can be very successful for a multitude of applications but a necessity for post-weld heat treatment can reduce the practicability of that approach.
It is good to know that everything is well thought out and under control - as usual at the WW&F.
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No. 11's frames are all tucked in. Picture from Jason...
Are they greased to prevent rusting?
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More "perks" are still being planned.
Oh, really? I see a $11E2 level of donation, and a $11E0 level. Will there be a $11E1 level donation?
Is there anyone crazy enough to donate $11E3 ?
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As most folks here know, the WW&F is in a long-term effort to recreate WW&F No. 7, which is to be identified as No. 11. The engineering group has created hundreds of drawings and multiple 2-D and 3-D images to this end. We've had some parts made, such as the frames, other parts are being manufactured right now, and we will soon have some major news concerning other important components of this new locomotive.
We have embarked on an ambitious five-year schedule to complete No. 11, with the starting date when the COVID-19 restrictions are lifted. Despite the pandemic, in 2020 we raised over $24,000 in donations, and we received a $50,000 donation from an anonymous donor. Now we are into the 2021 fund-raising campaign, with a goal of $50,000. We're using FundRazr.com (www.build11.org) again for on-line crowd funding, but we welcome donations made directly to the WW&F mailbox in Alna, or through the gift shop's credit card link, or in-person delivery.
We decided when we started this project to recognize lump sum donations of $1,100 or more with a full-size bronze replica of WW&F No. 7's Baldwin builder's plate. I am pleased to say that 13 members and friends so far have contributed, and we hope that more folks will consider doing so. I picked up the replica plates last week at Cattail Foundry in Gordonville, Pa. and will be sending them out to the recipients over the next few days. Below is a photo of one of the plates.
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If, (like me), :) you were wondering what the significance of "Burnham, Williams & Co." on the Baldwin builder's plate was, here is an explanation:
http://www.pacificng.com/template.php?page=/ref/locobuilders/blw/index.htm
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Build 11 – February Update
It’s been a quiet month since our last report, but things are happening to move the project along. In the first month of the 2021 FundRazr for No. 11, we are just shy of $3,000. So now we need a little more than $47,000 to reach our goal. We aren’t shy — we’re asking for donations! If we are to make this happen, we need donations large and small.
Pictured here are two 3-D renderings of the frame components of No. 11, provided by Dave Roche.
(http://wordpress.wwfry.org/wp-content/uploads/2021/02/3D-Model-Frame-and-Running-Gear.png)
Just the other day, the first 10 replica builder’s plates were packaged up and mailed out to the folks who have contributed $1,100 or more. We still have six more plates on hand, and of course we can always get more made. If you’d like to have one, send us your donation of $1,100 (or more) in one check or online contribution and we’ll get one out to you.
(http://wordpress.wwfry.org/wp-content/uploads/2021/02/No-7-Builders-Plate-Remake_sm.png)
WW&F member Russ Nelson has come up with another premium idea. He is offering a 5-inch diameter plastic resin replica of WW&F No. 7’s builder’s plate produced on his 3-D printer to the next 110 people who contribute $110 to the build 11 Project. Select this "perk" at build11.wwfry.org and Russ will make one for you and send it to you.
(http://wordpress.wwfry.org/wp-content/uploads/2021/02/No-7-Mini-Builders-Plate-Plastic_sm.png)
In other news, the radial drill press and the new to us Lodge & Shipley lathe are scheduled to be positioned in the shop this week. We have to wait a bit to use either machine until our electrician can come by to wire them in to the shop’s electrical system. The three-phase generator has finally had its new water pump installed, so it’s ready to go.
The engineering team has been reviewing the final quote for the patterns for the cylinder half-saddles, and as long as everything adds up, a purchase order is to be issued in the next few days. We are also ordering steel from two vendors. From one, we will receive various shapes and sections cut to order, while the other vendor will provide stock in standard profiles and lengths for us to cut to fit as needed. This steel purchase provides all the stock material necessary to complete the first three phases of the Build 11 project!
Finally, the main frames for No. 11 have been placed in the cradle to give us more floor space in the container. (shown here.)
(http://wordpress.wwfry.org/wp-content/uploads/2021/02/0.jpg)
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I think Russ's 11E1 perk is a great idea. The 11E2 level was a pretty high bar. On a per-annum basis the new perk comes out almost the same as the $11/mo subscription (110 vs 132). A nice option for people who'd rather donate a lump sum rather than subscribe.
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Build 11 - March Progress Report
(https://wordpress.wwfry.org/wp-content/uploads/2021/03/L11-401-Results.png)
The purchase order for the cylinder half-saddle castings, the largest and most expensive parts of No. 11, was forwarded to Dakota Foundry of Webster, South Dakota, on Feb. 24, and the folks at Dakota have already started work. They provided the solidification models for us within a week, and their pattern maker has begun the task of producing the multiple complex patterns and core boxes necessary to manufacture the two identical casting. When completed, in three months or so, they will be shipped to Maine for final machining.
(https://wordpress.wwfry.org/wp-content/uploads/2021/03/BIG-lathe-scaled-e1615429005429.jpg)
In other news, the large Lodge and Shipley lathe was delivered and positioned in the shop on March 3. The Cincinnati-Bickford radial drill press, which had been moved into the shop in late February has been wire brushed and cleaned, and it has received its first coat of machinery gray paint.
(https://wordpress.wwfry.org/wp-content/uploads/2021/03/BIG-drill-press-scaled-e1615428983149.jpg)
Several other machines were slightly repositioned to increase the available work spaces. The next step is setting up the smaller Monarch lathe.
The container dedicated to storing parts for No. 11 is temporarily housing the 20 new wheels recently received from McKees Rocks Forgings in Pennsylvania. Looks like a third container will soon be needed!
(https://wordpress.wwfry.org/wp-content/uploads/2021/03/IMG_3551_sm.jpg)
We have received an order we placed for steel stock to be used as needed for No. 11, which is also stored in the container. Another order, from a different vendor, should arrive soon. This order includes a number of pre-cut pieces for specific uses on No. 11. And the water-jet cut steel should be shipped from New York soon as well.
Finally, our 2021 FundRazr, at last count, had brought in over $6,200. Again, we emphasize that we need to keep the funds flowing if we are going to move this project forward. A number of WW&F members and friends have committed to monthly donations or $11 or $22, and that keep the funds moving, but our target of $50,000 this year is a steep climb.
Can you help us?
Donate at build11.wwfry.org
(https://wordpress.wwfry.org/wp-content/uploads/2021/03/No-7-Builders-Plate-Remakes-Combo.png)
And remember the two premiums we have.
The full-size bronze replica of WW&F No. 7’s builder’s plate for a donation of $1100 or more, and a 5-inch 3-D printed replica of the plate for a donation of $110 or more.
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Build 11 – April Update
Positive things continue to happen for No. 11.
(https://wordpress.wwfry.org/wp-content/uploads/2021/04/No.11LeadTruck.png)
The No. 11 engineering team has devoted considerable time in the last month to the lead truck of No. 11, verifying plans and drawings in advance of making the necessary patterns to cast several key components. The wheels for the lead truck were cast several years ago and are already completed.
Last week, a substantial number of custom-cut steel components were delivered to Sheepscot. All are stored in the container until needed. They join a stash of stock steel parts received last month.
In late June, we expect delivery of a 12 X 24-foot shed, to be placed next to the shop. Inside, racks will be positioned to store the steel stock currently in the container. In addition, several storage bin systems now located at several places in the shop will be consolidated. These will bring nuts and bolts, rivets, pipe fittings and so forth in a central location. We will also move rarely used items out from underfoot and out of various corners of the shop into this space. We’re calling it “the shop annex.” The structure will be placed in an area recently prepared with a gravel base, and is skid mounted so it can be moved elsewhere around Sheepscot as necessary.
(https://wordpress.wwfry.org/wp-content/uploads/2021/04/ShopAnnex.png)
During May, the engineering team plans to meet in person at Sheepscot for several days of intensive work, making about 30 components for the rear frame extension for No. 11. This is in preparation for beginning the assembly phase of the rear frame later this year. This work involves heating the parts, and using our flanging machine, making precise bends. If time allows, the team will also form several parts for the new trucks for No. 11.
Our fund-raising for 2021 for No. 11 is nearing the 20% mark, although we still have some distance to go to reach the $50,000 goal. Here’s an idea — if you received a stimulus check, perhaps you could see your way to donate some of that money to No. 11. You’ll certainly stimulate the fund raising if you do!
Keep in mind that if you can donate $110 or more, you are eligible to received a 5-inch diameter 3-D printed version of WW&F No. 7’s Baldwin builder’s plate, and if by chance you can afford $1100 or more in one donation, we will be thrilled to send you a full-size brass replica of No. 7’s Baldwin plate. (We still have a couple of the first run of the brass plates, and we can easily secure more, so step right up.)
(https://wordpress.wwfry.org/wp-content/uploads/2021/03/No-7-Builders-Plate-Remakes-Combo.png) (https://fundrazr.com/perks/dI6t2?ref=ab_a5atn6)
Finally, be sure to check https://www.facebook.com/WWFRailway (https://www.facebook.com/WWFRailway) on Saturday, April 24, for a special announcement concerning No. 11.
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Bernie Perch has completed the patterns for No. 11's Stanchions.
Shown in the photo is all the paperwork and templates used to form the patterns.
Even something simple like stanchions and flag pockets requires quite a bit of time and work.
Bernie reports that he plans to take these patterns to the Cattail Foundry sometime in mid May.
Thanks Bernie!
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It has been a while since I have seen some of Bernies work. Top notch as usual.
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Very impressive work.
Jeff S.
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(https://wordpress.wwfry.org/wp-content/uploads/2021/04/Build11-Builders-Plate-Raffle.png) (http://wwfry.org/raffle)
If you think you might really like to have a replica of WW&F No. 7’s Baldwin builder’s plate, but you don’t have $1,100 to get one, have we got a deal for you!
Starting today, and continuing through Saturday, Oct. 9 (the WW&F’s Fall Work Weekend), you can buy raffle tickets for a chance to own the very first plate produced. No, it’s not the only known surviving original, but the first replica turned out by Cattail Foundry exclusively for the Build 11 Project.
Raffle tickets go on sale today for a mere $11 each, or two for $20. You can buy your tickets at the WW&F Gift Shop, by mail order, or on-line (http://wwfry.org/raffle). On Saturday, October 9, we’ll hold a drawing, and some lucky person will own the plate. A second drawing that same day will award a second prize, a 3-D printed, 5-inch diameter copy of No. 7’s builder’s plate.
Get your raffle ticket at: wwfry.org/raffle (http://wwfry.org/raffle)
Today's announcement corresponds with what would have been the 2021 WW&F Spring Work Weekend. The drawing will occur during the 2021 WW&F Fall Work Weekend.
PS: We have some REALLY BIG news coming within the next two weeks. Stay tuned...
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That is great to hear Ed. I am very excited to hear what the news might be. Very pleased to see active progress on #11 and a few other important projects.
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Build 11 - May Update
Building Steam: $50,000 Challenge Accepted!
Friends — We are thrilled to announce a 100% match of all donations up to a total of $25,000 between now and October 31, 2021. Made possible by a generous anonymous donor, this unprecedented opportunity will allow us to not only reach our 2021 fundraising goal of $50,000 for the Build 11 Project, but to exceed it. Then it's full steam ahead to the construction of No.11!
(https://wordpress.wwfry.org/wp-content/uploads/2021/05/Building-Steam-Challenge.jpg) (http://www.build11.org)
That’s right — for each dollar donated by our members and friends, this wonderful person will add a dollar to his donation, effectively doubling your donation!
We'll keep you updated each month on the progress towards the $50,000 challenge.
To take advantage of this 1:1 match, visit build11.org to donate electronically or send a check with “Build 11” in the memo line to the WW&F Railway Museum. P.O. Box 242, Alna, ME 04535.
Meanwhile this week, the No. 11 engineering team is at Sheepscot in person. They are working in the shop to fabricate approximately 30 components for the rear frame extension of No. 11. They are using the flanging machine as a brake, to form angles on these parts. These items are heavy gauge steel and will require heating prior to bending. In addition, the team will also form several components for the new Jackson & Sharp-pattern trucks for Coach No. 9.
(https://wordpress.wwfry.org/wp-content/uploads/2021/05/rearframe.png)
This drawing shows No. 11's rear frame. This week the angled pieces in the corners of the rear frame are being formed, including the four long pieces that form an “X” in the center.
(https://wordpress.wwfry.org/wp-content/uploads/2021/04/Build11-Builders-Plate-Raffle.png) (http://www.wwfry.org/raffle)
We have also started a raffle, with the prize being one of the bronze replica builder’s plates. These replica plates are offered to donors who send us $1,100 or more in one check. For members and friends who can’t afford that amount, this is an opportunity to own a plate. Tickets are available online at www.wwfry.org/raffle or in person at the Sheepscot gift shop. Tickets are $11 for one or two for $20. The drawing will take place on the Saturday of the Fall Work Weekend, Oct. 9th.
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First day of production on No 11 today with the
clanging *flanging* machine used to flange 8 components for the rear frame. Alan also helped No 11 by boring a hole using the new to us radial arm drill.
Steve Lennox led a crew organizing the No 11 container- an underrated and critical task.
Exciting day!
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First day of production on No 11 today with the clanging machine used to flange 8 components for the rear frame.
I wish I had a “clanging” machine! But I suspect I would need hearing protection......
Keith
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It does occasionally clang, all in good spirit of course.
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We have the bell for #11 - that's a clanging machine.
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I didn't know a bell was a machine. 8)
Jeff S.
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First day of production on No 11 today.
On May 11th is it a mere coincidence Jason ?
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I took the stanchion and flag pocket patterns along with the patterns for MEC 470's complete whistle to Cattail a week ago. I recommend that anyone visiting that section of PA to stop in. It's like visiting a place that hasn't changed in 100 years. It is the foundry version of what the WW&F is trying to emulate. If I can, I will try to photograph the castings. I hope to finish 470's whistle bell and put it on my B & M bowl/valve and put it on CNJ 113. It should sound exactly like 113 as I used the core box from 113's whistle with additional spacers for the flat top version.
The reason you guys haven't seen many #11 patterns is that I have been working on the clamshell door patterns for CNJ 113 which were also cast at Cattail, and the patterns for 470's whistle. On the way to the foundry, the trunk and back seat of my car were filled with patterns.
Bernie
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Bernie, pictures of Cattail itself as well as interiors of the foundry and castings would be of immense interest to us here in Maine.
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. . . and those of us who aren't in Maine! :)
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When I get down there next time which will be about six weeks from now, I will ask permission to take some photos. It is run by the Amish, and they may refuse.
Bernie
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Rear frame pieces being bent in the shop last Friday.
(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3647.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/ede069f1-8463-4a0b-b3fe-3ee1496399ba)
(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3637.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/88a5f719-3ace-4549-914f-94be0b08e29d)
(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3639.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/b11e1ecd-6ebd-4436-bd0c-8e8741c3d2eb)
(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3641.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/d0eff79e-f755-4436-bee8-7178d87ea791)
(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3642.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/d90f8604-e6a3-4d0c-802a-dea08b027c54)
(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3644.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/a4715607-549c-4d04-aa90-f502ece55956)
(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3645.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/b128f30e-da73-454e-b311-f3f942470652)
(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3646.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/2a695194-fe5f-4c9f-ae9a-d39ef46c6afb)
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Thanks Brendan, that is a great series of photos of the flanger in action!
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Yes that is a neat sequence of shots. How long did it take to heat the bar?
Jeff S.
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Thanks Brendan for the pictures It's great to see something really concrete about building #11. I'm sure this is going to ramp up donations.
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(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3647.JPG?width=1920&height=1080&fit=bounds)
This picture is about the coolest I have seen. So much going on. The steel is reaching a pliable state, and the heat plumes can be seen headed to the atmosphere. This ranks right up there with a Stephen Hussar photograph..
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Yes that is a neat sequence of shots. How long did it take to heat the bar?
Jeff S.
Depending on the mass of the piece, anywhere from 5 to 15 minutes. Two torches were a must.
Wayne will have a more detailed report soon.
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The Build 11 Project received a tremendous boost last week, when all six members of the team were on hand at Sheepscot for the week. During the week, we manufactured a number of components for the locomotive’s rear frame. In addition to the actual making of these components, we reorganized and consolidated items stored in the No. 11 Project container, moving recently-delivered items into covered storage. Most of these items arrived by motor freight from Aqua Cut, a water-jet cutting operation in Syracuse, NY.
Over three days, we used propane torches to heat various items prior to bending them in the flanging machine. Most of the parts were in pairs, and in several cases there were right hand and left hand pieces, which required adjusting the position of stops to assure the piece did not move once the actual bending began. Several larger and heavier pieces required angled bends on both ends while others needed to be formed into a U shape. Because the steel was larger — some pieces were an inch thick and seven inches wide — we used two rosebud torches for heating, one one top and the other on the bottom of the workpiece. These were also a challenge to handle, since one end would be bent, then the opposite end of the piece was heated and placed back on the machine for the second bend. We were pretty pleased that these large pieces were formed precisely, with deviations from our measurements on the order of only 1/16 or 1/32 of an inch. We completed another 12 pieces.
By the end of the week, we had formed some 24 pieces. Six pieces we had planned to work were not included in the shipment from New York, so they will be worked at the next work session in June. We hope to hold monthly two or three day work events through the rest of the summer. After coach No. 9 is moved to the woodshop in June or early July, we hope to begin actually assembling the rear frame — the part behind the boiler that is supported by the trailing truck and contains the coal and water spaces — in Bay 2.
Team members include Jason Lamontagne, Harold Downey, Gordon Cook, Rick Sisson, Alan Downey and Wayne Laepple.
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Calling this work "outstanding" is an understatement!
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Great work to everyone involved. This will be as exciting as the coach project once things start to really develop and come together.
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Thanks for the report, Wayne.
Jeff S.
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Great work to all of you involved with flanging parts for the rear frame. The diagonal pieces are new for added strength, or were they part of the original design?
Dave Crow
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Wayne thank you for your comprehensive explanations. With those few pieces of metal an other thrilling to follow adventure has definitely taken shape. I can't wait for your next report.
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Looks like an extremely productive session. It's great to have such a talented team at work on this project. Thanks for the detailed report and photos. The excitement builds!
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It is great to see so much progress on the new locomotive! Here is a question; did any original parts of the original #7 survive?
Ted Miles, WW&F Member.
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The builders plate for #7 survived and is held in a private collection in New Hampshire. I don't know of anything else.
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The second builder's plate from No. 7, as well as the number plate from No. 6, survive in a private collection in New Jersey.
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I recall hearing someone say the WW&F has the throttle arm from No. 7. Is this correct?
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Ooopsie. Moved my photos to the Coach 9 thread..
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Fantastic work. Thanks for the photos.
Jeff S.
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Build 11 - June Update
During the week of May 11, some great progress was made by the Build 11 Project team. The entire team was at Sheepscot at various times during the week, and a significant number of components for the rear frame of the locomotive were created.
Over three intensive days, we were able to manufacture more than 20 items. We used propane torches to heat steel ships and then formed them on the shop flanging machine. Most of the parts were in pairs; and in several cases, there were right-hand and left-hand pieces. That required the repositioning of stops on the machine to assure that the work piece did not move once the bending process began.
(https://static.fundrazr.com/story/4e8c279ad11a49319946b944fa857b4e.jpg)
Some pieces needed bends at both ends or to be bent into an elongated “U” shape. Some of the shapes were made from larger and heavier steel — some one inch thick and seven inches wide — we used two propane torches for heating, one above and one below. These large pieces were a challenge to handle, due not only to their weight but also because after the initial heat and bend, the other end likewise needed to be heated and formed.
(https://static.fundrazr.com/story/535df5c23b454a4bafaa80f6b2f96633.jpg)
When we had completed all we could, we stacked all the parts on a pallet and moved it to storage in the No. 11 container. In addition to the actual making of these components, we reorganized and consolidated items stored in the No. 11 Project container, moving recently-delivered items into covered storage. Most of these items arrived by motor freight from Aquacut, a water-jet cutting operation in Syracuse, NY.
(https://static.fundrazr.com/story/7f10d6583b3940d3ab7ecccca6f5382d.jpg)
Since the announcement of the $50,000 challenge 30 days ago, you have raised $2222 in new donations! This includes $222 in raffle ticket sales for the replica locomotive #7 builder's plate (https://www.wwfry.org/raffle).
With the match from the generous anonymous donor, the challenge now stands at $4445!
(https://static.fundrazr.com/story/caeb1a373cef46ff9951e1d44a8cf6c0.png) (https://www.build11.org)
We have 5 months left to raise the remaining $22,777 to take full advantage of the match. Please keep the Build 11 project "on track" and donate at www.build11.org (http://www.build11.org)
Just for fun, here’s a photo of the Build 11 team, including, seated, Wayne Laepple and Alan Downey, and Rick Sisson, Gordon Cook, Jason Lamontagne and Harold Downey.
(https://static.fundrazr.com/story/66f33e85816a4846bd7a7552cb62c35c.jpg)
In other news, the Build 11 Team is planning to hold monthly two or three-day work sessions to advance the project. However, the first priority is to complete the final flanging projects for No. 10’s boiler. That includes completing the flue sheets and forming the throat sheet. Then those parts will be taken to Maine Locomotive & Machine Works to be included in the new welded boiler for the engine.
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Ed, I realize it sounds like once again I am being a nit picker.....but looking at the excellent pictures that does not appear to be “propane torches” being used but rather the much more powerful Oxy-Acetylene torches used in welding and flame cutting operations.
Keith
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Hi Keith,
These are indeed oxy/ propane torches. The largest oxy/ acetylene rosebud we can run on our standard gas kit can provide 175,000 BTU/ Hour. These oxy/ propane torches are providing 400,000 BTU/ hour minimum each. The difference is incredible- and propane is substantially cheaper than acetylene. We still have the oxy acetylene kit for small heating jobs and cutting.
Thanks,
Jason
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Thanks Jason, when I saw the oxygen hose paired with the fuel hose I asssumed oxy-acetylene.
The description just said propane which brought to my mind the plumbers little Bernz-O-Matic torches!
Keith
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Understood, Keith, yeah those wouldn’t quite cut it...
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Keith, we're dating ourselves by using Bernz-o-matic terms and equipment. According to my son who is a union steamfitter, nobody uses the old Bernz equipment. Even oxy-acetylene and oxy-propane is falling out of favor. The go-to these days is Oxy-MAPP gas torches as they are about 225 degrees hotter than even oxy-propane and also more compact and cheaper to operate.
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How come the young guy is the one of two sitting in the group photo? ;)
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That's Alan Downey who is doing great things making the WW&F machine shop a truly professional, safe, and capable facility.
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How come the young guy is the one of two sitting in the group photo? ;)
My response would be that its not about age, its about those in the front row not blocking our view of those in the second row. Having two rows allows the photo to be more of a close-up, and better suited for publication in the WW&F newsletter.
:)
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I’m sure Bill’s tongue was firmly in cheek with his question about front row seating. It just so happened that Alan and I moved faster than the other guys. 😄
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If you want to go back further than Bernz-O-Matic it was Prest-O-Lite,
(Acetylene air torches) Sold quite a few tanks to plumbers in the 70s
before they started moving to 20# propane tanks.
Before plumbing it was used for auto head lights and may have been used
on #9's early headlight- looking at early photos when it was #5. Just speculating.
When scraping out a bunch of iron awhile back we used Propane-Oxy because it was
a lot cheaper than Acetylene.
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Build 11 - July Update
(https://static.fundrazr.com/story/c249da80768641049197bb27b4c9d29c.png)
Over several days in June, various members of the No. 11 engineering group worked at Sheepscot. They installed new cranes in bay 1 and bay 3 of the shop. In addition, during another work session they completed all the components for the rear frame extension of No. 11 that required bending. Several of those items were machined and found to be within 0.01 of perfect.
(https://static.fundrazr.com/story/b8919d6711b845a1834539f261bad27b.png)
Gordon Cook has produced an image of the Phase 1 work on No. 11, the assembly of the main frames of the locomotive. As work progresses on the actual assembly, we will update this image.
(https://static.fundrazr.com/story/ee83c188a9f54c0290232cf206dd046d.png)
We received the welcome news that pattern work for the locomotive's cylinder half-saddles is proceeding at Dakota Foundry. They have sent us several photos.
(https://static.fundrazr.com/story/87c373b7a05e4b6abd285b380419bcda.png)
Thanks to a couple of eagle-eyed members, we have been able to acquire an appropriate steam gauge and a genuine Eames Vacuum Brake gauge though on-line auction. Several WW&F members contributed funds to allow the purchase of authentic items needed for No. 11.
(https://static.fundrazr.com/story/253ddbd7bb7c415dab99b5239e6fae11.png) (http://build11.org)
Our 2021 fund raising for No. 11 is proceeding amazingly well. As of July 11, we have received $39,677.00, including $12,820.00 in matching funds from our anonymous donor. This brings us to 51% of the $50,000 Challenge (which concludes on October 31st) and to 80% of our overall goal for 2021!
Meanwhile, we've sent out more 20 of the full-size builder's plate replicas, as well as 10 of the 3-D printed version. Our raffle for one of the bronze plates has raised more than $350 - and there are plenty of tickets available. The drawing takes place on Saturday, October 9 during the Fall Work Weekend.
Learn more, and contribute at build11.org (http://build11.org)
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I just sent in a bit to the matching grant for the WW&F #11.
And I have a question. why is boiler work for the #10 and #11 shifting to the Maine Locomotive and Machine Works instead of Boothbay Railway Village? Do they not want the work?
Ted Miles, WW&F Life Member
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Boothbay Railway Village no longer holds the ASME accreditation required to construct boilers. ML&M does, and they have been active partners in many of our activities.
Thanks,
Jason
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Dick Glueck took and shared these photos from Cattail Foundry in Lancaster County Pa. They were very cordial and he had an excellent tour of the place. Photos were taken with permission and shared (with permission) via Bernie Perch.
While these photos are not of the Build 11 project specifically, Cattail is manufacturing many of the castings for the project, along with Coach 9.
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2 more photos from Cattail...
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2 more from Cattail
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Last photo from Cattail...
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Build 11 - August Update
(https://static.fundrazr.com/story/701b03beac924b1ab5dd079ebaf6dd40.png)
GOAL!!!
Arguably more exciting than watching the Olympics, the WW&F "FundRazr" goal of $50,000 in 2021 for building locomotive no. 11 has been achieved this week! Thank you to all who have contributed; your generosity will ensure that the project does not pause in 2022 due to a lack of financial resources.
That said, we're not quite out of the woods yet! We still need to raise $3500 to complete the $50,000 challenge set forth by one of our most generous donors. Lean more and donate at: build11.org (http://build11.org)
Of course, any funds raised above and beyond our 2021 goal will make the 2022-2025 campaigns all the easier.
(https://static.fundrazr.com/story/6c08f4dc85f144c1927b1a2ad91eacd3.png)
If you’ve been keeping up with the news, you know that the national economy is roaring ahead, but at the same time is plagued with a shortage of willing workers. This problem has led to a delay in the manufacture and delivery of crucial components from Dakota Foundry for No. 11. That being the case, we are temporarily shifting our focus from No. 11’s frame to No. 10’s boiler. In the coming weeks, we plan to flange the last few pieces for No. 10’s firebox, make some modifications to the front and rear tube sheets, and then take all those parts to Maine Locomotive & Machine. ML&M will move ahead with manufacturing the new boiler, welding the components as we provide them. The shell is already at their shop.
Meanwhile, Gordon Cook is designing a fixture and jigs for the flanging machine. It will be used to form the large radius curved sections of the top of the door sheet and the rear tube sheet. The idea is to hold these large sheets in the proper position to achieve the best results. They are difficult to maneuver in the flanging machine, and the pivot will ensure that they will have the correct radius.
And our own shop crew is now actively seeking machinists who would like to volunteer their talents towards the Build 11 project. In short, we are ready to machine a plethora of castings and parts - and could use some help. If you are a qualified machinist in the Midcoast Maine area, please email us at info@wwfry.org to learn how you can help Build 11.
(https://static.fundrazr.com/story/f0b56d7fd27f4291b67a56215db29091.jpg)
It is also planned to modify our home-built Beatty-style flanging machine to serve as a brake, adding another layer of versatility to this most useful tool. With that, we will be able to manufacture various parts for coach No. 9’s trucks. While we have a number of parts already on hand made for us by Cattail Foundry, we need a few more components before we can begin to machine and then assemble the trucks. As for Coach No. 9 itself, the exterior is essentially complete, so Eric and Ron and Lou will soon turn their attention to the interior of the car.
(https://static.fundrazr.com/story/876d36a951e34f259675053c8005da22.jpg)
And to the delight of our hard-working steam crews, a brand spanking new Nathan “Simplex” No. 4 boiler injector, made by Eccentric Engineer of Orange, California, has been purchased and is being installed to replace a troublesome “legacy” injector on locomotive No. 9. Some minor modifications of the piping will be necessary, as will making a bracket to hold the device. If this injector proves successful on locomotive No. 9, additional injectors will be ordered for locomotive No. 11.
Learn more, get involved, and contribute at build11.org
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It is also planned to modify our home-built Beatty-style flanging machine to serve as a brake...
As in a train brake? We have to toss it out the end of the car like an anchor.
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It is also planned to modify our home-built Beatty-style flanging machine to serve as a brake...
As in a train brake? We have to toss it out the end of the car like an anchor.
It will probably take at least two people to lift it in order to toss it off!! :)
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I recall years ago on a excursion over Laveta Pass eavesdropping on a father intently explaining to his son that the hand brake wheel on the open car we were riding was used to drop the emergency anchor which would catch the ties to stop the train. I made no attempt at correction.
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Boothbay Railway Village no longer holds the ASME accreditation required to construct boilers. ML&M does, and they have been active partners in many of our activities.
And rather than having to truck materials back and forth, we can Use Our Train For Freight! Actual deliveries! Spotting flatcars on industrial spurs. Swoon!
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Build 11 - September Update
Flanging and more!
On August 31 and September 1-3, several members of the No. 11 Project group worked at Sheepscot flanging boiler components for both No. 10 and No. 11. Straight flanging was done on the backhead and the throat sheet for No. 11 and the throat sheet for No. 10.
(https://static.fundrazr.com/story/e63846a5a3754a8e9cd33ee89ba7149b.png)
Here, Wayne Laepple (center) and Jason Lamontagne (left) are positioning the first sheet for bending in the flanger.
Fortunately, these bends were all straight bends so no heating of the sheets was necessary. Gordon Cook (far right) and Rick Sisson (not pictured) devised a stop that allowed us to make the bends at the correct angles. For the first try, a sheet of MDF plyboard was tried. It worked fine for the initial bends, but as we progressed, the force of the flanging operation caused fasteners to elongate the holes in the pltboard. Sections of steel bar stock were successfully substituted and the work continued.
(https://static.fundrazr.com/story/0ba3e264e5fd4c5a8eda5a533ea0550d.png)
The first attempt to use steel bar as a stop, seen here, was unsuccessful. A second try, bolting the bar directly to the sheet, worked much better.
The next work session will include additional flanging of No. 11’s throat sheet, the more difficult to execute curves. This operation will require heating the sheet to make it pliable. At this time, we expect to do that in early October.
While it may seem like we did not accomplish much at this session, a good deal of time was necessary to lay out the bends to follow the contours of the sheets. The actual forming operations took less than a third of the entire time we worked.
(https://static.fundrazr.com/story/b22778cd824a43b5b1a9ecfc763b08be.png)
Here, the toggle of the flanger is just beginning to bend the steel for the initial bend.
(https://static.fundrazr.com/story/4fb5c136df3b45db9bcd882eb87d963e.jpg)
In other news, the arrival of the “shop annex,” a 12 x 24 foot structure that has been positioned adjacent to the shop, was followed by the installation of a rack for storage of lengths of flat, angle and round steel stock, steel shelving, and bolt bins. Materials from several locations in the shop have been consolidated into this structure, which will also house various tools and equipment not frequently used that occupied valuable floor space in the shop. Thanks to Brendan Barry, the storage spaces have been set up and lighting has been installed.
(https://static.fundrazr.com/story/02d8340a2ce44f1db68a71053cf3b878.png) (http://www.build11.org)
Finally, we are pleased to announce that the fund raising for No. 11 continues to move forward. As of today, the total donations raised in 2021 amount to nearly $59,500. At this time, we need just $979 to fully access the $25,000 matching challenge donation received during the spring.
Put us "over the top" for 2021 at www.build11.org (http://www.build11.org)
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Build 11 - September Update
This is really great news!
Dakota Foundry reports they have completed all the patterns and cores for the cylinder half-saddle castings for No. 11, and they sent some photos. They will be preparing the molds and are planning to pour the pieces soon. We can expect the completed castings, each of which will weigh about 1500 pounds, sometime around the end of the year.
(https://static.fundrazr.com/story/d98a71b6dae447a2b9348b76ecaff2a8.jpg)
This photo shows the completed pattern for one half of the mold. As you can see, it is a large piece. The tape measure at the bottom shows that it is about 32 inches wide.
(https://static.fundrazr.com/story/c709d85db46a41daa44e64a924ae0ebc.jpg)
This photo shows several of the cores and core boxes, which create cavities inside the mold during the pour.
(https://static.fundrazr.com/story/2a8ee4bc113a4fe4ac5436e844ae1865.jpg)
This image is of the cope, or top half, of the two part pattern used to make the casting. On the right side, the curve is where the casting will be mated to the smokebox of No. 11. At the center left is the valve portion of the casting, and on the extreme left is where the frame of the locomotive will be bolted to the half-saddle. The bottom half of the mold (not shown) is known as the drag.
(https://static.fundrazr.com/story/e302fe83fd144f84b43d43a7a2abfffc.jpg)
In other news concerning Dakota Foundry, the drive wheel center patterns, as well as the cranks (created by Bernie Perch) and the rear frame extension (by Alan Downey) castings, were crated by Harold and Alan Downey and were picked up by the trucking company on Thursday morning. Those pieces will be ductile iron rather than grey iron.
Several members of the No. 11 Project engineering committee were in Sheepscot over the past several days, during which they continued the work of forming parts for locomotive fireboxes. Jason, Rick, Gordon (pictured) and Wayne were involved in the process, using the flanging machine to form the rear firebox and the door wrapper sheets. In addition, a method was developed to form the throat sheet using the flanger.
(https://static.fundrazr.com/story/b1493bc00b214b348031696fe0ed088f.png)
Donations for No. 11 continue to come in, and donations contributed during 2021 stand now at $66,642. There is still time for you to contribute if you have not done so, however. The fund raising doesn’t officially end until Dec. 31, 2021. Donate at www.build11.org.
Finally, on Saturday evening, as No. 9 was rolling into the engine house for the first time, the two names were drawn for the raffle winners from among those who purchased raffle tickets to support our fundraising for No. 11. Grand prize winner is Bill Baskerville, and Peter Kuntz is the runner-up. Congratulations to both, and thanks to everyone who purchased tickets. The raffle raised over $1000 to help us make progress on No. 11.
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Glad to see progress on #11!
I am still working on my pattern - hope to have it done in a month or so and will send it up to be put in the inventory of patterns to #11 so I can move onto the next pattern I can help with.
Keep up the great work! I am happy to be supporting this endeavor. I have been tallying the hours put into this project and my employer is providing WW&F with a grant for the hours I am putting into this, so it is an all around win.
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Various forums around the net have a link to a video about #11, so I figured the WW&F forum should too. ;D
The video is hosted on Facebook:
https://www.facebook.com/WWFRailway/videos/599742581108331/
I am not a Facebook member, but it plays OK for me without any horsing around required. I expect that it will also work for other non-Facebook people.
The video plays with 'subtitles' enabled (at least for me). It seems clear that the subtitles were 'auto-generated' by some computer system as there are a number of spelling errors :D , but still an interesting show.
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Thanks Graham. I meant to post it here too, but I have been travelling this week.
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On Nov. 30 and December 1, a four-man crew including Jason Lamontagne, Gordon Cook, Rick Sisson and new volunteer Eric Snyder completed flanging the throat sheet for No. 10. This work included forming the knuckle by hand, using wooden mallets to form the final curve over a die. The flanging machine was used to hold the workpiece in position on the template during this operation.
(https://static.fundrazr.com/story/81149b8f12914dbb9e7d0b58df9f9b4d.png)
That work completed the flanging of components for No. 10’s new boiler. They will be sent out for normalization by heat treatment, and when the parts are returned, the crew will begin to fit-up and test assemble the parts before sending them to Maine Locomotive & Machine for welding. This should mean that No. 10’s boiler will be completed other than installation of the flues. Sometime in late winter or early spring the boiler will be reunited with No. 10’s frame, and we may then see No 10 returned to service sometime in 2022!
Watch the video! (https://wordpress.wwfry.org/wp-content/uploads/2021/12/IMG_3363-1.mp4)
After the parts for No. 10’s boiler are sent to ML&M, the next step will be to make the throat sheet for No. 11’s boiler. That’s the last component for the boiler, so all those parts can also be normalized.
(https://static.fundrazr.com/story/241f22effa46424d93fdc1a9bf041449.png)
The latest word from Dakota Foundry is that a subcontractor making the cores for No. 11’s cylinder half-saddle castings is backed up, and they now expect to cast them in January. They will cast our other components — drive wheel centers, cranks and rear frame extension at the same time. They will go to another shop for heat treatment to produce ductile iron.
(https://static.fundrazr.com/story/df4e32acc454403cb30b7dd4a5d12b00.png)
We can sympathize with Dakota, as our shop is backed up with projects, too, and there is currently no space available for us to begin assembling No. 11’s frame at this time. Next spring…
As we raise funds to build WW&F No. 11, we previously had two levels of fund-raising, the full-size brass builder's plate for $1100, and the 3D printed mini builder's plate for $110. Now we’ve got something for everyone! For just $11, you can have the Build 11 Challenge Coin. Challenge coins started in the military, with each outfit making their own coins. The lore around these coins is that if you challenge someone with your coin, and they have theirs on hand, you have to pay the penalty — buy a round of drinks or do push-ups. Otherwise, they pay.
Due to a mix-up in the manufacturing process, the first 100 coins have a spelling error, never to be reproduced. These coins will make great stocking-stuffers! If you want one, you can buy one from the WW&F Museum Gift Shop for $11 (https://giftshop.wwfry.org/product/challenge-coin/550?cs=true). Once they're gone, they’re gone, and the new ones will be correct.
(https://static.fundrazr.com/story/6ed58cb387134a2a976640c2063f55ce.png) (https://giftshop.wwfry.org/product/challenge-coin/550?cs=true)
In other news, the 2021 fund-raising effort for the Build 11 Project is winding down. It will conclude on Dec. 31. Right now, the total on hand is $89,118, which is 178% of our $50,000 goal. To all of you who have supported this project in 2021, thank you, thank you. We’ll be announcing the 2022 version of the Build 11 Project on January 11, 2022.
Finally, may we wish everyone who follows this project a Merry Christmas and a happy, healthy and prosperous 2022!
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The 2021 Build 11 fund raising has concluded with a final total of $97,784! This represents 196% of the original goal of $50,000. It's an incredible achievement, thanks to the generosity of over 100 donors. A special word of thanks to those folks who have donated month after month, as well as to the anonymous friend who gave us $25,000 as a dollar-for-dollar match. In fact, thanks to everyone!
Stay tuned. The 2022 fund raiser for No. 11 kicks off tomorrow, January 11.
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BUILD 11 - January Update
An end and a beginning.
At an early December work session, the Build 11 team formed the throat sheet for No. 10, the last piece of the new boiler. Following heat treatment and a preliminary fit up, the boiler components will be prepared and welded by Maine Locomotive & Machine Works. By mid-2022, the completed boiler will be placed on No. 10’s frame, offering the possibility that No. 10 may return to active service this year.
(https://static.fundrazr.com/story/e4c9bd24330e44a08cf0db8114b64ee7.jpg?cb=1641865482630)
And the best news of all, on January 5, the folks at Dakota Foundry poured the first cylinder half-saddle for No. 11. The 1800-pound casting is a major component of the locomotive, and the other half, as well as other major parts of the locomotive chassis, will be poured in subsequent days. Dakota Foundry has been major partner in our effort, overseeing and producing these complex castings, a point of pride for them.
(https://static.fundrazr.com/story/286dbe616bc74dae907c6ac609d4677a.png?cb=1641865562150)
On February 2 and 3, the build 11 team is planning the first of what we intend to be regular work days devoted to making and finishing parts for No. 11. We are looking for some more folks who would like to be involved in this project, and we invite anyone interested to sign up to join us.
Learn more and sign up at: www.wwfry.org/volunteer (http://www.wwfry.org/volunteer)
(https://static.fundrazr.com/story/c31c9a7e6e6843e29f7be1d6324fa2aa.png?cb=1641865706176)
As soon as shop space is available, in April or May, we will begin assembling No. 11’s rear frame extension. In the meantime, however, the team will be working on the main frame sections, making the pedestal binders which hold the drive wheels in position, machining a number of castings and forgings that then will be attached to the main frames, and readying other parts for assembly of the frame.
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Gordon and first time volunteer Scott worked on these parts of the rear frame assembly, drilling the holes today.
(https://i.postimg.cc/zfwwPR0d/0202221610.jpg)
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Build 11 - March Update
Gordon Cook has been spending several days each month at the museum, most recently running the horizontal mill. He’s been finishing work on two rear frame bolster castings. These and three additional castings form the support for the rear truck under the tank and are an important component of the rear frame of No. 11.
These pieces need to be faced on five sides so the entire assembly is square and tight with the strength to support the weight of the water tank and coal. In addition, they must resist twisting and bending forces as the locomotive rolls around curves and on uneven track
(https://static.fundrazr.com/story/f9a31e88257d4169abfd2baa493a2be4.jpg?cb=1646967177010)
Harold Downey has been at work in Texas, making patterns for a number of components for No. 11. Photos show the front spring equalizer pedestal and core box, the lead truck oil cellar and core box and the lead truck journal box and core boxes. This is all rather tedious work, and Harold has continued to do this, along with a number of engineering drawings for No. 11. He’s also working on patterns for several small parts for coach No. 9.
(https://static.fundrazr.com/story/392177761bae47b0b52b9124e26bf6b4.png?cb=1646967199833)
Gordon and his friend Dave Roche made a “solid model” of the main drivers, with the cranks and the valve gear, to prove the angles needed for the key ways in the axles. Gordon explained that this was necessary to make certain everything was correct prior to manufacturing the axles, especially the cutting of the key ways.
(https://static.fundrazr.com/story/9612b9c538e24bf0a259c90b8743c3d9.jpg?cb=1646967221701)
Friends, we’re well into the 2022 fund raising effort for No. 11, and we're grateful for all the donations to the project. About 35 individuals, some being one-time donors, while others are regular monthly or bi-monthly donors, have contributed about $3,700. However, we need to receive at least $982 every week for the remainder of the year if we intend to reach our $70,000 goal for 2022. Don't forget, we have a standing offer of $25,000 in matching funds that is only activated when we achieve $25,000 in individual donations. If you are able to do so, please help us Build 11.
Can you help make this dream a reality?
(https://static.fundrazr.com/story/48557f5dc7b94c4f9b133f205d76df5f.png?cb=1646967294272)
Remember, we have two great premiums for donors. For $1,100 or more, you can get your own full-size bronze replica of WW&F No. 7’s Baldwin builder’s plate. For just $110, you can receive a high-quality 3-D plastic casting of No. 7’s plate, and in the WW&F’s gift shop (http://giftshop.wwfry.org), we’ve got the No. 11 Challenge coin for only $11.
Contribute at www.build11.org (http://www.build11.org)
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A special Build 11 update from one of our volunteers...
(https://static.fundrazr.com/story/61b5ecf7b3634338a507cb264ac8fb45.png?cb=1649644108451)
Hi everyone. I’m Rick Sisson, a member of the WW&F Ry Museum for more than 20 years. I love volunteering there, but because I live more than 200 miles away, and because of Covid era restrictions, I’m not able to get to Maine as often as I’d like. As a member of the Build 11 engineering team, I’m able to contribute to that project by working from home, or “remote working”. I develop designs and drawings on my computer using CAD programs that are shared with and reviewed by the Build 11 team. I can collaborate with the entire team using Zoom meetings.
We’ve partitioned the Build 11 construction efforts into 5 phases. The first of these constitutes the forward frame which incorporates two cylinder saddle castings. These are large, complex components weighing about 1600 pounds each. We expect to receive the raw castings this summer which we will send to a local shop to get them machined to our specifications. This operation is complex, requiring specialized machine tools and will take a fair amount of shop time to complete.
Accordingly, this will consume a significant portion of this years Build 11 budget. Your contributions to the Build 11 campaign will ensure that we will be able complete phase 1 of the Build 11 project. And let’s not forget, the first $25,000 contributed this year will be matched by the Candelaria Fund. This matching grant will accelerate Build 11 progress. A heartfelt thank you to everyone who contributes. You’re all part of the Build 11 team!
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Rear frame assembly last week.
(https://hosting.photobucket.com/images/s5/bbarry74/IMG_5785.JPG?width=1920&height=1080&fit=bounds) (https://photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/2ade4a6d-8227-45aa-adc5-276f7bc685c7)
(https://hosting.photobucket.com/images/s5/bbarry74/IMG_5809.JPG?width=1920&height=1080&fit=bounds) (https://photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/2eaab2cb-dccc-4772-8d7d-3cd1fe36f056)
(https://hosting.photobucket.com/images/s5/bbarry74/IMG_5803.JPG?width=1920&height=1080&fit=bounds) (https://photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/996b8ec6-4bf0-4d11-85c3-ef4fcc0e2799)
(https://hosting.photobucket.com/images/s5/bbarry74/IMG_5809.JPG?width=1920&height=1080&fit=bounds) (https://photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/2eaab2cb-dccc-4772-8d7d-3cd1fe36f056)
(https://hosting.photobucket.com/images/s5/bbarry74/IMG_5810.JPG?width=1920&height=1080&fit=bounds) (https://photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/f7c1787a-8bfd-42b0-9b91-cce0b010bd2f)
(https://hosting.photobucket.com/images/s5/bbarry74/IMG_5818.JPG?width=1920&height=1080&fit=bounds) (https://photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/61871f1a-033c-4cb2-8013-de42f770ddc8)
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We have great news to report!
First of all, during the WW&F’s Spring Work Weekend, several members of the Build 11 Project, as well as other volunteers, began assembling the rear frame extension of No. 11 in Bay 2 of the Sheepscot shop. Over the course of three intense days, components were moved from storage, identified, and laid out on the shop floor. Then the pieces were clamped together and drilled in sequences.
(https://static.fundrazr.com/story/3efa0b774b30417bbcd0794aedd3a654.jpg?cb=1652236500373)
Multiple holes were drilled through water-jet cut holes in the steel sills and into several cast iron brackets. Then temporary bolts were inserted and tightened. Once that had been accomplished, the next step saw the entire framework lifted onto six screw jacks, which allowed the workers to carefully level the frame fore and aft and side to side. The final step will be to permanently mate the various components with either fitted bolts or hot rivets.
Many volunteers and visitors passed through the shop during the weekend and admired the work going on. This work marked the first tangible evidence that building a new locomotive at Sheepscot was becoming a reality. The Build 11 crew was pleased as well, and then more great news broke on May 2, when we received word from Dakota Foundry that the long-awaited cylinder half saddles and the main rear frame casting were both complete and would be shipped shortly.
(https://static.fundrazr.com/story/5fddafb9d3574c448f66af4e65286eb3.jpg?cb=1652236535040)
We received a nice note from WW&F member Bill Sample, who made a generous donation to the Build 11 Project. Bill said, “What really made me go through with the donation was reading Rick Sisson's posting on the "Build 11" project. Seeing Rick's post encouraged me to participate and dedicate the contribution to all you "Build 11" participants who are not only building the new locomotive but are also making a major accomplishment in heritage railway history. We here "in the Colonies" can also build new full sized locomotives!”
Our 2022 fundraising is off and running, but four months into it, we’ve only reached about 15% of our goal of $70,000. We need your help, in any amount, if we are going to continue to Build 11. Be like Bill Sample — support the Build 11 Project. Buy a "typo edition" Challenge Coin for $11, donate $110 and receive a 3-D printed replica of WW&F No. 7’s builder’s plate, or go for broke, and for a donation of $1,100, you’ll receive a full size cast bronze replica of the builder’s plate. Remember each donation will be matched by the Candelaria Fund!
Learn more and contribute at www.build11.org.
(https://static.fundrazr.com/story/0b8ebd6037404bfe968ea8d15159e430.png?cb=1652236773293) (http://www.build11.org)
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While #53 was the star of today's deliveries to Sheepscot, the cylinder castings for #11 also arrived.
[Photo by Jason Lamontagne]
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While #53 was the star of today's deliveries to Sheepscot, the cylinder castings for #11 were also delivered.
[Photo by Jason Lamontagne]
Are we going to lose the deposit on the pallet? Looks like somebody broke one of the slats!
:)
Keith
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While #53 was the star of today's deliveries to Sheepscot, the cylinder castings for #11 were also delivered.
[Photo by Jason Lamontagne]
Are we going to lose the deposit on the pallet? Looks like somebody broke one of the slats!
:)
Keith
Marcel will restore it to it's previous 1940's appearance. Stewart will paint it red.
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My God, there are going to be a lot of rivets in the frame of that locomotive! I hope the crew has a couple of air powered rivet guns ready to go! It is real good to see actual construction of this copy of a Baldwin locomotive starting to happen at the Engine House!
Ted Miles, WW&F Member Built 11 contributor
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(https://i.postimg.cc/c1BqccYM/0528220752.jpg)
(https://i.postimg.cc/gjdCWw9Z/0528220752a.jpg)
(https://i.postimg.cc/XJ9RmfPW/0528220753a.jpg)
(https://i.postimg.cc/t4THJVsd/0528220755a.jpg)
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There is an impressive amount of heavy steel in that frame design. She is going to be a stout locomotive!
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Wow, just a few more pieces to fill in the gap between the rear tank frame and the cylinder half's and we will have a complete locomotive. (He said with tongue firmly in cheek.)
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Wow, just a few more pieces to fill in the gap between the rear tank frame and the cylinder half's and we will have a complete locomotive. (He said with tongue firmly in cheek.)
I hope this is not what model railroaders call a "shake the box kit." We'd need a really hefty shaker.
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[Moderator's Note]
This statement was authored by the Build 11 team in advance of the normal 11th-of-the month updates. Also, Stewart has posted some good photos of the frame being constructed on our Facebook page (http://"https://www.facebook.com/WWFRailway").
There was much excitement at Sheepscot on May 17, when just as the diesel locomotive was unloaded, a second truck pulled in bearing the two new cylinder half-saddle castings for No. 11. A few days later, however, a detailed inspection of the castings revealed several flaws which rendered the castings unacceptable for use.
The foundry was contacted, and following some discussion, they agreed to manufacture two new castings and ship them to us, at no cost to the Build 11 Project or the WW&F. This process will take a couple of months, as minor modifications to the patterns are necessary and new cores for the patterns must be made.
While we were all disappointed at this turn of events, the final outcome will be satisfactory. More importantly, the long delay in receiving the cylinder half-saddle castings does not materially delay the assembly work now underway on the rear frame.
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Monthly work sessions have continued to be productive, with more progress on No. 11’s rear frame. Everything has been drilled and bolted together, and the large rear frame extension castings that will enclose No. 11’s firebox has arrived. It needs some machining before it can be attached to the rear frame, but it’s shown fitted to the rear frame in these photos:
(https://static.fundrazr.com/story/0ebeae4db1ec41fdb135e7c31ccaa85e.jpg)
(https://static.fundrazr.com/story/24102a23debf4c2f98e21b4dfa2ec421.jpg)
There was much excitement at Sheepscot on May 17, when just as the diesel locomotive was unloaded, a second truck pulled in bearing the two new cylinder half-saddle castings for No. 11. A few days later, however, a detailed inspection of the castings revealed several flaws which rendered the castings unacceptable for use.
The foundry was contacted, and following some discussion, they agreed to manufacture two new castings and ship them to us, at no cost to the Build 11 Project or the WW&F. This process will take a couple of months, as minor modifications to the patterns are necessary and new cores for the patterns must be made.
While we were all disappointed at this turn of events, the final outcome will be satisfactory. More importantly, the long delay in receiving the cylinder half-saddle castings does not materially delay the assembly work now underway on the rear frame.
(https://static.fundrazr.com/story/98ad4da2d0984a7a9c898aac7f7cfb7f.png)
Our fund-raising for No. 11 is making slow progress toward the $70,000 goal. Right now, we are focused on reaching the $25,000 mark in contributions. That will unleash a $25,000 matching grant from the Candelaria Fund, immediately moving our fund-raising total to $50,000, or 51% of our goal. Please consider making your dollar for dollar donation count right now!
http://www.build11.org (http://www.build11.org)
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Build Locomotive 11 - July 2022 Update
During the most recent work session for No. 11 (July 5-7), Gordon Cook, Harold Downey and Jason Lamontagne concentrated on making preparations for riveting the various components. Gordon was making tack sleeves to accompany the tack bolts. The sleeves fit in the reamed holes so that standard bolts can be used to hold the components firmly in position for riveting. Harold, in the meantime, began the task of disassembling the various components from the outside of the frame toward the center sills.
It’s expected this work will conclude in August, after which riveting will begin. The majority of the riveting will take place in September. (Want to help? See http://www.wwfry.org/volunteer (http://www.wwfry.org/volunteer) for Build 11 work dates!)
(https://wordpress.wwfry.org/wp-content/uploads/2022/07/11-rear-frame-1-672x372.jpg)
Elsewhere in the shop, Alan Downey has been machining the large rear frame casting, using our H&K mill. Machining is a necessary process to properly fit the casting to the rear frame; then, the casting will be riveted to the rear frame.
On the fund-raising front, we have received a little more than $24,333 which leaves us just $677 shy of the $25,000 we need to raise to release the $25,000 in matching dollars from the Candelaria Fund. With those funds in hand, we’ll still need to secure another $20,000 in contributions to reach our $70,000 goal by the end of 2022.
Have you made your donation yet? Learn more and contribute at http://www.build11.org (http://www.build11.org)
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I am more than pleased to announce that this afternoon, we reached (and surpassed) our initial fund-raising goal for No. 11 for 2022. With the support of many donors, we hit the $25,000 mark, which triggers a $25,000 matching grant from the Candelaria Fund. When we receive those funds, we'll have $50,907 toward the final goal of $70,000 for this year. That's $19,093 we still need to raise. I know we can do it! Thank you, thank you to everyone who has contributed so far. More donations and donors are welcome, too!
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We will be having a No. 11 work session this coming week, August 2, 3, and 4. All who are interested are welcome to join us at Sheepscot. We usually start around 9.
The primary task will be to continue reaming the rivet holes in the rear frame pieces. Right now the frame is assembled with bolts and we have carefully adjusted the alignment of the pieces so the overall dimensions of the frame assembly are in spec. To preserve this exact position of all the pieces, the process is to remove one of the bolts that is holding two or more frame pieces together, match ream that hole to a precise diameter, insert a precision bushing and bolt it through the bushing to hold the pieces in alignment, then repeat for another hole in that assembly.
Once two holes in a joint are reamed and bolted, the remaining holes can be reamed.
When we have all the rivet holes reamed, the frame can be disassembled. The precision bushings and reamed holes will guarantee the alignment of the frame and proper fit of the rivets when the rivets are set.
After all the holes have been reamed, final assembly of the rear frame can begin.
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I'll be there, Gordon. Looking forward to it.
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While at Sheepscot Wednesday, I was able to take a few photos of the August work session. Gordon described the August plan in his July 30th post above. First photo is of (left to right) John Kokas, Wayne Laepple and Rick Sisson drilling rivet holes in the rear frame pieces.
(https://i.imgur.com/BgmdsGO.jpg)
Meanwhile, Gordon Cook was milling bushings to align the rivet holes for now until the frame is later riveted.
(https://i.imgur.com/lR8GCEh.jpg)
You might notice the back of a sign on the right of the first photo. This sign presents a Baldwin erecting diagram for WW&F No. 7--our future No. 11. This helps explain the project to the public, and perhaps it's a handy reference for the Build 11 (http://build11.org) crew.
(https://i.imgur.com/8gI32yo.jpg)
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Build Locomotive 11 - August 2022 Update
Riveting News!
We did it!
Thanks to your support, on July 11th 2022, we achieved the $25,000 mark in our 2022 Build 11 project fund-raising, releasing an additional $25,000 in matching funds from the Candelaria Fund. As of today, we have $52,378 toward our $70,000 goal. We need $17,622 by the end of the year. Can we make it? It’s up to you!
(https://static.fundrazr.com/story/428c7b7ff08341a1a4186305c1ac367c.png?cb=1660184646640)
Over three days at the beginning of August, the Build 11 team made great progress. With the help of four new volunteers joining three regulars, we were able to match-ream nearly all of the holes in the rear frame of No. 11. The process involved removing each bolt one by one, reaming the previously match-drilled holes to size, inserting a sleeve to maintain the alignment and finally replacing the bolts. We did not expect to complete the work, but with the help of the new volunteers, we did it.
(https://static.fundrazr.com/story/e3e241a490e042938373935fd12bfa1e.png?cb=1660184673382)
That left us time to explore our big Hanna riveter. You may recall the machine was overhauled over a year ago and was successfully tested by riveting the smokebox ring for locomotive No. 10. We experimented with altering its orientation from vertical to horizontal, figuring out how to perform that operation safely. Remaining work includes changes to air piping to more efficiently receive the air to squeeze the rivets and redirecting the air exhaust away from the operation.
Next month, we’ll continue preparations for riveting during the October Fall Work Weekend. The September work session is planned for Sept. 20-22 and may include additional work on the Hanna riveter, making test coupons for test riveting, and the actual testing of the rivet furnace. Work generally begins around 9 a.m., and new volunteers are encouraged to come by.
Want to join the crew? Sign up at www.wwfry.org/volunteer
(https://static.fundrazr.com/story/fab46b5399114672b681e0899a365445.png?cb=1660184715362)
So now we need rivets. We’ll eventually need a lot more — maybe a thousand of them — but right now we need 146 in several sizes. Your donation of $11 will buy four. If 37 of the folks who read this each send us $11, we’re there!
(https://static.fundrazr.com/story/798a137735d844ff90a391708301bc67.png?cb=1660184730575)
We recently took delivery of 10 new bronze replica builder’s plates, which we are offering upon request as a premium to folks who contribute $1,100 or more in a single donation to the Build 11 project. We also have 3-D printed miniature builder’s plates, in return for a $110 donation to the project. Build 11 challenge coins - with the infamous typo now corrected - are available in the WW&F Gift Shop for $11.
Learn more and contribute at www.build11.org
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Build 11 September Update: Ready to rivet.
The Build 11 work sessions that occurred on Aug. 23-24 continued the prep work for riveting No. 11’s rear frame. A few test rivets were heated and installed in test plates to determine the correct lengths, and Gordon is working on a fixture to allow precision cutting of rivets as required. The big electric compressor was wired in to provide air to power the Hanna riveter. We’re just about ready. One more work session on Sept. 20-22 should do it.
Want to come and help? Sign up at www.wwfry.org/volunteer
(https://static.fundrazr.com/story/ea2e4585d9b048f59fb8f89f5690a16d.jpg?cb=1662930998691)
All the silver bolts and nuts seen here will be replaced by rivets.
(https://static.fundrazr.com/story/74a7c86d11ca42d3ac4c2c86e26479b6.jpg?cb=1662931035954)
Harold looks over the Hanna riveter positioned to drive a rivet in the frame
On the fundraising front, the magic number is $13,333! ("Three, it's a magic number." Thanks, Schoolhouse Rock!) That’s what we need to reach our stated 2022 goal of $70,000. That’s right – our current 2022 total stands at exactly $56,6667, or just over 80% of this year's goal. Can we make it by the end of the year in three months?
You can donate via our FundRazr page: build11.org, by credit card directly to the museum through the museum store, or by check. Let’s do it!
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Special News Update!
Following weeks of preparations and tests, today the first rivet was driven into the frame of Locomotive 11.
Ron Ginger captured the historic moment:
https://fb.watch/fHmz6mlWHs/ (https://fb.watch/fHmz6mlWHs/)
Eric Schade documented a subsequent rivet:
https://www.facebook.com/100005420616816/videos/1219623585559320/ (https://www.facebook.com/100005420616816/videos/1219623585559320/)
Thank you to all who have contributed to this project with their time, expertise, and donations. Learn more (and get involved) at www.build11.org
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(https://i.postimg.cc/wBwfp5q5/0924220902a.jpg)
(https://i.postimg.cc/W3t9bDzB/0924220903a.jpg)
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Build 11 - October (Video) Update
We have some great progress to report this month. During the September and October work sessions, the team, along with some additional volunteers, essentially completed riveting the rear frame extension together. The big Hanna riveter was used for about 85 percent of the work, while hand riveting finished the job. More than 70 rivets have been installed. In locations where it was impossible to drive the rivets properly, fitted bolts will be installed.
Here's a video showing the Hanna riveter at work, with Rick Sisson operating the Hanna and Jeff Schumaker assisting. (https://fb.watch/g5HJXY8O7t/)
We are pleased to report that the 2022 Build 11 Project fundraising has reached the 85% mark. We’re less than $11,000 from our goal of $70,000. Have you made your contribution at Build11.org (http://Build11.org) yet?
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Build Locomotive #11: November Update!
Fitted bolts was the name of the game for the work session held Nov. 2-3. Gordon Cook made the bolts, and he and Rick Sisson were able to install five bolts in the frame. These special bolts are necessary to protect cast-iron components from potential damage during the riveting process.
On Tuesday, Gordon and Jason took the cylinder half-saddle castings to Mountain Machine Works in Auburn, Me. This firm has the capabilities to machine the mating surfaces between the two castings, plane the valve faces and bore the cylinders. In addition, the large rear frame casting will be taken to Mountain Machine for final machining. We expect these pieces to return to Sheepscot early in 2023.
Over the next several months, the pedestal binders and cross frame braces will be made. When the parts are returned from Mountain Machine, the three major frame components and the cylinders will be united into a single unit to support the rest of the locomotive.
(https://static.fundrazr.com/story/589010f6cbdf480d9e825f26ac5cb1ea.jpg?cb=1668306616482)
Gordon cook carefully hammers a fitted bolt home. At the left side of the photo, two completed fitted bolts are circled. Photo by Rick Sisson.
On the fundraising front, we are just $2846 short of the overall goal for the year of $70,000. We're grateful for your continued interest and support.
We’ll start a new round of fundraising for No. 11 on January 11, 2023 with a goal of $50,000. To all the folks who have contributed to the Build 11 Project over these past years, we thank you. Thank you for sticking with us as we strive to make this happen. We’ve raised three-quarters of the final goal of $350,000, and at every work session, No. 11 becomes more of a reality.
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And just like that, now we're only $2,777 from the goal!
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As of this evening, we are less than $2,500 from the goal. Help if you are able, please.
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I have more that I have yet to report. Going to bring those numbers down some more..
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Right now, the unofficial tally for the 2022 Build 11 fundraiser is $69,673. We need just $327 to reach the goal! Can you help?
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I'll do that. It will officially put me on the Build 11 roster.
Bob
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Thank you, Bob. Thanks to you and a FundRazr donor, we are over the top now, at $70,111. Thanks to all who have and continue to support the Build 11 Project. We're making great progress. In fact, the December work session will take place this coming week.
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Great news! Thank you to all the donors and everyone working on this project. And thank you, Wayne, for keeping us up-to-date on the project here on the forum and via the WW&F Newsletter.
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Build 11 - News Video!
We’ll let the video (https://youtu.be/NwlU4m2f37o) speak for our progress over the last few months, but we want to offer a huge Thank You to all you good folks who have contributed to and followed the Build 11 Project in 2022.
As of Dec. 9th, the $70,000 goal for 2022 was met and exceeded. The 2022 total currently stands at $82,771. We’ll have a final accounting for you next month, when we’ll also introduce the 2023 fund raiser.
In the meantime, we wish all of you the Joys of the Season, and Hope in the New Year!
https://youtu.be/NwlU4m2f37o
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Given that nuts and bolts are used in locations where the riveter won't fit, how are they secured? Lock washers? Loctite? Interference fit?
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Joints that could not be riveted were connected with fitted bolts. The holes were reamed to a known size and a bolt custom machined to be exactly .002" larger in diameter than the hole. The bolt was driven into the hole by hammering. A nut is added and torqued to ensure that the joint can't work loose.
The interference fit ensures metal to metal contact between the bolt and the pieces to be joined together, similar to a riveted joint.
There will be many more of these fitted bolt joints to attach the rear frame extension casting to the front and rear frames.
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So, no nut on the other end?
Jeff S.
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So, no nut on the other end?
Jeff S.
Jeff. are you referring to a hex nut on the bolt? Then yes they will have retaining nuts. If you are referring to the nut holding the wrench..then a big yes to that too!
Keith
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I thought that video was a great snapshot of what's going on with #11 - and it would be great if we could a campus-wide video of everything that's going on periodically. Alas that probably takes away a little from the newsletter, but both have their place.
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True, James. But think of the extra eyes that would see it on other platforms -- YouTube, Facebook, etc.
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True, James. But think of the extra eyes that would see it on other platforms -- YouTube, Facebook, etc.
I thought the video was excellent. It's a great way for members/donors, who can't make it to Sheepscot or rarely get to visit, to see with their eyes how much is really happening, as described by the engineers and craftsmen who are actually doing the work. Over the last few years, the incredible progress that has taken place up in Alna has created an expectation among members/donors that the funds they contribute will be well-managed and they will see tangible, near-term results. This is a great way to continue to assure these folks that their expectations are indeed being met. Perhaps it should be a quarterly thing on a WW&F YouTube channel, which can be linked to various on-line, RR-related boards like RYPN, NGDF, Trainorders, etc. Our museum already has a very successful information campaign on social media platforms. This might be a way to expand that even further.
/Kevin Madore
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Today, we are launching the 2023 "Some Assembly Required" campaign to fund the construction of locomotive 11.
(http://wordpress.wwfry.org/wp-content/uploads/2023/01/Build-11-2023-Facebook-Banner.png)
WW&F #7 was damaged in an engine house fire and never repaired. It was scrapped in 1937. The Build 11 project is to replicate this lost locomotive for use on today's restored WW&F Railway.
The first 2023 work session on No. 11 started Tuesday, with Rick and Gordon working to ream out the last few holes in the rear frame for fitted bolts. This after Gordon designed a system to hold a ream in proper alignment using a lathe tailstock. The rear frame extension casting is back from the machine shop, ready to be positioned for bolting to the front and rear frames. Today, Rick and Gordon began setting up the front frame for eventual marriage to the rear frame while Jason was busy making the binders that will support the pedestals for the main drivers.
(https://static.fundrazr.com/story/973523e634ac4f82a64f7c25720a8e05.jpg?cb=1673483729440)
Rick Sisson and Gordon Cook ream out one of the final holes in No. 11's rear frame.
(https://static.fundrazr.com/story/4a5c37ffbad74d6bb4c0d872dda44064.jpg?cb=1673483770182)
Gordon designed this reamer arrangement to fit in the small space and hold the reamer steady.
(https://static.fundrazr.com/story/d999d2e5d72a4434a58ab21c1ac4c0dd.jpg?cb=1673483810182)
Today, Rick and Gordon began setting up the front frame for eventual bolting to the rear frame.
In other news, the 2022 Build 11 Project fundraising finished up with an amazing $84,279, more than 20 percent over the goal. Thank you to everyone who contributed. We're opening the 2023 Build 11 Project fundraiser today with a goal of $50,000. We've already got a few dollars in the pot from folks who contributed to 2022 but not quite in time for the end of the campaign.
Thanks for your continued interest and support. Learn more at www.build11.org (http://www.build11.org)
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A note to add that Jason finished fitting the binders to the frames so that the frames would be properly supported as we moved them around. You can see them on the top of the frames in the last photo (the frames are upside down).
Binders connect the bottom of the frame where there are openings for the driving boxes. They complete a 'box' around that opening and are precisely fitted to tabs on the bottom of the frame so the joint isn't dependent on bolts alone.
Also, the reaming shown was done with a tapered reamer so that we could fit a tapered bolt into these locations. The joints around the x-brace center casting have to be very strong to resist the twisting forces as the locomotive goes over uneven track.
These two bolts also hold the brake beam hanger bar, which has to pass through the middle of the bolt. The hanger bar has to be removable to allow the brakes to be assembled. These hollow tapered bolts were custom machined to match the taper. Hence the extra precautions to make sure the reamed holes were accurate and the bolts were a perfect fit. We were very pleased with the final result.
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Thanks for the detailed explanation, Gordon. It certainly fills in the blanks of my brief description.
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Looking forward to the next update on the frame progress.
Jeff
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(https://i.postimg.cc/025zNDTZ/0114231307a.jpg)
(https://i.postimg.cc/GpD2fQD3/0114231308a.jpg)
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Having the frame together will be a major milestone as everyone will be able to see something other than a collection of parts. We will be able to see how big the locomotive will be. I’m looking forward to watching as parts large and small are added to the frame. Making parts is important but watching it grow as parts are added will be fun.
M. Nix
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Build 11 - February 2023 Update
Good progress was made on No. 11 by Rick, Gordon and Jason, with welcome help from new volunteers Noah MacAdam and Eric Snyder. During the most recent three-day work session (Jan. 31-Feb.2), the last two holes on the rear frame were reamed and the fitted bolts were installed.
(https://static.fundrazr.com/story/341d7424d31443f28d1db7b842bc8524.jpg?cb=1676000392233)
Test-fitting the parts.
Then, using a circular saw with a diamond blade and a hand-held grinder, the square edges of the large rear frame extension casting were chamfered to provide a perfect fit between the casting and the forward frame. First, a 45-dgree cut was made with the saw, and then using the grinder, the edges were rounded off. The same technique was applied to the forward frames for a great fit.
(https://static.fundrazr.com/story/ec25f1a266cb430f8aeecca5910b8c5e.jpg?cb=1676000326414)
Rear frame test fit.
Next, the forward frames were flipped right-side up. They were then clamped to the rear frame extension casting to test the fit and alignment. Careful measurements showed the forward frames were almost perfectly parallel, off by only a few thousandths of an inch! The rear frame will be flipped over during the next session in March, and fitting it to the rear frame extension casting will begin.
(https://static.fundrazr.com/story/0a50f5c46ddd44d3bd0a70bb4e86d943.jpg?cb=1676000444426)
The forward frame fits well.
New volunteer Noah is joining Gordon in machining parts at his home workshop in New Hampshire. He is a skilled machinist and will join the team whenever possible. Eric will also assist as he is able.
On the fund-raising front, the 2023 effort has gotten off to a slow start. During January, we raised about one percent of the target amount of $50,000. If you haven’t contributed, we’re always happy to receive your donations to keep progress moving forward. The premiums for larger contributions are still available.
Thanks for your continued interest and support. Learn more at www.build11.org (http://www.build11.org)
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What do you consider a "larger contribution"? What are the "Premiums" for making a larger contribution? Sorry, but I could not find answers to these questions on your website.
John Houghton
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John, the Build #11 project fundraiser has a page here:
https://fundrazr.com/build11.2023?ref=ab_1CvFKgBBdmf1CvFKgBBdmf
. . . where different sizes of 'builder plates' are offered as Premiums at different donation levels.
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(https://i.postimg.cc/TPHRtBM1/0218230820.jpg)
(https://i.postimg.cc/GmK3yHXk/0218230820a.jpg)
(https://i.postimg.cc/vBgGkXbz/0218230820b.jpg)
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What do you consider a "larger contribution"? What are the "Premiums" for making a larger contribution? Sorry, but I could not find answers to these questions on your website.
The WW&F Gift Shop has a #11 challenge coin with a list price of $11 plus shipping. One side of the coin is the builder's plate, and the other side is an image of the locomotive and the words "Wiscasset, Waterville & Farmington Railway" circling the image, with #11 at the bottom. The museum makes a tidy profit on these and at $11 + shipping, it's hard to justify not buying one. If you're at the museum, no shipping charged!
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Great! Things are really taking shape now.
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(https://i.postimg.cc/NGV8d6vG/0311230852.jpg)
(https://i.postimg.cc/BvMHHDC0/0311230852a.jpg)
(https://i.postimg.cc/Fz2j14Vk/0311230852b.jpg)
(https://i.postimg.cc/vT1rQBfd/0311230853.jpg)
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BUILD LOCOMOTIVE 11 - March Update
The work days in March were taken up by fitting up the forward frames to be perfectly level, square and correctly spaced. The goal was to be within 0.005 inch in both spacing and parallelism for the length of the frame. Meeting that tolerance took quite a lot of time and care, working with a machinist level and rule while making tiny adjustments with a series of screw jacks.
Jason, Gordon and Harold were also working to develop and design the rear draft gear. There was no Baldwin drawing or even specifications to follow, so the entire design was from scratch. The rear draft gear is a sprung design, which was something Baldwin had put on WW&F no. 7. It was unusual on a locomotive of that era, according to Jason. Gordon Cook said, “We wanted to be sure that it wouldn't cause a problem with harmonic oscillations in normal service, so the spring will be pretensioned so that it is only deflected under abnormal loading. Harold figured out what spring would meet that requirement, and found that an off-the-shelf truck spring would be about right. The next challenge was fitting everything in the short space that was defined by the erecting drawing. The coupler would need to pivot sufficiently to accommodate the sharpest curve the engine would encounter, while also providing the ability for the spring to function as desired. After several hours of modeling and thought, Jason realized that the pin that will hold the bolt which connects the spring plates and the spring to the coupler shank could provide that pivot point.” See illustrations.
Fund-raising is moving along slowly. We have raised a little more than $5,000 so far, or 10 percent of the goal for 2023. John Houghton, a long-time WW&F member from California, a strong supporter of the Build 11 Project, has offered to match all donations in March and April up to $1,000. This is a challenge that should not be passed up, since it doubles the dollars. If you haven’t yet made a contribution to the Build 11 Project, now is the time! Thank you, John!
Learn more and contribute at build11.org
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Are the couplers for the #11 going to be the ones that were salvaged from the East Broadtop a couple of years ago?
Ted Miles, Build 11 Contributor
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No. The EBT couplers are not suitable for this project.
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Build Locomotive 11 - April Update.
On the fundraising front, we are within shouting distance of 20 percent of the goal, thanks in part to a challenge grant from John Houghton, who matched the first $1,000 that came in for March. Since we are a third of the way into the 2023 fundraiser, we have about eight months to raise the other 80 percent of the dollars. So we need to bring in an average of $5,000 a month for the balance of the year. Please help us move this project along.
Don't forget that we still have the bronze replicas of No. 7’s Baldwin Locomotive Works builder’s plate for those who can contribute $1,100 or more in one donation. The plates look great, and they’d certainly look good in someone’s man cave or train room. We also have the half size 3-D printed replica plates for a donation of $110, and the gift shop is carrying the No. 11 challenge coins for just $11.
Good progress to report again this month. Gordon and Rick, with help from Jason, were able to drill all the holes needed to attach the forward frames to the rear frame extension casting. They acquired a new magnetic base drill that was small enough to fit into the space, and they drilled the hole that was in the tightest location first, or as Rick said, “Thought we’d go for broke.” They did have to file the drill’s casing a bit, just to be certain.
Gordon was making fitted bolts again, and they drove the first one. They installed regular bolts in two holes to hold everything in perfect alignment for reaming on both sides of the rear frame casting. Gordon will make the rest of the fitted bolts in his home shop prior to the next work session, which is planned for the week leading up to the Spring Work Weekend. They expect to work Wednesday through Saturday.
(https://static.fundrazr.com/story/658935abe0f344f99f50cc0368982eb7.jpg?cb=1681182514572)
It's a tight fit for the new magnetic base drill, but it gets the job done with little fuss or muss.
(https://static.fundrazr.com/story/79102c9c9fbf438b8e33daf498862fba.jpg?cb=1681182529804)
The first fitted bolt is in place.
(https://static.fundrazr.com/story/9f7c812009394462b4662d778a3ffb2d.jpg?cb=1681182541257)
We made chips. Drilling through all that cast iron produces lots of drill chips.
(https://static.fundrazr.com/story/1c9a181fc38b47e98bb98a61f801d949.jpg?cb=1681182551874)
Holes drilled. Each hole is faced to provide a level surface for the fitted bolts.
If you are going to be at Sheepscot for the Spring Work Weekend, coming up April 28, 29 and 30, stop in the shop and to say hi and see the great progress we’re making. Everyone is welcome!
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Build 11: May Update from the Spring Work Weekend
Another challenge
We have another challenge! An anonymous friend of the Build 11 Project has offered a $1,500 challenge, as soon as other donors match that amount. That will double our dollars. Let’s see how quickly we can do this.
Right now, we have just over $12,500 in donations, or one quarter of the goal for 2023. When we meet the latest challenge, we’ll add at least $3,000 to the total, pushing us past the 30 percent mark. We’re making progress!
(https://static.fundrazr.com/story/f25b1ea09aaf4bf19d2c9814bb1cd2ba.jpg?cb=1683844931971)
During the WW&F Railway’s annual Spring Work Weekend (April 28-30), we were able to accomplish quite a bit of work on No. 11. While the work weekend itself was billed as three days, we actually were able to manage five days of work. Several members of the team began working on Tuesday and we continued through Saturday. We had actually planned to work Sunday, but we ran out of materials by Saturday, so Sunday was canceled.
(https://static.fundrazr.com/story/f11d1e01f5a64e2cacdf203e25c79b81.jpg?cb=1683845000484)
Tasks worked on by the team included straightening of the bunter beam supports on the front of the locomotive. These will eventually support the pilot and front coupler. Then we tackled the rear coupler pocket, specifically riveting the cheek irons in place. These pieces will check the fore and aft movement of the rear draft gear of the locomotive. It all sounds so easy, but it was serious work. A great team of regulars and volunteers spent most of Friday on the cheek irons. Finally, we positioned the large gussets that will attach and support the connection between the rear and front frames to the rear frame extension casting.
(https://static.fundrazr.com/story/8e23da19663b4e1fb1b13896242523a5.jpg?cb=1683845017181)
Other work accomplished on No. 11’s frame included manufacture and installation of the final half dozen fitted bolts joining the forward frame to the rear frame extension, planning and layout of the permanent attachment of the bunter beams to the front of the frame, and planning and layout of the attachment of the connecting gussets of the rear frame to the rear frame extension casting. All in all, good progress.
(https://static.fundrazr.com/story/fb1074b772f9447998d6b691eecbe4c7.jpg?cb=1683845039514)
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Tease Alert!!!
Here's a picture of a boiler which is very similar to the one we will build for No. 11. It is sitting in the shop at Brecon Mountain Railway (https://www.bmr.wales/) (https://www.bmr.wales) in Wales, waiting for its hydro test. It is of welded construction except for the front tube sheet, which is riveted. it will go into a replica of SRRL No. 10, for which they have frames, cylinders, drivers, and many smaller parts already done. It is a long term project and will be finished when it's finished.
(https://i.ibb.co/ZWTsM1Y/No-10-boiler.jpg)
They have a very beautiful ride and a professionally run operation and they really have the Maine 2 footer 'bug'!
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If the link in Gordon's post doesn't work for you, try this one: https://www.bmr.wales
(the link in Gordon's post appears to be malformed)
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[link is fixed]
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Somehow, their website looks just like ours...can't imagine why
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Since that's a copy of SRRL 10, that makes it the same size at B&SR 7 and 8, which were a bit larger (33/38 tons) than WW&F 7/11 was/is (26 tons?).
Some very interesting things that separate that British style boiler from the ones that are on 7 and 8. All flanged boiler connections on the backhead for the throttle (will it be rotary like all the others on property?) and two sight glasses. Not sure what the one with the butterfly valve is gonna be.
All welded stays and no flexible stays, so I wonder what the insides look like. I haven't seen the drawings so don't know it that's how the Baldwin boilers were, but the Dillon ones have them. The Dillon boiler originally had welded stays but the overhaul we finished 5 years ago (!) we did threaded stays.
Also no couplings in any of the locations that the washout plugs go (they're tapped right into the boiler).
The big one noticeable immediately is the British style flanged dome. Makes it a lot easier to service the throttle valve but probably only if you have a shop to pull the cover since it's so heavy. (not saying 7's lid is light but 4 people can get it off by hand in a pinch). I think I remember seeing a picture of Edaville 11's new boiler that Brian did it this way.
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...
Some very interesting things that separate that British style boiler from the ones that are on 7 and 8. All flanged boiler connections on the backhead for the throttle (will it be rotary like all the others on property?) and two sight glasses. Not sure what the one with the butterfly valve is gonna be.
...
The BMR South African Pacific has a rotating regulator lever, as this is standard on SAR locos. But No. 1 Santa Teresa (Mogul rebuilt as a Main Prairie with new boiler) has the standard American pull out throttle. As the BMR are such US enthusiasts, I am pretty sure the 10 and 23 will also have the pull out type.
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June Build 11 Update
There was no work session in May since there were two work sessions in April including 5 days during the Spring Work Weekend. There will be an engine 11 work session this month on 14th thru the 16th.
There was however progress in May including rear draft gear design as well as a visit to Mountain Machine Works to finalize plans for machining the cylinder castings. Early this month, repair work on Engine 9's valve gear lifting links took shop crew time away from #11 but the pit in the new engine house made the work much easier.
The Build 11 Fund Raising has slowed in the last 30 days and we barely passed the one-third mark on the current $1,500 challenge. So far we have raised $13,263 of our $50,000 goal. Remember we have nice gifts for donors including a full-sized cast bronze replica of WW&F #7's Baldwin builders plate (for one-time $1,100 donors) as well as half size 3-D plastic builders plates for $110 and the very popular challenge coin plates for $11 which are sold in the WW&F gift shop and on-line store.
(https://static.fundrazr.com/story/0159f677577e499da0613c51df672741.jpg?cb=1686622409771)
One of the cylinder saddle castings that will be machined at Mountain Machine Works.
(https://static.fundrazr.com/story/558cb3ef2e544dc798d3a097469b6d59.jpg?cb=1686622460868)
The April work session included riveting the draft gear pocket on engine 11's tail frame.
(https://static.fundrazr.com/story/fa7c82bdf43a4adfa09341b7ead8cc14.jpg?cb=1686622522241)
A view of the tail frame (which is upside down) showing the bolster casting and the rear draft gear pocket.
(https://static.fundrazr.com/story/bd95883b96bb448a8e496119ecd901a3.jpg?cb=1686622579348)
Engine 9 needed repair work on the valve gear lifting link rods and new bushings had to be made. This took time away from #11 but engine 9 was back in service by June 9th for a school charter.
(https://static.fundrazr.com/story/9d43f02122c9410c9b3ca1e4142078c4.jpg?cb=1686622743195)
This full-sized replica of WW&F Engine 7's builder's plate may be had for a one time donation of $1,100 to the build 11 Project. Smaller reproductions are also available for smaller donations.
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Harold Downey was machining the rear truck journal boxes today (June 24th).
(https://i.imgur.com/GeOdUH1.jpg)
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The tank truck journal boxes, as seen today.
(https://i.imgur.com/Ll2MbFK.jpg)
Harold Downey was machining another casting for the tank truck.
(https://i.imgur.com/wE5f6Y1.jpg)
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BUILD LOCOMOTIVE 11 - JULY UPDATE!
A very successful and productive No. 11 work session took place June 14-16, facilitated by five volunteers. They worked on several facets of the lengthy riveting process, including learning how to make flat head rivets, which are necessary in the gusset plates that join the rear and forward frames and also cradle the firebox of the locomotive.
In addition to driving up those rivets, the crew also partially riveted the bunter brackets on the front of the main frame as well as some work on the rear coupler pocket.
During the July work session, the final handful of flathead rivets will be installed on the frame gussets and the capture plate that goes on the bottom of the rear coupler pocket will be manufactured and bolted in placed. If all goes according to plan, the rear frame will be flipped over and lined up with the forward frame.
We are pleased that the $1,500 challenge grant offered by a friend has been met, and we’re thrilled to announce that another good friend of the Build 11 Project has offered a $6,000 match. If we can raise $6,000, he will match the amount, dollar for dollar. Does this sound like Public Television? If we can raise that $6,000, we’ll have $12,000, putting us over the 50% mark in our effort to raise $50,000 in 2023. Remember, every dollar counts, and we need your help to keep up the momentum. You can donate directly by check to the museum, use a credit card to donate through the gift shop, PayPal, or you can go to: https://www.build11.org/
(https://static.fundrazr.com/story/0edc9e8a84c94046af1ba11a2e74fe9e.jpg?cb=1689044294769)
Harold Downey used the big radial drill press to countersink holes for flat head rivets in the frame gusset plates.
(https://static.fundrazr.com/story/c0776278f7d34a1584820b706f56fe4b.jpg?cb=1689044333264)
The rivet heads in the near gusset plate are normal, but the inside rivet heads on the opposite side have been flattened to allow for expansion of the firebox of the locomotive.
(https://static.fundrazr.com/story/3f9a192b128c4eba861807e2122a51e0.jpg?cb=1689044359024)
New rivets holding the bunter bracket at the front of the frame. A couple of additional rivets remain to be driven using a “holder-on” device.
(https://static.fundrazr.com/story/fbbbcb7ed63a4b40a8b9bd0696703544.jpg?cb=1689044398065)
The riveter had to be tilted in order to drive a rivet close to the frame.
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In Wayne’s memory, I hope anyone who hasn’t contributed to the build 11 fund will join me in donating in honor of Wayne. I am guilty of not contributing to the campaign thus far, but thought what better way to honor such an important part of our organization than by donating to a project he was such a huge part of.
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Joe,
An excellent idea. In memory of Wayne, I am following your lead.
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I had thought of doing it on Wednesday, bit forgot. Turns out, it was his birthday. So that may be an annual donation on his birthday for me, if I remember...
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Here is a link to Paypal. This should be included in every post.. Make it easy..
https://www.paypal.com/donate/?cmd=_donations&business=treasurer@wwfry.org (https://www.paypal.com/donate/?cmd=_donations&business=treasurer@wwfry.org)
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Is the schedule for #11 work days posted somewhere?
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Is the schedule for #11 work days posted somewhere?
Wayne said in his last Build 11 article in the WW&F Newsletter that July's work session is planned this coming week: the 18th, 19th and 20th. I don't know if future work session dates are posted anywhere or how far out the Build 11 team schedules monthly work sessions.
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I heard about the matching grant for the Build 11 fund; so i put a check in the mail today. I just love matching grants! Everybodies money goes further. TM Built 11 Contributor several times TM Life Member, Build 11 Contributor again
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The August Build 11 Work days are the 15th, 16th and 17th.
We typically check key individual's schedules during those work days and plan the next month's days.
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The August Build 11 Work days are the 15th, 16th and 17th.
What's planned for the August work days? I really enjoyed joining you in July!
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Pete - we plan to move both the forward and rear frames to the north end of bay 2 (where Jerry and Carlos were), crib them up and level them in preparation for installing the fitted bolts that join the forward and rear frames.
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BUILD LOCOMOTIVE 11 - AUGUST UPDATE!
On July 10, the Wiscasset Waterville and Farmington Railway Museum lost one of our key members. G. Wayne Laepple was one of #11's earliest supporters, helping arrange the first pieces of hardware to be made in 2008 when there was only a smattering of hand drawn plans and a big idea.
From the spring of 2020 when the Build 11 team formed, Wayne was our spokesman and fundraising chair, crafting our monthly reports, WW&F newsletter updates, and spearheading our fundraising efforts and working with donors. He frequently made the trip from his home in Pennsylvania to join us for our work sessions on-site in Alna. Usually he made the trip with patterns or castings in-tow to set the project up for the next step. Incredibly, that is still only a fraction of his impact and involvement with the WW&F, and railroad preservation as a whole.
(https://static.fundrazr.com/story/0794f78a938d41a6b3ff3fbe636b361a.jpg?cb=1691792716127)
G. Wayne Laepple, founding member of the Build 11 team.
Wayne authored these Build 11 updates over the years. With his passing, members of the Build 11 team will continue in his stead.
Another productive No. 11 work session took place on July 18-19, focused on fabricating the rear draft gear capture plate. This work involved forming the 3/8” plate into a wide “C” channel which will be bolted to the rear frame located below the rear coupler. Once the plate was cold formed using our plate flanging machine small areas were cut away to provide clearance for some rear gusset rivets and for coupler pin access. The capture plate was then drilled for the attaching bolts on our large radial arm drill.
(https://static.fundrazr.com/story/3731ef0ab8d94b9ab87cc0b139846398.jpg?cb=1691792786525)
Forming the draft gear capture plate in our flanging machine.
(https://static.fundrazr.com/story/77e12e34efea4f169b3069c677173283.jpg?cb=1691792827688)
Fitting the capture plate in place.
The completed rear frame was flipped to its final orientation, that is, right side up. This allowed the team to use our Hanna riveter to complete riveting the remaining flat head rivets on the rear frame gussets.
(https://static.fundrazr.com/story/2afe8e6bd90f465cbe269182e46f7871.jpg?cb=1691792872967)
Flipping the rear frame. Watch a time lapse video at: https://www.facebook.com/reel/3243619595929268 (https://www.facebook.com/reel/3243619595929268)
While this work was proceeding, Harold Downey machined the finished surfaces of the rear truck center castings.
(https://static.fundrazr.com/story/ce213cc216744d6c8375844fde5ef6c1.jpg?cb=1691792960701)
The newly machined rear truck center castings.
Our next Build 11 work session is scheduled for August 15th – 17th. The team plans to relocate both forward and rear frames to the north end of bay 2, occupying the space formerly used to assemble the passenger car trucks. The frames will be cribbed up, leveled, and positioned to allow us to drill, ream and fit the fitted bolts that will bind the frames together.
The 2023 fundraising total got a huge boost over the last month. Nearly $3,000 was contributed in memory of G. Wayne Laepple. We have received a total of $29,278 to date (59% of the $50,000 goal for 2023.) We have also received $3,200 towards our $6,000 match. If we can raise $6,000, he will match the amount, dollar for dollar. Does this sound like Public Television? If we can raise that $6,000, we’ll have $12,000, putting us over the 82% mark in our effort to raise $50,000 in 2023. Remember, every dollar counts, and we need your help to keep up the momentum. You can donate directly by check to the museum or you can go to: https://www.build11.org/ (https://www.build11.org/)
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(https://i.postimg.cc/8PtxKYdG/0819230958.jpg)
(https://i.postimg.cc/xT0WPQzg/0819230959.jpg)
(https://i.postimg.cc/SRGHpTwW/0819231000.jpg)
(https://i.postimg.cc/0yjFLCZw/0819231000a.jpg)
(https://i.postimg.cc/Vkhp1bHH/0819231000-HDR.jpg)
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Others have taken much better photos, but this is my attempt today to give a sense of the length of No. 11's frame. I don't think this poor photo does justice, but I will say seeing the frame's length in person is impressive.
(https://i.imgur.com/cDqdpHv.jpg)
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BUILD LOCOMOTIVE 11 - SEPTEMBER UPDATE!
A Build 11 milestone was achieved during the August 15-17 work session. The locomotive’s front and rear frames were moved to the northern end of bay 2, raised on blocking and screw jacks and readied for joining! After two days of meticulous alignment and leveling, the first four fitted bolts were machined and installed, thereby pinning the joint. Noah, Gordon and Quentin developed an efficient procedure for fabricating the required countersunk fitted bolts. Each hole needs to be match drilled, reamed, reverse spot faced and countersunk. Once reamed, each hole diameter is measured so that the corresponding bolt can be machined to provide an interference fit. We will continue fabricating and installing the remaining (16) bolts during our next work session. When this work has been completed we plan to concentrate on fabricating components for the rear truck assembly.
When Harold was not helping with the frame he was continuing to machine the rear truck swing link hanger castings. Harold has already completed machining on the rear truck journal truck castings.
Our 2023 fundraising is proceeding well. Over $4,600 has been contributed in memory of former Build 11 team member G. Wayne Laepple. We have received a total of $6,000 toward and qualified for our $6,000 matching grant. To date we have received a total of $ 40,014 (80% of the $50,000 goal for 2023.) Only $9,986 left to go! Remember, every dollar counts, and we need your help to keep up the momentum. You can donate directly by check to the museum, use a credit card to donate through the gift shop, PayPal, or you can go to: https://www.build11.org/
(https://static.fundrazr.com/story/2d981466e14641428942ce46e5a2a355.jpg?cb=1694478254473)
Shims are required between the front and rear frames. These were tack welded in place before final assembly.
(https://static.fundrazr.com/story/8e91a169887d4f56acc338cf65f70d9c.jpg?cb=1694478273516)
Gordon fabricated a gage to center the mag drill; the gage can be used with both the 7/8” drilled holes and the 29/32” reamed holes.
(https://static.fundrazr.com/story/0b7d4bee6595422095bc76f46949146a.jpg?cb=1694478299431)
Noah is driving the first fitted bolt. Prior to this, Rick drilled, reamed, reverse spot faced and countersunk the hole. Gordon measured the reamed hole and machined a countersunk bolt to fit.
(https://static.fundrazr.com/story/ec6a9711421642ae92f15fd4253c5a4e.jpg?cb=1694478316457)
A view of the first two fitted bolts installed; these serve to pin the frames together.
(https://static.fundrazr.com/story/f1126b62c4a2429c844fa0fd0e0262f4.jpg?cb=1694478340714)
Harold is machining the rear truck swing link hanger castings.
(https://static.fundrazr.com/story/53d758c026694b50ab822b5de3a87f7f.jpg?cb=1694478356127)
Harold has completed machining the four rear truck journal castings.
(https://static.fundrazr.com/story/0d0e9bb251a947dc9fa79a9b87bd2e4d.jpg?cb=1694478367905)
At the end of the work session – the forward and rear frames joined!
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Congratulations to the Build 11 team!
Jeff
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Have the dates of the next Build 11 session been determined?
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The cylinders were picked up from the machine shop today.
(https://hosting.photobucket.com/images/s5/bbarry74/IMG_7910.JPG) (https://hosting.photobucket.com/images/s5/bbarry74/IMG_7910.JPG)
(https://hosting.photobucket.com/images/s5/bbarry74/IMG_7913.JPG) (https://hosting.photobucket.com/images/s5/bbarry74/IMG_7913.JPG)
(https://hosting.photobucket.com/images/s5/bbarry74/IMG_7914.JPG) (https://hosting.photobucket.com/images/s5/bbarry74/IMG_7914.JPG)
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Beautiful -- almost a work of art!
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They look great.
Jeff
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What is the planned activities for Build 11 from Wednesday through the weekend? I need to plan on proper clothing for the jobs required.
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BUILD LOCOMOTIVE 11 - OCTOBER UPDATE!
Exciting news! Our cylinder castings have arrived. We absolutely wish to thank our friends at Mountain Machine Works in Auburn, Maine for doing an outstanding job machining our cylinder castings. Here we see (left to right) Sean, Joe and Greg proudly standing with their work:
(https://static.fundrazr.com/story/9de7a3f090ed4eb8b533521a7ffe9e54.png?cb=1697069711328)
Additionally, a great deal of progress was made during our October 4-6 work session. Harold Downey had machined the rear truck side bearings during the interval between work sessions and Noah MacAdam machined new fitted bolts in his home shop to be used to join the cylinder half-saddles.
On Wednesday Gordon Cook completed machining the rear frame fitted bolts and Rick Sisson ground and filed a fillet on each side of the forward frame to receive the cylinder castings.
Thursday Harold and Rick reamed the cylinder castings to receive eight fitted bolts which were individually fit and driven home by Noah; these rigidly tie the left and right halves of the cylinder assembly together. At the same time Gordon was completing installation of the rear frame fitted bolts. Gordon and Noah were able to use the Monarch and Victor lathes simultaneously to complete machining the fitted bolts; this demonstrates the value of having two lathes in service for busy Build 11 days. At the same time, Harold was using the horizontal mill to machine the lead truck equalizer pedestal.
At the end of the day, the Build 11 crew, aided by Bill Steussy and Ken Steeves, hoisted the cylinder assembly, turned it over and placed it upside down on blocking in preparation for further work. Meanwhile, Jason Lamontagne designed and fabricated a fixture to hold our riveting buck in place so that we could finish riveting the gusset plates to the rear frame.
Friday morning the entire crew supplemented by Jeff Schumaker, Bob Longo and Brendan Barry was able to successfully drive the remaining rivets in the rear frame gussets. New this session, we preheated the material that would receive the rivet; this change to our process worked out quite well as each rivet cooled more slowly than before providing us more time to form the rivet head.. The setup worked so well we proceeded to drive the remaining rivets tying the forward frame to the front bunter brackets. Gordon drilled and tapped the bottom of the cylinder casting to receive the lead truck equalizer pedestal while Harold was finishing up machining the same pedestal. Gordon also drilled and tapped a number of holes which will provide live- and exhaust-steam passage drains. The cylinder assembly was next flipped right-side-up, raised by overhead cranes and set in place on the forward frame.
Our 2023 fundraising is proceeding well. Over $4,600 has been contributed in memory of former Build 11 team member G. Wayne Laepple. To date we have received a total of $ 42,978 (86% of the $50,000 goal for 2023.) Only $7,022 left to go! Remember, every dollar counts, and we need your help to keep up the momentum. You can donate directly by check to the museum, use a credit card to donate through the gift shop, PayPal, or you can go to: https://www.build11.org/
(https://static.fundrazr.com/story/d41c8560ddd04396a1cfabf4f0347feb.jpg?cb=1697069781294)
Factory fresh fitted bolts – machined by Noah McAdam in his home shop.
(https://static.fundrazr.com/story/e59314e3d313407b85c6e6d24fa542cc.jpg?cb=1697069802832)
Harold and Rick reaming the cylinder casting for fitted bolts.
(https://static.fundrazr.com/story/d8395572758345fdab526eb923b6e686.jpg?cb=1697069829877)
Gordon driving the last rear frame fitted bolt.
(https://static.fundrazr.com/story/3d6708b6d3be4038ba11d52f23a6a01c.jpg?cb=1697069857225)
Noah driving the last cylinder casting fitted bolt.
(https://static.fundrazr.com/story/0542ea0826564a1d8f14201fb841e1ef.jpg?cb=1697069902357)
The Build 11 crew turning the frame upside-down.
(https://static.fundrazr.com/story/7039a03165564b17a88dc5601238e435.jpg?cb=1697069930290)
Jason driving the remaining rear frame gusset rivets.
(https://static.fundrazr.com/story/27ef9f7062424d758c4154e95548d707.jpg?cb=1697069959072)
Gordon tapping the cylinder castings for the lead truck equalizer pedestal.
(https://static.fundrazr.com/story/4e9ae1a4eef44b11a953096a45daff0a.jpg?cb=1697069976110)
The completed cylinder assembly – the last time we’ll ever have this view!
(https://static.fundrazr.com/story/11b3f48120eb4629bd814bec2d57cc23.jpg?cb=1697070049484)
Mating the cylinder assembly to the forward frame.
(https://static.fundrazr.com/story/21622d21747742a396f1c498ddaea6f6.jpg?cb=1697070074389)
Machining the lead truck equalizer pedestal.
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Harold Downey machining components for No. 11's lead truck today.
(https://i.imgur.com/kyhRqyW.jpg)
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[Mod Note - I forgot to post this on 11/11/2023.]
BUILD LOCOMOTIVE 11 – NOVEMBER UPDATE!
Again, a great deal of progress was made during our October 25-27 work session and we are grateful for the skills and talents brought to the project by our dedicated volunteers. The Build 11 team focused on fitting the cylinder castings to the forward frame. We began by identifying a 0.002” space between the castings and frame rail – we needed this space to disappear. Noah MacAdam led the effort to precisely fit the cylinder castings to the forward frame during which we identified fit interferences, hoisted the cylinder castings clear of the frame, filed high spots in the frame and then lowered the castings. This evolution was repeated several times until we were satisfied the fit was perfect; and our effort consumed a whole day in the shop. Noah’s skills and expertise were crucial to obtaining a perfect fit.
Quentin Bethune spent this work session preparing axle stock for the rear truck. He was able to true up each axle and machine them to length, and has started to machine the finished contour on the first axle. Quentin has a lot of machining experience which is accelerating our progress.
(https://static.fundrazr.com/story/c6dddd5c702741e7a5cfc4878ca6789c.jpg?cb=1699673690286)
Noah and Gordon working on the frame fit.
(https://static.fundrazr.com/story/d5a7886e7e7941de9cddcc0985899960.jpg?cb=1699673702819)
Quentin machining our rear truck axles – Harold’s consulting.
(https://static.fundrazr.com/story/7612589eb3c04384afdeb5c641e222b5.jpg?cb=1699673717364)
Gordon and Quentin machining fitted bolts and rear truck axles.
(https://static.fundrazr.com/story/9eca98288ba442ba85ecf3abfcc4ed7d.jpg?cb=1699674011224)
Rick Sisson and Harold Downey reamed and reverse spot faced each of the eight holes to receive fitted bolts joining the cylinder castings to the forward frame. Our Fein mag drill, which is much lighter than our Milwaukee, works much better in this application. We were working in a confined area of the castings with little clearance for the drill.
(https://static.fundrazr.com/story/b7874eea5d9a454a935ec3fde3f9f613.jpg?cb=1699674113662)
Noah supplied us with eight fitted bolts which he machined at home...
(https://static.fundrazr.com/story/f3928bae1abb4d3fafda0d202d5f8923.jpg?cb=1699674143794)
...And Gordon Cook turned each one to the correct diameter as measured for each hole, which is a time consuming process. And Gordon also drove each of the fitted bolts – no easy task underneath the locomotive.
(https://static.fundrazr.com/story/78667425a290497fbfaa8acb4f011811.jpg?cb=1699674168140)
Rick match drilled the lead truck cross tie to receive fitted bolts joining it to the forward frame. Rick also match drilled holes in the pilot backer plate which will receive bolts fastening the front pilot beam to the locomotive.
(https://static.fundrazr.com/story/547f404fd2154ba49bc0bb48ead25c3a.jpg?cb=1699674186533)
At the end of the day we test fit the pilot deck. It looks pretty good!
(https://static.fundrazr.com/story/0ee30c8356e349aab99211ddf5c6f1c3.jpg?cb=1699674234076)
Harold continued to machine the rear truck transoms.
(https://static.fundrazr.com/story/9b2b9d261dd24679ac4336280aa42080.jpg?cb=1699674244190)
While he wasn’t helping the rest of the team, Harold was busy test fitting the rear truck components. These are all pieces which Harold had previously machined in our shop. The Build 11 team will work toward assembling the rear truck in the near future.
Our 2023 fundraising is proceeding well. To date we have received a total of $44,214 (88% of the $50,000 goal for 2023.) Only $5,786 left to go! Remember, every dollar counts, and we need your help to keep up the momentum. You can donate directly by check to the museum, use a credit card to donate through the gift shop, PayPal, or you can go to:
http://www.build11.org/
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Thanks for the photo update, Ed.
Jeff
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Due to the holidays and busy schedules, we won't be having a formal No 11 work session in December. However, there will be ongoing work in the machine shop on the front and rear truck assemblies. Members are machining parts in their home workshops for those too.
A complete 3D model of the running gear is coming along that will be animated to confirm that the relationship between all the parts is correct. (And is also fun to watch.)
The drive wheel centers and main cranks are being cast soon, and we will be sending those along to be machined.
The remaining castings are being readied to send out for bid.
With everyone's help, we hope to be able to get wheels under the frame next year, which will be a major milestone.
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WW&F Build 11: December Update
We have more progress to report during our November 13-15 work session. Click on the photos for details. We accomplished quite a lot during this work session and we’re taking a break in December to enjoy the holidays. But we’ll be back at it in January. Stay tuned for our next update.
But first.... WE DID IT!!
Our 2023 fundraising has exceeded our target, thanks to supporters like you! To date we have received a total of $57,587 (115% of the $50,000 goal for 2023.) Remember, you can still donate directly by check to the museum, use a credit card to donate through the gift shop, PayPal, or you can go to: build11.org
We’ll have a report on 2024’s fundraising campaign on Jan. 11, 2023 - which will include our target, and a really (wheeley?) snappy new name.
(https://static.fundrazr.com/story/53bcbb8f2cd54f858029ffacbc42f261.png?cb=1702343884718)
During our November 13-15 work session, the Build 11 team focused on fabricating the lead truck radius bar cross tie. This is composed of 8 pieces of bar stock drilled, reamed and riveted together. Here we see Gordon Cook laying out and drilling some of the required holes.
(https://static.fundrazr.com/story/b1944808671445ebad26afafc0d25411.jpg?cb=1702344418714)
Here, Harold Downey and Quentin Bethune are positioning our Hanna riveter to drive one of four rivets in the assembly.
(https://static.fundrazr.com/story/99f70126003041e892c92eeb9dbc8727.jpg?cb=1702344532833)
And, finally, the lead truck radius bar cross tie assembly being set up to drill the last hole for the retaining pin.
(https://static.fundrazr.com/story/8a89a87d425842ad85001dbc8d9ce6f0.jpg?cb=1702344569254)
During the last work session, the lead truck cross tie was prepared by match drilling the cross tie to the frame. Gordon is completing the job by tapping these holes and the installation is now complete.
(https://static.fundrazr.com/story/60e439cc30b34f4b9e8a529c5fb8a104.png?cb=1702344641048)
Quentin continued turning the rear truck axles – here we see the second axle in progress and completed. Quentin plans to grind the axles to improve the finish during the next work session.
(https://static.fundrazr.com/story/6cc3d13006bb4d3f9fb860e044df2194.png?cb=1702344689628)
Meanwhile, Noah MacAdam stepped up to bore the rear truck swing links.
(https://static.fundrazr.com/story/f6451de7e3b9447882e62645c6be1b18.png?cb=1702344717796)
Jerry and Carlos Steinke assisted Harold in forming (bending) arch bars for the rear truck. Jerry and Carlos have quite a lot of experience using our flanging machine to form arch bars for our passenger trucks. Harold had made plywood templates to ensure the correct bend angles were obtained.
(https://static.fundrazr.com/story/4cd412c173e7491eacc435c5b09ede72.jpg?cb=1702344872685)
And, finally, Harold has completed machining the pilot brackets.
THANK YOU to all our friends, followers, and funders for finishing 2023 strong. We'll be announcing the 2024 campaign on Jan., 11 - and it will be wheely exciting!
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The plan is to get more castings up to Alna right after New Year's. Cattail has been backed up but as soon as things break free, I'll be bringing stuff up unless someone is in the area and going to Alna anyway.
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"lead truck radius bar cross tie" is a hell of a noun stack. ;D
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Great progress on No. 11! Is there a photo that better shows the cross-tie assembly in its installed position?
Dave Crow
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We are planning on installing that assembly during the January work session.
Holes will to be drilled and tapped in the frame to hold it in place.
Here's a view of the cross tie assembly in the 3D model:
(https://i.ibb.co/5j1Zkg7/Screenshot-2023-12-12-215136.png) (https://ibb.co/R6g8Nk5)
Please note that this model leaves out some of the pins and bolts.
As you can see, the front suspension gets a bit complicated up in the front. Part of the complication was that we made the
front frames deeper in front of the lead drivers, as the original design was not strong enough there for the calculated stresses. This
lowered the crosstie, which caused the lead truck equalizer (the gray-blue piece) to interfere with the cross tie. The cross tie had to move
up vertically to give the equalizer clearance to pivot up and down with the suspension.
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Gordon,
Thanks for the explanation and great 3-D view of the front end. I was asking my question because the description provided with one of the photos stated the cross tie assembly installation was now complete.
Happy Holidays!
Dave Crow
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BUILD LOCOMOTIVE 11 – JANUARY UPDATE!
The Build 11 team, after enjoying a holiday break, was back at it again during our January 2-4 work session. Quentin Bethune completed polishing the first rear truck axle journal bearing surfaces using a tool post grinder generously donated by Noah MacAdam.
(https://static.fundrazr.com/story/6bad19dfed1b4a388c85105abe76d2cd.jpg?cb=1704948446892)
Finish grinding the axle journal bearing surface.
(https://static.fundrazr.com/story/4dfda146969649da9445da95412af522.jpg?cb=1704948497206)
The completed axle journal bearing surface – it looks great!
Meanwhile, Gordon Cook, Rick Sisson and Jason Lamontagne completed installation of the lead truck radius bar cross tie. This effort included drilling the through hole for the radius bar retaining pin, drilling and tapping 4 holes in the underside of the forward frame to mount the cross tie, and finally countersinking the through hole to receive the retaining pin. This work alone took us almost two days to complete.
(https://static.fundrazr.com/story/5b2d2da292d8466c978910dc5d721bcd.jpg?cb=1704948562334)
Gordon is countersinking the pin hole in the lead truck radius bar cross tie.
Harold Downey assisted us in cold flanging the 7/8” thick radius bar. This component looks like a gigantic hairpin and required four bends, which came out rather well. We used a purpose built anvil placed in our flanging machine to form these bends. We start the bend and remove the work piece when we judge the bend to be close to the desired angle. Then we use a plywood template to quantify the achieved bend angle, reinsert the work piece in the press, and repeat the process a number of times until the proper bend angle has been formed. On occasion when we have over bent the work piece, we’ll have to remove the work piece, flip it over, and try to bend it back to the correct angle.
(https://static.fundrazr.com/story/72945f6622f14946b4d21bdbdcde8f82.jpg?cb=1704948595586)
Harold is evaluating the lead truck radius bar bend angle prior to further bending.
(https://static.fundrazr.com/story/5e64242576a1420bb1f7977d1c4ef62c.png?cb=1704948654519)
The lead truck radius bar is sitting on the floor; the hole matches the hole in the lead truck cross tie mounted to the forward frame above.
We need to form four lead truck pedestals – these are C-shaped components formed from 1” by 3” bar stock, about 2 feet long. We have to heat these with an oxygen – propane mixture until the area is glowing (orange), move them carefully (the work piece gets really hot) to the anvil and begin the bending process as described above. We were able to form the first bend on each of the 4 pedestals during this work session; we’ll form the remaining bends during our next work session.
Noah has started to machine the rear cylinder heads in his home shop. This is the first step in installing the crosshead guides on the locomotive.
(https://static.fundrazr.com/story/dc5fb89f03094298a4facf582408e026.jpg?cb=1704948691389)
Rear cylinder head in the lathe.
Noah has also completed the lead truck bearing boxes – the boxes have been bored and machined to accept the bearing retainers.
(https://static.fundrazr.com/story/e954403dfa514b808eef0a491333b242.png?cb=1704948731938)
Lead truck bearing box.
Gordon has machined the lead truck spring hanger pivots and pins in his home shop and brought them to Sheepscot.
(https://static.fundrazr.com/story/929e1ce2581e46338994b9c262091d9b.png?cb=1704948774753)
Lead truck spring hanger pivots and pins. (drawings)
Quentin has brought home the lead truck swing links, where he will machine the holes, insert the bushings and drill oil holes:
(https://static.fundrazr.com/story/44059687a8e545c6aaa10c1b6cd1980f.png?cb=1704948824911)
Lead truck swing links. (drawings)
Here's an illustration of the components we’ve worked on this session.
(https://static.fundrazr.com/story/e435b32c30d04dbbb01e9ee78878e52d.png?cb=1704948894542)
Work session components.
2024 FUNDRAISING GOAL ANNOUNCED!
With 2023's goal surpassed with $64,111 raised, we are moving forward with a $50,000 goal in 2024 to make "Wheel Progress". Learn more, and contribute, at build11.org (https://fundrazr.com/build11.2024)
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We made the news!!
See this article published TODAY by The Lincoln County News - https://lcnme.com/currentnews/decades-of-dreams-at-work-rebuilding-alna-locomotive/ (https://lcnme.com/currentnews/decades-of-dreams-at-work-rebuilding-alna-locomotive/)
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BUILD LOCOMOTIVE 11 – FEBRUARY UPDATE!
The Build 11 team was back for our February 4-6 work session. Harold Downey, Joe Monty and Rick Sisson completed hot bending the lead truck pedestals using our flanging machine. The shorter bends were performed during the January work session. These components will be machined to ready them for assembly.
(https://static.fundrazr.com/story/b4b8a191186a4a478311a47cded7bdc8.jpg?cb=1707625202593)
Lead truck pedestals
(https://static.fundrazr.com/story/e0d928d472a54cdcb2c283e968e6f535.jpg?cb=1707625224760)
Harold is fine tuning the pedestal bend
Meanwhile, Harold finished machining the rear truck swing link hanger castings. These are mounted to the top of the rear truck transoms and support, through the swing links, the spring plank.
(https://static.fundrazr.com/story/039a1e4ecfe0417883da71f6f2d9b2ee.jpg?cb=1707625259075)
Machining the swing link hanger castings
During the time between work sessions Alan Downey machined the poling pocket castings. These will be mounted on either side of the pilot beam.
(https://static.fundrazr.com/story/d65c3b6e243747ccba15932b7d18658b.jpg?cb=1707625311655)
Poling pocket castings
Alan Downey also machined the rear truck center plate which will be bolted to the bolster. Joe Monty drilled mounting holes in the spring plank.
(https://static.fundrazr.com/story/f74af418ed4d49cda69d8d2b1ec337d8.png?cb=1707625702666)
After a morning of preparation Harold, Rick, Jason Lamontagne, Gordon Cook and Dave Buczkowski were able to rivet the rear truck assembly. Harold had developed a pneumatic buck which we used to back up each rivet as it was driven. This truck assembly uses 24 rivets which were done in one day.
(https://static.fundrazr.com/story/761d9aaae7ef48dda8b60256b7901473.png?cb=1707625340158)
(https://static.fundrazr.com/story/a1fe4da4049e4dda8e24d9ebe0dda075.png?cb=1707625371520)
Riveting the rear truck. Harold is operating the pneumatic buck.
Once the riveting was done we test fit the rear truck assembly. Gordon had brought up the swing link pins that he made in his home shop.
(https://static.fundrazr.com/story/8566dd134ea346dcae513ac6fe4ad352.jpg?cb=1707625476391)
Meanwhile, Noah MacAdam has been busy in his home shop machining the lead truck bearing boxes and rear cylinder heads.
(https://static.fundrazr.com/story/30796207d69f4096975e3411157ce5ac.jpg?cb=1707625452530)
Lead truck bearing boxes
(https://static.fundrazr.com/story/3aac4bc15feb4be5956fcd333b051cd1.png?cb=1707625512682)
Rear cylinder head
Noah has started work on the crosshead guide assemblies utilizing the precision milled bar stock we recently received. His next step will be to machine the spacer blocks that capture the crosshead guide ends and mount to the rear cylinder heads and guide yoke.
Our 2024 fundraising off to a great start! To date we have received $8,737 (17% of the $50,000 goal for 2024.) Remember, you can still donate directly by check to the museum, use a credit card to donate through the gift shop, PayPal, or you can go to build11.org (http://build11.org)
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The driving wheel centers, two counter weights, and the patterns were picked up from foundry in Springfield, MA today.
The big pallet is the patterns and two wheel castings up against the cab.
(https://hosting.photobucket.com/images/s5/bbarry74/IMG_8648.JPG) (https://hosting.photobucket.com/images/s5/bbarry74/IMG_8648.JPG)
Wheel castings
(https://hosting.photobucket.com/images/s5/bbarry74/IMG_8659.JPG) (https://hosting.photobucket.com/images/s5/bbarry74/IMG_8659.JPG)
(https://hosting.photobucket.com/images/s5/bbarry74/IMG_8661.JPG) (https://hosting.photobucket.com/images/s5/bbarry74/IMG_8661.JPG)
(https://hosting.photobucket.com/images/s5/bbarry74/IMG_8651.JPG) (https://hosting.photobucket.com/images/s5/bbarry74/IMG_8651.JPG)
(https://hosting.photobucket.com/images/s5/bbarry74/IMG_8658.JPG) (https://hosting.photobucket.com/images/s5/bbarry74/IMG_8658.JPG)
(https://hosting.photobucket.com/images/s5/bbarry74/IMG_8657.JPG) (https://hosting.photobucket.com/images/s5/bbarry74/IMG_8657.JPG)
Counter weights
(https://hosting.photobucket.com/images/s5/bbarry74/IMG_8653.JPG) (https://hosting.photobucket.com/images/s5/bbarry74/IMG_8653.JPG)
(https://hosting.photobucket.com/images/s5/bbarry74/IMG_8656.JPG) (https://hosting.photobucket.com/images/s5/bbarry74/IMG_8656.JPG)
(https://hosting.photobucket.com/images/s5/bbarry74/IMG_8654.JPG) (https://hosting.photobucket.com/images/s5/bbarry74/IMG_8654.JPG)
(https://hosting.photobucket.com/images/s5/bbarry74/IMG_8655.JPG) (https://hosting.photobucket.com/images/s5/bbarry74/IMG_8655.JPG)
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Thank You Brendan !!! ;D
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I’m curious, on the castings I see several notations of “sand inclusions.”
Will this affect machining?
Keith
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The notations are the result of x-ray inspection of the castings to insure there were no areas that were porous or otherwise weak.
The issues found were small and not in critical stress areas and the castings passed all the tests that we required for acceptance. We don't think the sand inclusions will affect any machined areas of the parts.
We're really pleased with the quality and response of this foundry, located in Springfield, MA.
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The notations are the result of x-ray inspection of the castings to insure there were no areas that were porous or otherwise weak.
The issues found were small and not in critical stress areas and the castings passed all the tests that we required for acceptance. We don't think the sand inclusions will affect any machined areas of the parts.
We're really pleased with the quality and response of this foundry, located in Springfield, MA.
Thanks Gordon!
Keith
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Brendan unloading the truck today at Sheepscot following the trip to Springfield, MA.
(https://i.imgur.com/EphzVor.jpg)
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The February work looks wonderful! Those drive wheels are a very important part of the the locomotive.
I just sent in my first Build 11 contribution for the year; I am retired so I can not do a lot, but every little bit helps to
meet the year's target! Ted Miles retired but likes the WW&F 11
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Would it be possible to see photos of the various castings without all the packing?
Bernie
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Sorry, they are still packed on the pallets, so a clearer picture isn't available.
We're sending everything over to Mountain Machine in Auburn so we had not planned to uncrate them.
They will machine and assemble the lead and main drive axle assemblies.
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We're sending everything over to Mountain Machine in Auburn...
They will machine and assemble the lead and main drive axle assemblies.
Does this mean that they will do the quartering? I remember the effort it took to quarter 9 during the rebuild. It took invention of an amazingly complex machine by our mechanical engineer to accomplish that.
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Build 11 - March 2024 Update
The Build 11 team was back for our March 5-7 work session.
We had a number of team members working on projects during the March 5-7 work session: Harold Downey and Rick Sisson used our flanger to complete all the bending operations described in the captions. Harold also machined the 180 degree bends to finished dimensions. Rick, Bob Longo, Jason Lamontagne and Joe Monty fabricated the tooling required to bend the spring staples and spring hangers. Quentin Bethune and Gordon Cook kept our lathes busy.
Meanwhile, between the February and March work sessions, Harold Downey machined the lead truck pedestal surfaces to fit the lead truck radius bars and journal boxes.
One goal of the March work session was to compete the 180 degree bends on the ends of the lead truck lower radius bar and the rear truck arch bars. This mutli-step process entailed 1) heating and bending each bar 90 degrees in our flanger, 2) reheating the bar, clamping it in the flanger and striking the end with a sledge hammer to increase the bend to roughly 135 degrees and 3) reheating the bar and “squishing” it in the flanger until the full 180 degree bend is achieved.
(https://static.fundrazr.com/story/4d82db67e27f4076b65b7a264f36af2d.jpg?cb=1710205223050)
Heat # 2
After hot flanging the bar to 90 degrees Harold is reheating the bend so that it can be extended.
(https://static.fundrazr.com/story/f169f6d0bba6489fae60233c47ca4122.jpg?cb=1710205270050)
Harold is "fine tuning" the lower radius bar.
Actually, Harold is extending the 90 degree bend closer to 135 degrees so that it can be flattened in the flanger, here being used as a giant vise.
(https://static.fundrazr.com/story/ba0bb70d04524051800f390f92bcc2b4.jpg?cb=1710205314481)
Heat # 3
The 180 degree bend is complete. We performed a total of six 180 degree bends this session.
Harold machined the 180 degree bends in the lower radius bar to the finished dimension on our vertical mill. He also machined the arch bar bends to the finished dimensions.
(https://static.fundrazr.com/story/a0eb15200d4148c694f34ad723acef8d.jpg?cb=1710205355072)
Another goal of this work session was to form the lead truck spring staples and spring hangers, indicated by blue text, below:
(https://static.fundrazr.com/story/fedaa59106944b88bd628aa5d864e0f7.png?cb=1710205375909)
We fabricated separate bending forms (anvils) for each and realized the process we had envisioned wasn’t going to work. We then fabricated a keeper that our flanger could press down on the material (secured to the anvil) to bend our material to conform to the anvil while keeping the two legs parallel.
(https://static.fundrazr.com/story/b02d936fd8344366b9938631394774f8.jpg?cb=1710205441334)
The spring staple bending form on the left; the keeper on the right.
(https://static.fundrazr.com/story/8ef3e1a1f55341979b87360e61e1c8f4.png?cb=1710205469313)
(photo taken during spring hanger tool fabrication)
(https://static.fundrazr.com/story/4aa1af1eecac46afa6a7a176af98e422.jpg?cb=1710205495288)
Joe Monty fabricating our tooling.
(https://static.fundrazr.com/story/146fcf3e5e3a4af4b1ebcae76d4a8997.jpg?cb=1710205528594)
Bob heating the spring staple bar stock; Rick is ready to move the material with tongs.
(https://static.fundrazr.com/story/7fe4dbe44dd0405781dba0e65de38bda.jpg?cb=1710205607589)
Harold and Rick are clamping the spring hanger material to the anvil.
(https://static.fundrazr.com/story/88dd7f08034e491b9950380432a635bd.png?cb=1710205623117)
Forming a spring staple.
(https://static.fundrazr.com/story/7c42935637c54c3aa9b79ab3a8d8a0b7.jpg?cb=1710205660654)
Finally - 2 spring staples and 4 spring hangers after hot forming. One of the spring hangers is shown sitting on its anvil. These components will be cold formed in our flanger to ensure precise 90 degree bends.
Although we spent 2 days fabricating the tooling to produce just 6 components, we are extremely pleased with the resulting parts. This investment in time and talent paid off handsomely for us.
Meanwhile, Quentin Bethune was able to bore the wheel centers for the rear truck axles using a clamping fixture fabricated by Jason Lamontagne. This was painstaking work that will ensure a precise fit. Quentin was able to complete 4 wheels in just two days work.
(https://static.fundrazr.com/story/692fef66d10d46da8fc76926c983768f.jpg?cb=1710205709717)
Boring the rear truck wheel center.
Gordon Cook started to use our Victor lathe, was setting up some work and the lathe refused to resume operation. Gordon studied a schematic diagram stored in the machine and while tracing the wiring with Brandan Barry’s help found 3 loose wires, which he suspects were not properly connected at the factory.
Our 2024 fundraising is continuing! To date, we have received $ 11,486 (23% of the $50,000 goal for 2024). Remember, you can still donate directly by check to the museum, use a credit card to donate through the gift shop, PayPal, or you can go to: build11.org
Thank you from all of us for your continued interest and support!
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The computer generated illustrations of the lead truck for No. 11 (two illustrations so far) are very detailed and technically complicated. They do leave me with an unanswered question: is there any lateral, side-to-side movement of No. 11's pilot truck or are the axle and wheels locked in alignment with the drive wheels. A 2-6-0 model steam locomotive in HO or O gauge would have its pilot wheels swing wildly, which probably wouldn't serve much purpose in guiding the locomotive smoothly through tight curves. The illustration of No. 11's lead truck show what look like pivot points where it attaches to the frame under the cylinder saddle. This would mean possible lateral movement. However, there is also shown a round column, which I don't know the name of, that protrudes upward from the center top of the truck through the front pilot deck. This would seem to inhibit any side-to-side swing of the truck. There is my conundrum: does it swing? Is it fixed? Is it allowed to swing just a little? Help***
Bruce Colburn
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Bruce,
I am not an expert, but in layman's terms there are lead truck swing links that appear to allow the truck axle to move left or right when entering a curve, this is pivoted from under the cylinders. This exerts a force in the direction of the curve which pulls the locomotive drive wheels in that direction. A similar design is on car trucks which allows the wheel sets to move left or right under the pivot point while exerting a force to center the car over the rail center. I hope my understanding is somewhat correct.
Look at the color graphic on page 40 just above the bottom of the string of messages.
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Here's a (greatly) simplified example, courtesy of Lionel Trains...
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The round column which Bruce referred to is the lead truck bushing. This is actually the final component which makes the lead truck useful. This bushing is constrained by the locomotive frame and in turn it puts a lateral force on the frame when the truck is off-center. The lateral force is developed from the swing links being forced out of plumb- they want to self-center and in so trying exert the lateral force on the frame which is the entire point of the truck. The locomotive frame does not put any weight on the truck at this location; instead the locomotive rests on the lead truck equalizer, which hangs from the lead truck pin, which is supported by the lead truck bushing, in turn putting its weight on the center casting. The center casting is hung from the lead truck frame via the swing links.
You know, the knee bone connected to the leg bone kind of thing.
Hope that helps,
Jason
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Thank you Jason. Your description helps a great deal. I don't know all the names of the many parts of the lead truck and your reference to them sent me back to study the computer generated illustrations. I suspected the four "swing links" played a major part in explaining how this ingenious design works. Now I'm wondering if a nifty animated computer illustration could be made available showing the lateral movement of the lead truck's parts.
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Last week a small crew of guys from the WW&F consisting of Nick Simoneau, Tom Ross, Dante’ Lakin, Dan Malkowski, and myself went to the EBT to do some track work. However we got rained out, and ended up doing some various shop work instead which was equally enjoyable.
In the process of driving down, we brought an oval Railroad Crossing sign down that is more traditional to the PA area, including the EBT. The East Broad Top was kind enough to donate two vacuum pots that they had on hand, as well as one additional vacuum pot that was donated from someone who wishes to remain anonymous. The vacuum pots will be rebuilt, and used on #11 in the near future.
I would like to thank the East Broad Top, and our anonymous donor, for their generosity and kind donation to the project.
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(https://i.postimg.cc/1tfxDTR2/IMG-1083.jpg)
(https://i.postimg.cc/TP2v31zR/IMG-1142.jpg)
(https://i.postimg.cc/7Zny40Qs/IMG-1143.jpg)
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Many thanks, guys. And also thanks to the EBT and donor for the vacuum pots.
I have been working for the past couple of weeks on finalizing the design of the driver brakes for No. 11. As you can see in the builders photo, No. 7 had a very funky vacuum brake design with the vacuum pots facing backwards under the cab and pulling on the brake rigging with outside links running around the ashpan and under the frame.
Also note the round vacuum brake "muffler" on top of the cab. This quiets the noise from the escaping steam from the brake ejector when the brakes are applied. We will be replicating all these 'features' of the original.
Having the actual pots that we will be using lets me accurately design the parts so we can create and add the supporting components to the frame while we have good access.
(https://i.ibb.co/MN99B7L/BLW-Builder-s-Photo-WW-F-7-cropped.jpg) (https://ibb.co/F7nnHzt)
In the next couple of weeks I hope to finish this and publish a note on the final design and the reasons for its unorthodox configuration.
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BUILD LOCOMOTIVE 11 – APRIL UPDATE!
A springtime snowstorm did not slow down our progress this month; an abbreviated Build 11 team was back for our April 3-5 work session. Between sessions Harold Downey continued assembly of the rear truck frame.
(https://static.fundrazr.com/story/3847dafd4749452a81ae5bd69052afd5.jpg?cb=1712883141850)
Gordon Cook spent part of the day Wednesday working on locomotive 9’s injector with Roger Whitney and Jason Lamontagne. Later Gordon worked on machining one of the sleeves for the rear truck axles. Gordon tried to return on Thursday but was unable to reach the museum during the snow storm due to fallen trees blocking route 218!
Rick Sisson spent the day Wednesday completing the anvils that will be used as tooling to form the main spring staples, equalizer pedestals and main spring hangers:
(https://static.fundrazr.com/story/ad540ab76a984d5f80b86aedbee1a370.jpg?cb=1712883168213)
Thursday Rick was able to fillet the driving axle jaws in the forward frame. The jaws have to be rounded to accommodate the inside corners of the driving box shoes and wedges. We were able to borrow a 30 degree plate beveling machine from our friend Brian Fanslau of Maine Locomotive and Machine Works in Alna, Maine. Using this tool, we were able to remove most of the material in two passes, as shown in the drawing. We then removed the remaining material with a hand grinder and finished the surface with a file.
(https://static.fundrazr.com/story/42da317366464b009326af84ffdaec84.jpg?cb=1712883199897)
Brian’s plate beveling machine saved us an enormous amount of time; we used to remove all the material with a great number of passes with the hand grinder.
Below is a photo of the frame as received:
(https://static.fundrazr.com/story/33d7489868484e5ca4f66f5d2efe25fd.jpg?cb=1712883215071)
And here you can see the first pass completed on the outside faces with the plate beveling machine:
(https://static.fundrazr.com/story/6827af3ab8f64aac831fe0a8cb5350f8.jpg?cb=1712883231396)
And a photo of the completed work – all ready to fit shoes and wedges!
(https://static.fundrazr.com/story/9213ab363946427282a02918cf4c9b8b.jpg?cb=1712883244759)
The plate beveling machine we borrowed from Brian:
(https://static.fundrazr.com/story/a349e6cda5a9403583d046bffc8c3024.jpg?cb=1712883266880)
On Friday morning Rick fabricated the bosses for the lead truck frame:
(https://static.fundrazr.com/story/1ddc93fc75c8418f945a108caf84b047.jpg?cb=1712883287992)
Here we have test fit the lead truck boss, pedestals and lower radius bar:
(https://static.fundrazr.com/story/5d1fbee084954aaa8b706067f5f753bb.jpg?cb=1712883303437)
The boss will be welded to the lower radius bar when fitting up the pedestals and journal boxes.
On Friday afternoon, Jason and Rick completed forming the lead truck spring hangers. When formed in our flanging machine during the last session, the legs sprung back as we anticipated. We were able to reheat the corners and square up the hangers in the bench vise while holding the pin holes in alignment with a shoulder bolt. Below we see before (left) and after (right) examples:
(https://static.fundrazr.com/story/f8f30e59bde34d76b3049a93ed946e68.jpg?cb=1712883322215)
We look forward to seeing everyone at our next work session scheduled during our Spring Work Weekend, April 26-28. We invite you to stop by, say “hello” to the Build 11 team and let us show you what we’re up to!
Our 2024 fundraising is continuing! To date we have received $15,161 (30% of the $50,000 goal for 2024) – which includes a $2000 anonymous donation made today! Remember, you can still donate directly by check to the museum (which is preferred for large donations), use a credit card to donate through the gift shop, PayPal, or you can go to: build11.org (http://www.build11.org)
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When are the May and June build #11 work session dates?
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BUILD LOCOMOTIVE 11 – MAY 2024 UPDATE!
Our last Build 11 work session was held April 25 – 28 during our Spring Work Weekend. Between sessions Harold Downey has continued working on the rear truck frame – the arch bars and journal boxes have been bolted in. We plan to prime all the components before final assembly.
Quentin Bethune brought back the lead truck center casting he machined at home. He did a great job and those bolts he made are exceptional!
(https://static.fundrazr.com/story/c43531ddbb2c4595b35da11a64b3b3cd.jpg?cb=1715475935174)
Harold, Bill Steussy, Joe Monty and Rick Sisson used our flanger to hot form the main spring staples. We eventually settled on three heats and squeezes in the flanger to form the correct shape in three orthogonal planes. Joe was able to fashion a sort of enclosure using ceramic fiber blankets which accelerated our torch heating – very clever! Once again, this was a learning process for us - the first staple took us between 4 and 5 hours to get right; the remaining three staples took about an hour to complete. This is becoming a recurring theme for your Build 11 team. Below we see the completed staples; the critical surfaces will be machined in a future work session.
(https://static.fundrazr.com/story/18bee4535a214feb92ec10a13436708b.jpg?cb=1715475958056)
We used a keeper as before to ensure a flat top on each staple:
(https://static.fundrazr.com/story/2eedd60b4aa944f0b667875b708dbfbd.jpg?cb=1715475972936)
We turned our attention next to hot forming the equalizer pedestals. We used the same processes to form these as the main spring staples. Here we see Harold reheating one of the pedestals prior to final forming:
(https://static.fundrazr.com/story/838a7aaf1d234f07a95965c950664c86.jpg?cb=1715476013143)
And here we can see the equalizer pedestals test fit on forward frame:
(https://static.fundrazr.com/story/7a75098a86c04ab4817492c925474d78.jpg?cb=1715476028639)
Since we were on a roll, we continued to form the brackets that support the driving box wedge bolts. Jason Lamontagne had built a set of dies (used for locomotives 9 and 10) that we used to hot form our brackets. We were able to heat our material in our propane forge. Before and after photos are shown below:
(https://static.fundrazr.com/story/ea9e111b169c4825b01de3019d6b8823.png?cb=1715476051503)
We had some hand work to do after pressing our material to straighten the ends.
Harold was able to pour babbitt into the bronze truck bearings that we had cast for us. Babbitt is a lead, tin and antimony alloy that provides an anti-galling bearing surface.
(https://static.fundrazr.com/story/b39e467acb80445289adbb1e1b34d048.jpg?cb=1715476078700)
Harold was able to complete 20 bearings. Harold will machine these to print in our shop.
(https://static.fundrazr.com/story/211f4f4585254aa89063037a6f325941.jpg?cb=1715476096127)
In an earlier Build 11 work session we attempted to press the rear truck wheels onto their axles, machined by Quentin. Because the wheel bores lacked lead-in, or an entrance taper, both the axles and wheels were scored when we pressed the wheels on. We disassembled the wheelsets, diagnosed the root cause, and developed a corrective action plan. Our solution entails reducing the axle diameter, increasing the wheel bore diameter and fitting a sleeve between the axle and wheel. Gordon Cook and new volunteer Gorham Rowell turned the inside of the sleeves to the prescribed diameter; Quentin then turned the axles to provide a 0.005” interference fit to each sleeve.
Gordon was able to heat two sleeves in the WW&F Ry barbeque (one at a time) to expand the sleeve so that each sleeve could be dropped over the corresponding axle. Because the barbeque was used by the kitchen crew during our Spring Work Weekend we had to wait until lunch was served. Soaking each sleeve at a temperature between 400 and 500 degrees Fahrenheit allowed an easy slip onto the axle as shown below:
(https://static.fundrazr.com/story/3aa9753c64014f4a996f4cc4ae5ba9ad.png?cb=1715476125943)
Finally, we want to thank our great friends at the East Broad Top Railroad for donating two original Eames vacuum pots to us. The crews of the EBT discovered these extremely rare objects in their lumber shed! These likely came from some of the earliest EBT locomotives before conversion to air brakes. While the WW&F Ry is constructing new vacuum pots for our rolling stock, these unique pieces will be a historic addition to our #11. Gordon is measuring these vacuum pots so that he can design mounting brackets specifically for these pieces. We’ll be posting an update on these when they get attached to the frame.
(https://static.fundrazr.com/story/a0298fbbbe114f5aade8bdab906cf482.jpg?cb=1715476215491)
Our 2024 fundraising is continuing! To date we have received $21,026 (42% of the $50,000 goal for 2024). Remember, you can still donate directly by check to the museum, use a credit card to donate through the gift shop, PayPal, or you can go to: www.build11.org (http://www.build11.org)