W.W.&F. Discussion Forum

WW&F Railway Museum Discussion => Work and Events => Topic started by: Bill Baskerville on April 18, 2017, 03:14:02 PM

Title: Coach 9 - Official Work Thread
Post by: Bill Baskerville on April 18, 2017, 03:14:02 PM
I'm here for two weeks with a few goals in mind:

Help Eric with documentation for new coach #9
Disassemble a seat from #3 to use it to create patterns for Coach 9 seats

Spring is starting to spring here in Maine.  I see reddish buds on maple trees. 



Harold, Eric,

If either of you are around the SWW, and if you have gotten the details worked out, perhaps you could brief me on the door and window requirements for coach 9 so the Southern Narrow Gauge Door and Window Shop can do some advance fabrication planning.

That is unless there is a more pressing need for other items.

Bill

Bill,

We have been looking at the windows in detail.  (Maybe this should be moved to new coach thread).  We believe that the only original window is in the saloon (bathroom).  It has details that none of the other windows have.  I have measured all the critical parts, and will make a drawing with all the joinery.  They are pretty straightforward.  Mahogany for the wood, minimal decorative details.

I also have measured the end doors.  Still need to pull and measure a clerestory window.

Harold,

Thanks for the info, I didn't realize the coach 3 windows were not original.  I also forgot all about the clerestory windows. 

Is not having Mahogany a deal killer?  I haven't searched for a source of Mahogany.

Bill
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on April 18, 2017, 04:18:54 PM
Bill,
When you drop the doors for coach 8, you can stop in the Portland area and get some rough Mahogany. I forget the name of the company, but have heard the commercial on the radio several times. "The wood of the world is available at"...
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on April 18, 2017, 04:23:45 PM
Downes & Reader, Gorham, Me.
Title: Re: Coach 9 - Official Work Thread
Post by: Steve Zuppa on April 18, 2017, 04:24:20 PM
IIRC, according to Jason's research, the interior trim in coach 3 that we always thought was mahogany, was oak. If that's the case, trim supplies should be readily available.
Title: Re: Coach 9 - Official Work Thread
Post by: Philip Marshall on April 18, 2017, 06:02:32 PM
It should be pretty simple to differentiate oak from mahogany. Oak is a ring-porous wood with really large and dramatic rays (which give quarter-sawn oak its character), whereas mahogany is a diffuse-porous wood with very fine rays -- somewhat resembling birch. (In fact, 19th-century furniture makers would sometimes stain birch to make it look like mahogany.) If possible, look for end grain on the inside of a joint where it's not covered by varnish.
Title: Re: Coach 9 - Official Work Thread
Post by: Jason M Lamontagne on April 18, 2017, 07:04:38 PM
Eric and Harold have a thorough handle on the wood species we need.

What I thought was mahogany trim is mostly oak, hence Steve Zuppa's statements.  Actually, Eric verified that.

Since then, Eric has discovered that the window sills are actually mahogany.

Harold has found the only surviving original window and confirmed that it is mahogony.  Doors are oak.

In short- the decorative woods appear to all be oak.  Mahogany was chosen in a couple places where dimensional stability was desired. 

See ya
Jason
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on April 18, 2017, 07:11:13 PM
Inside trim is all oak.  Builder photos from archives confirm it was always oak.  The end doors are 100% oak currently, and it is quartersawn with visible rays.   I think it is important to stick with quartersawn oak for new doors, to assure stability -- resistance to warping. 

Most of the current windows are mahogany, or at least a similar tropical wood.  The single original window is also mahogany.  This wood is used for stability in a very tough application, not to match the rest of the oak trim.    At the time this coach was built, even foundry patterns used mahogany.    The window frames are 11/16" thick, not very substantial. 

I am sure mahogany or an equivalent is available at most hardwood suppliers.  I have seen it in Austin.   

Harold. 
Title: Re: Coach 9 - Official Work Thread
Post by: Bill Baskerville on April 18, 2017, 09:37:08 PM
All,

Thanks for the information.

I live in a small community with limited shopping sources unless I go to Richmond about 70 miles away.  However, I have found both Honduras and African Mahogany in several sizes about 20 miles from here, the 'SNGD&WS'.  Do we care which source.  The same sizes are not necessarily available in both sources.

Once I have the dimensions of the necessary lumber I will see what I can round up.  I have been making doors and coach 8 windows out of red oak.  Will that work for the doors on coach 9?

Bill
Title: Re: Coach 9 - Official Work Thread
Post by: Bill Baskerville on April 19, 2017, 12:03:47 AM
Harold, Ed,

With apologies for being scattered, I will also need to know if there is any special glass in the clerestory window.  I have been using either 1/8" or 3/16" clear tempered glass for the windows and doors.  I doubt they had tempered glass then, but it may be a good idea to use it now.

Bill
Title: Re: Coach 9 - Official Work Thread
Post by: John McNamara on April 19, 2017, 12:11:20 AM
On the subject of clerestory glass, do we know if the WW&F used clear glass, frosted glass, or etched glass?

-John M
Title: Re: Coach 9 - Official Work Thread
Post by: Philip Marshall on April 19, 2017, 01:06:32 AM
I have found both Honduras and African Mahogany...Do we care which source.  The same sizes are not necessarily available in both sources.

I imagine the mahogany in coach 3 is West Indian or "Cuban" mahogany (Swietenia mahagoni), but that species is now so rare due to historical exploitation that it's unavailable as lumber. Honduras mahogany (Swietenia macrophylla) would be a good match, even if it's not exactly the same wood. I don't know if African mahogany (Khaya senegalensis) was even commercially available in the US in the 1890s, though it was already being exported to Europe by that time, apparently.
Title: Re: Coach 9 - Official Work Thread
Post by: Jason M Lamontagne on April 19, 2017, 06:29:52 AM
Hi Bill,

The lower window glass needs to be safety glass; we're moving all window glass to safety glass.

The clerestory windows are particularly special- stamped, colored glass.  I'm certain that will be a special sub-project to find a supplier or reproduction method.

We'd discussed the possibility of your making windows and doors for coach 9; our initial thought was frames only- though that could still be refined.  Maybe the safety glass could make the trip fine, but the clerestory windows have glass added in maine. 

The dimensions and joinery details must be very tightly controlled with these.  Harold is making drawings which match the originals, but there won't be freedom in developing details like on coach 8.

We look forward to discussing fine details when you get here for SWW.  Be sure to seek out Eric (Harold will be here till the Wednesday prior).

See ya
Jason
Title: Re: Coach 9 - Official Work Thread
Post by: Bill Baskerville on April 19, 2017, 08:26:13 AM
Jason,

Thanks for the vote of confidence.  I am aware that the coach 9 windows and doors will have to be historically correct reproductions which is why I want to gather as much information as I can. 

The half a dozen coach 8 windows I made a few years ago traveled inside the little car with the glass already mounted.  If I use the larger car and start early I can bring the coach 9 windows inside the car over a couple of work weekends and/or my summer trip.  The doors may be narrow enough that I can also bring them inside the larger car. 

The larger coach 8 doors I will bring on a trailer with the glass unmounted, inside the car.

The Southern Narrow Gauge Door and Window Shop is at your disposal.

Bill
Title: Re: Coach 9 - Official Work Thread
Post by: Benjamin Campbell on April 19, 2017, 06:19:50 PM
Will we replicate a working toilet despite the fact that we can’t use it? Will we include a coal stove? If so – do we know what model was original to the prototype?
Title: Re: Coach 9 - Official Work Thread
Post by: Jason M Lamontagne on April 19, 2017, 06:26:39 PM
Yes and yes- we'd really like to install a water-heater type stove.  While it's clear they were used on the SR&RL, it's not clear whether the WW&F did.

It does appear that coaches 2 and 3 had different stoves, at least at different stages of life.

See ya
Jason
Title: Re: Coach 9 - Official Work Thread
Post by: Carl G. Soderstrom on April 20, 2017, 02:10:00 AM
Check out Ultimate Restorations show on the Badger fish car

http://www.ultimaterestorations.com/badger-2/

As I remember the restorer for Mid Continent RR Museum found someone to make
the special patterned glass for the clerestory.
Might be worth contacting them if you do not have a local source.

http://www.midcontinent.org/equipment-roster/wooden-passenger-cars/wisconsin-fish-commission-2/

Avalon Rail inc. may have done / did the work.


A side point of interest
https://vimeo.com/112666164
Title: Re: Coach 9 - Official Work Thread
Post by: Dave Crow on April 20, 2017, 08:19:56 AM
Many of the pressed glass patterns can be sourced through stained glass supply houses; older commercial glass houses also have a lot of specialty glass options available due to old home restorations and other architectural demands.  Baltimore Streetcar Museum has used Chaudron Glass for years; I remember looking through books of glass samples when researching "ripple" glass for one of the streetcar restorations.

Dave Crow
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on May 10, 2017, 10:45:15 AM
I am working on seat reproductions for coach 9.  I have one of the seats from coach 3 in my shop, and I am figuring out, among other things, how to make patterns to reproduce it.

One of the first things I am doing, before stripping all the paint, is to determine what the original color of the seat frame may have been.  They are currently black.

I have taken paint chip samples from three of the inner areas, potted and polished them to determine the paint layers.  (Inside of the outer frame, inside of the window side frame, and the window side of the walkover mechanism.)

The results are surprising.  I am seeing unusual colors.  But I don't know if the frames have ever been stripped to bare metal and repainted during their history, nor do I know what primers may have been used  that may explain the colors I am seeing.

Rather than reveal what I have so far, I will first ask the community if anyone knows of historical references to the seat frame color.   

The black and white builders photo from the Delaware public archives shows the seat frames to be quite bright, or very reflective.  The seat arms definitely have some remaining nickel plating, but they are a separate part. 

The seats are made by Hale & Kilburn of Philadelphia.  They are not the same seat that is being reproduced by Strasburg RR.  It is a specific model for narrow gauge cars.
Title: Re: Coach 9 - Official Work Thread
Post by: Dave Crow on May 10, 2017, 12:53:40 PM
Do we happen to have a copy of the order that was placed with Jackson & Sharp for Coaches 2 & 3?  Possibly the colors for everything would be on either the order itself or on the order confirmation from J&S?

Just a thought.

Dave Crow
Title: Re: Coach 9 - Official Work Thread
Post by: Stephen Piwowarski on May 13, 2017, 12:45:30 PM
I was just taking a look at #3's builders photo. I had no idea that the lettering and numbering on the car sides were originally shadow lettered. How cool!

Also, if we don't have them, some order books for Jackson and Sharp are available from the Smithsonian.

http://sova.si.edu/record/NMAH.AC.0156#summary (http://sova.si.edu/record/NMAH.AC.0156#summary)

There are also some job books at the Hagley Museum in Wilmington in addition to photos there and in the state archives.

If there is something to gain from it, I'm up for a little trip for researches sake.

Steve
Title: Re: Coach 9 - Official Work Thread
Post by: Eric Schade on May 15, 2017, 11:08:54 AM
I did some research and found some glass for the clerestory.  http://www.wissmachglass.com/textures.html (http://www.wissmachglass.com/textures.html) scroll down to "Florentine 01"  this stuff comes in different colors.  if it is not an exact replacement only a skilled eye can tell without them being side by side.  If we send them an original piece of glass they can match the color.
Title: Re: Coach 9 - Official Work Thread
Post by: Brendan Barry on May 17, 2017, 07:34:44 PM
Glass samples for the clerestory windows. I believe that is an original window in Eric's left hand and between the two pieces of glass in the second picture.

(http://i148.photobucket.com/albums/s5/bbarry74/bbarry74011/IMG_0027.jpg)

(http://i148.photobucket.com/albums/s5/bbarry74/bbarry74011/IMG_0028.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on May 18, 2017, 09:38:46 AM
The left hand pattern looks to be a match.

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: Wayne Laepple on May 18, 2017, 04:12:02 PM
My own opinion, based on cars of a similar age at the Railroad Museum of Pennsylvania, is that both the glass in the center is not original. That type of glass was made in a press, which put the design in the glass while it was still hot. The sample on the right is more appropriate to the period.
Title: Re: Coach 9 - Official Work Thread
Post by: Jason M Lamontagne on May 18, 2017, 07:43:08 PM
Given the ornateness of the car as built, and the constant dumbing down of the niceties thereafter, we've got every reason to believe the center piece, the long skinny one which we got from the car, is original.  There are about 14 or 15 like it in the car; the others are clear plain panes, or plastic.  

Looking at the interior builders photo on the Delaware public archives, zooming in on those windows, shows a pattern.  Obviously color and the exact pattern can't be discerned, but what circumstantial evidence we have supports our belief.  

I presume they were made by hot stamping colored glass in 1894, just as now.

See ya
Jason
Title: Re: Coach 9 - Official Work Thread
Post by: Eric Schade on May 24, 2017, 10:00:19 PM
I got some more samples from the glass manufacturer and we are getting VERY close to the original color.  The "Florentine" texture is also very close. The only noticeable difference seems to be that the new stuff has a button in the center of each rosette while the original does not.  The rosettes are nearly the same size and character.  I am getting two more color samples and should be really close.  I'll get some prices and replace the plastic panels in coach 3 to see how it looks.
Title: Re: Coach 9 - Official Work Thread
Post by: Ted Miles on June 06, 2017, 10:05:22 PM
Folks,
         I hope this is the right place to ask this question. If not; maybe someone can move it?

I heard that a set of Jackson & Sharp passenger trucks are at the WW&F Museum.

Why not use them under the new #9? The original passenger car was a J&S car. Just the wheel sets for a pair of new trucks will run into a lot of money. Maybe it is better to spend the money on the lumber.

Ted Miles, WW&F Member
Title: Re: Coach 9 - Official Work Thread
Post by: Stephen Piwowarski on June 06, 2017, 11:59:53 PM
Ted,

Perhaps I can offer a partial response to your query. While they are J&S trucks (actualy one is, at least in part, and Edaville reporduction), they are not the same as the trucks under Coach 3. So, even though they are J&S, they would not be the appropriate trucks for that car.

Steve
Title: Re: Coach 9 - Official Work Thread
Post by: Wayne Laepple on June 07, 2017, 04:50:03 PM
Well, if that's the case.... If the Edaville "J&S" trucks are not going to be used under the new coach, they should be put under combine 8. Then the freight car trucks currently under combine 8 can be used under whatever the next freight car is.
Title: Re: Coach 9 - Official Work Thread
Post by: James Patten on June 07, 2017, 05:56:46 PM
There's some sort of truck swap that will happen, or maybe it's just a wheel swap, or maybe wheels stay with cars and the truck bodies gets swapped.  We went over it at the last board meeting and I didn't really get what was going to happen.
Title: Re: Coach 9 - Official Work Thread
Post by: Jason M Lamontagne on June 07, 2017, 07:19:00 PM
There is a tentative arrangement to utilize the existing J&S trucks and build new, appropriate trucks for coach 9.  There's still some details to settle- so for now I'll post more details in the members only section.

See ya
Jason
Title: Re: Coach 9 - Official Work Thread
Post by: Brendan Barry on August 10, 2017, 12:17:15 AM
The door post/trim on coach 3 sanded down to the original factory paint.

(http://i148.photobucket.com/albums/s5/bbarry74/bbarry74011/IMG_5469.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: Philip Marshall on August 10, 2017, 03:02:51 AM
Very neat picture! The thin layer of Edaville yellow really stands out.

So was the original color really brown, or perhaps maroon "lake" ?
Title: Re: Coach 9 - Official Work Thread
Post by: Eric Schade on August 10, 2017, 04:02:53 PM
we held up color chips to see what we were looking at. of the chips we had the "Kilz" color LM 100 (b3) "Incence Stick" looks really close -- think UPS truck Brown. which is "Pullman Brown" according to Google.

I also spent some time sifting through Jackson and Sharp images and found some good shots of similar cars.  This one shows the striping really well. http://delaware.contentdm.oclc.org/cdm/singleitem/collection/p15323coll6/id/3733/rec/1 (http://delaware.contentdm.oclc.org/cdm/singleitem/collection/p15323coll6/id/3733/rec/1)
(http://delaware.contentdm.oclc.org/utils/ajaxhelper/?CISOROOT=p15323coll6&CISOPTR=3733&action-2&DMSCALE=10&DMWIDTH=512&DMHEIGHT=478&DMX=0&DMY=0&DMTEXT=&DMROTATE=0)
Title: Re: Coach 9 - Official Work Thread
Post by: Bob Holmes on August 10, 2017, 08:28:17 PM
So Eric, do you want to paint your new model coach in "WW&F Brown" as a test of what it would look like on the prototype?...
Title: Re: Coach 9 - Official Work Thread
Post by: Eric Schade on August 10, 2017, 09:11:38 PM
Nope  but haw about Wiscasset and Quebec brown!
Title: Re: Coach 9 - Official Work Thread
Post by: Alex Harvilchuck on September 11, 2017, 12:34:12 PM
[I would like more information regarding the Coach 9 cloning project] because I own an artisan woodworking/cabinetry shop.

Equipment-wise I seem to gravitate towards mid-century Rockwell and Delta, with a smattering of Acme, Poitras, Kuster Woodworks, Handy, Crouch, Sand-Rite Mfg., Wetzler, Beach Mfg., Boice Crane, Crescent, Newton, Dake-Johnson, Stanley, GE, Van Norman, and anything else I may have forgotten. I do only North American manufacturers unless I have no choice. I don't like plastic machines, only machines made of materials directly on, or alloyed from, elements on the periodic table.
Let me know some details what you need for Coach 9 when you get a chance. Maybe I can help to fab up some sub-assemblies when there is some slack time in the shop as an in-kind donation.
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on November 30, 2017, 11:27:44 AM
A short update on Coach 9 progress:

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

There are four castings needed for the base frame: 

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

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

I have nearly completed all of the patterns for these.

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

Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on November 30, 2017, 11:28:48 AM
And the female counterpart:
Title: Re: Coach 9 - Official Work Thread
Post by: Dave Crow on November 30, 2017, 01:02:29 PM
Very nice work, Harold!
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on November 30, 2017, 08:23:22 PM
Here are the completed center castings, ready for finish.   

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

Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on November 30, 2017, 08:25:19 PM
Here are the completed body support casting pattern and the queen post casting pattern.
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on November 30, 2017, 08:27:14 PM
.... and the last one - the bolster truss rod casting, with its three core boxes.  This pattern took more time than the other four put together.   But, it was kind of fun to make. 

Title: Re: Coach 9 - Official Work Thread
Post by: Wayne Laepple on November 30, 2017, 08:32:49 PM
Outstanding work, Harold. I received a call yesterday from Cattail Foundry that they have completed the Jackson & Sharp truck castings, and I plan to bring them along to Maine when I bring the East Broad Top couplers, hopefully sooner rather than later.
Title: Re: Coach 9 - Official Work Thread
Post by: Ira Schreiber on November 30, 2017, 09:50:04 PM
Great work, Harold and a supreme addition to our upcoming coach #9.
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on December 01, 2017, 10:40:18 AM
Excellent work, Harold. What's next on your list?

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: Dave Crow on December 01, 2017, 11:36:41 AM
Harold, the "cups" in the ends of the carbody in which the ends of the truss rods and tensioning nut go - are those castings?

Dave Crow
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on December 01, 2017, 06:40:47 PM
The truss rods on Coach 3 terminate with washers and nuts.  So - no castings.
Title: Re: Coach 9 - Official Work Thread
Post by: Dave Crow on December 03, 2017, 06:06:25 PM
Harold, thanks for the clarification.
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on January 30, 2018, 08:09:38 PM
I am starting work on the patterns for the Hale & Kilburn seats.  This is the window side casting that supports that side of the seat, and where the flip-over mechanism attaches as well.   

It is very challenging, even though it doesn't look too complicated.  I also need to make a complex core box to form the back side cavity.  This is just a warmup for the aisle side casting -- that one is giving me nightmares.   

The first picture is the pattern in process. I am gluing on the first level of core prints in this step.  You can see the actual part just above it.

The second picture is showing something I am trying out.  The original casting has a part number on  it - 71M-3.  The letters are very similar in size and detail to the Hale and Kilburn lettering that definitely needs to be reproduced on the aisle side casting.  I got some mold making silicone rubber.  I poured this over the letters.  Once that hardens, I can peel it off and use it as a mold to make letters out of epoxy.  Then I can glue the epoxy letters to the pattern.  I hope this works!

I'll update as I get further along. 
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on January 30, 2018, 08:10:08 PM
Silicone mold making
Title: Re: Coach 9 - Official Work Thread
Post by: Wayne Laepple on January 30, 2018, 08:35:05 PM
Hi Harold --

We have had very good luck making silicon casting patterns at the Railroad Museum of Pennsylvania. We've made builder's plates, number plates and quite a few small bits of hardware. Good luck!

Cheers -- Wayne
Title: Re: Coach 9 - Official Work Thread
Post by: James Patten on January 30, 2018, 08:39:59 PM
It looks like Hale & Kilburn's successor is the Kustom Seating Company.  Did you talk to them to see if casting pattern 71M-3 (or any other pattern) still exists?  Doubtful, I know.
Title: Re: Coach 9 - Official Work Thread
Post by: Stephen Hussar on February 03, 2018, 09:16:30 PM
Wow.
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on February 03, 2018, 10:31:21 PM
A couple more pictures: 

The silicone mold peeled off the letters.  It seems to have worked really well.
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on February 03, 2018, 10:32:42 PM
And with the epoxy letters placed on the pattern.  The pattern is a little further along.   The core box for this is taking a lot of time.  I will have a picture of that to post in a day or two.
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on February 04, 2018, 10:45:36 AM
Fantstic work, Harold.

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on February 08, 2018, 08:43:20 PM
This pattern is a one-sided pattern with a cover core.  It will be molded completely in the drag (bottom half of the sand mold flask).  The cover core forms the back side indent and takes care of the offsets in the parting plane. 

On top is the pattern -- the darker wood backing is the core print.  Below is the core box. 

Still have lots of finish work to do -- filling holes, fillets, etc.
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on May 25, 2018, 07:32:35 PM
I've started on the biggest seat part, the main side frame.   Since the silicone mold making seemed to work well for my first try with letters, I thought that it might allow me to make the most intricate part of the side frame pattern, the open basket weave.   I backed up the weave area with a waxed piece of acrylic, and brushed on a thickened silicone mixture to make the mold.   After curing and peeling it off, it didn't seem all that great, but I decided to go ahead and make an epoxy casting with it, to at least learn something.  The basket weave is on a curved surface, which doesn't lend itself to making an epoxy casting very well.  So I flattened the silicone mold, and put plaster on the back side to keep it flat. 

I made a dam around the silicone with molding clay, mixed up epoxy and poured it yesterday.  I unmolded it today, sanded down the back side to get it to the correct thickness, and did a little clean up with a paring chisel and files.    I am very pleased with how it turned out.  No need to do it again. 
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on May 25, 2018, 07:35:09 PM
Here is the silicone mold I made to reproduce the Hale & Kilburn lettering.   I am stoked about how well this is working.  The new seats will look very authentic.
Title: Re: Coach 9 - Official Work Thread
Post by: John Kokas on May 25, 2018, 07:41:44 PM
Shouldn't the new label read kilburn. And Downey?

Title: Re: Coach 9 - Official Work Thread
Post by: Bill Baskerville on May 26, 2018, 09:21:58 AM
Harold,

The quality of the pattern and casting work you are doing is simply amazing.  Although using simple and your pattern work in the same sentence seems counter intuitive. 

Really great work and like so much of what our group accomplishes, your work is up to the best preservation museum quality to be found anywhere.
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on May 26, 2018, 11:12:00 AM
Let me second what Bill said. Simply amazing work.

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: Bill Reidy on May 28, 2018, 01:45:51 PM
That is amazing work, Harold!  Wow!
Title: Re: Coach 9 - Official Work Thread
Post by: Eric Schade on May 29, 2018, 10:05:26 PM
A second try posting a photo using a 3rd party web site my wife sue found, let me know if there is a photo below...if so what do you think of our colors?

(https://lh3.googleusercontent.com/aixDOdyshaMMV0EbEIq05NAZOri0qWvLBlElrrmn7CNUwIocKh9QfkaTSs0hpPktdkutog7aySGuJEbe3XslNAcQxHl9-M_-2UMNysDn1s-Y2cA38L1fsov4WbwYh9IFeb4Q-4NowA=w1200)

My full size mock up of the lettering on brown background with varnish covering all...just a rough bit of plywood

(https://lh3.googleusercontent.com/gWF_Lw5zrYGmhVLFOnDTAbPkGtrjItL6fUVFRHoHETTwdTbgT5yMTYpd1zTpMgAIfcsKUtf3xTydkIBnVzuG2x-WKvqIZF8Gpy7oa9di4_v8oe1L-kcfogfKt3o25tqMT4AkIVbz5A=w1200)
Title: Re: Coach 9 - Official Work Thread
Post by: Bill Baskerville on May 29, 2018, 10:16:34 PM
Eric,

Looks great.  However, I am so use to the current green that the brown/green will take some getting use to. 

Nice consist by the way.

Bill
Title: Re: Coach 9 - Official Work Thread
Post by: Eric Schade on May 29, 2018, 10:19:48 PM
Bill, the brown has grown on me so that the green looks funny... that is what happens when you play with models!
Title: Re: Coach 9 - Official Work Thread
Post by: John McNamara on May 30, 2018, 01:06:48 PM
Very, very nice model and photograph. :)
John M
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on July 06, 2018, 10:33:34 PM
Here is what the seat side frame pattern is looking like so far.  This will be the top side pattern.  There are 17 separate pieces here, all loosely assembled on a base plate.  Many of the pieces required curves to be cut in two different dimensions.   Once this is glued up, all the features get added, such as the lips along the edges, the lettering and the feet. 

There will be a corresponding core that will form the underside of the seat frame.   There is a corresponding piece to each of the 17 pieces which will form the same parting line for the core, but looks like an impression of this top side pattern.  You can see the pile of them just to the left. 

This is the most difficult pattern I have done.  It has been a crazy amount of time so far -- over a hundred hours.  A lot of the time is set up, measuring and creating drawings.  I am trying to make it as robust as I can, since this will be used for more than a couple of seats -- 24 just for Coach 9. 
Title: Re: Coach 9 - Official Work Thread
Post by: Joe Fox on July 07, 2018, 04:31:02 AM
That looks awesome. Lots of fine craftsmanship there.
Title: Re: Coach 9 - Official Work Thread
Post by: Win Nowell on July 07, 2018, 09:51:24 AM
Now that is a piece of work - or should I say many pieces! The talent that the WW&F has attracted on all fronts is amazing! Imagine what could be accomplished if the winters didn't slow everything down. But then there has to be a time for rest and contemplation! Kudos to all for your accomplishments!
Win Nowell
Title: Re: Coach 9 - Official Work Thread
Post by: Bill Baskerville on July 07, 2018, 11:38:49 AM
Harold,

That is simply fantastic work.  Such patience and craftsmanship.  Our Museum is so very fortunate to have so many volunteers with such talent who are willing to devote so much time, energy and resources to the preservation of the WW&F and the Maine 2 footers. 
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on July 11, 2018, 07:54:34 PM
This will be another update on the seat pattern.  I will do it in a series of posts, so that I can upload pictures and stay under the limit. 

First picture:  This is the frame or skeleton that will become the core box.  It is ready to be glued to the 17 pieces that mate with the top side mold parts. 
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on July 11, 2018, 07:56:25 PM
Now this frame is placed on the assembly, with glue to attach it to the pieces it touches.   

(I assume everyone knows to click on the picture to embiggen, not the hyperlink below it.)
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on July 11, 2018, 07:57:03 PM
Now a side view of the same assembly.
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on July 11, 2018, 07:59:11 PM
After the glue dried (actually its epoxy, so it was an overnight cure), I cut 5 degree angles on all four sides.  This was not as simple as it looks, but I did it on a large bandsaw after a couple of different setup attempts. 
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on July 11, 2018, 07:59:59 PM
Then I attached 4 sides to the top half, to form the core box. 
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on July 11, 2018, 08:04:46 PM
Then I finally was ready to separate the two halves.   Shown first is the mold half, which will form the top of the seat frame.   Since this mating assembly as I constructed it, splits on the back surface of the seat frame, this mold will get built up by the thickness of the frame (about 3/16"), and also the side webs and other features will be added. 
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on July 11, 2018, 08:05:46 PM
This is the core box which will form the bottom side of the seat frame
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on July 11, 2018, 08:07:58 PM
Here is another view of the bottom side core box, with the seat frame sitting on it, so you can compare.   As you can see there are lots of features to be added to this. 

But the hard parts are done, and the rest will just take some time.    I promise to show the completed versions. 

Harold
Title: Re: Coach 9 - Official Work Thread
Post by: James Patten on July 11, 2018, 08:30:49 PM
In the Top Side Mold picture we see the lattice work, but don't you need the negative of that?
Title: Re: Coach 9 - Official Work Thread
Post by: John Kokas on July 11, 2018, 09:15:47 PM
I can't wait to see the first rough casting come out.  I hope you know there are tourist/historic lines that are looking for someone to make new seat frames for restored coaches.
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on July 11, 2018, 10:08:50 PM
Quote
In the Top Side Mold picture we see the lattice work, but don't you need the negative of that?

James, the pattern is a positive shape.  A sand mold gets made from this by packing sand around it, and then extracting the pattern.     Similarly, for the bottom side core box, it is packed with a special chemical curing sand, and extracted from the core box.  This sand core then drops in the sand mold made from the top side pattern.  The resulting space between the two will be the seat frame once filled with iron. 

 The way I am building this is --  that right now, if a mold and core was made from these two as shown, the net space is exactly zero.   So I add material to the top side pattern on the baseline form that exists now.  The lattice work is like that - I just set it on there for the picture.   I know this may not make a  lot of sense.  I keep having to make sketches to keep it all straight in my mind.    Maybe I should post one of those to better describe it. 

So - the lattice is a positive shape.   

Title: Re: Coach 9 - Official Work Thread
Post by: Steve Smith on July 11, 2018, 11:01:35 PM
Harold, what splendid work! Thank you so much for taking the time to explain.
Title: Re: Coach 9 - Official Work Thread
Post by: Carl G. Soderstrom on July 12, 2018, 12:19:48 AM
Beautiful work!!!

I am glad you know where you are going - I got lost shortly after the lattice.

The original helped.
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on July 12, 2018, 09:55:20 AM
Simply amazing work, Harrold.

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: Alex Harvilchuck on July 12, 2018, 01:45:45 PM
My shop just received an upgrade two days ago. It's replaces a circa 1908 version of the saw with a "new" early 1950's version. It will saw up to 34" wide and 18" thick. It cuts a might fine veneer also. Looking forward to maybe cutting some stuff for Coach 9 with it...
Title: Re: Coach 9 - Official Work Thread
Post by: Stephen Hussar on July 13, 2018, 06:57:42 AM
WOW.
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on August 03, 2018, 08:02:00 PM
I am adding all the details to the top side mold.  I thought this would be easier.  But many of the edge pieces have 3-D curvature, and I couldn't just bend them out of thin pieces.   For example, here is one of them.  I start with a cube that contains the part I want, and glue paper patterns to two sides.  I cut it on a bandsaw in one plane, then keeping the stack together, cut it in the other axis.   Here is the cube with all the cuts done.
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on August 03, 2018, 08:03:03 PM
Then the cube is separated into the three vertical stacks.   (the part I want is in the center of the middle stack).
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on August 03, 2018, 08:03:51 PM
Then the part I want is here.
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on August 03, 2018, 08:04:37 PM
It goes on the left side, as shown:
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on August 03, 2018, 08:06:53 PM
Here is the current progress.  Most of the edge pieces had to be made the same way.   Everything is just loosely placed at this point.  I will glue everything down once all the pieces are done.   All that remains on this part of the pattern are the edges to the legs, the feet, and the lettering. 
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on August 03, 2018, 08:32:23 PM
Very nice report Harold. You make it look so easy
Title: Re: Coach 9 - Official Work Thread
Post by: Carl G. Soderstrom on August 04, 2018, 01:37:06 AM
I have to look at it over and over in admiration.
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on August 17, 2018, 08:59:05 PM
Here is the final pattern of the back side.  It is complete other than finish (polyurethane).   I put the actual seat frame next to it for comparison. 
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on August 17, 2018, 09:03:42 PM
And here is the final front side pattern.   I added up my hours ... 230 so far for this pattern.  About a third of the time was measuring and creating drawings to work from. 

There are eight total patterns needed for the seat:
Aisle side frame - this pattern
Window-side frame - done - see earlier in this discussion
Two link arms for the seat back
Plate for the seat back attachment
Two different bottom plates for the linkage
Armrest

6 more to go...
Title: Re: Coach 9 - Official Work Thread
Post by: Richard Johnson on August 17, 2018, 09:15:11 PM
patience and skill. whs-at a great job
Title: Re: Coach 9 - Official Work Thread
Post by: Richard Johnson on August 17, 2018, 09:18:09 PM
see what happens when I see something great, my spelling goes out the window.
Title: Re: Coach 9 - Official Work Thread
Post by: Dave Buczkowski on August 17, 2018, 11:03:58 PM
I am in awe of your creativity and skills! We are very lucky that you choose to share them with the WW&F.
Title: Re: Coach 9 - Official Work Thread
Post by: Duncan Mackiewicz on August 20, 2018, 08:52:17 AM
Just curious, the lettering that can be seen within the 2 patterns appears "normal" and read-able. Shouldn't it be in reverse? Perhaps I'm missing something.
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on August 20, 2018, 09:04:40 AM
Looks great Harold.
Title: Re: Coach 9 - Official Work Thread
Post by: Benjamin Richards on August 20, 2018, 09:48:18 AM
Just curious, the lettering that can be seen within the 2 patterns appears "normal" and read-able. Shouldn't it be in reverse? Perhaps I'm missing something.
The back-and-forth of normal and reverse images for the casting process can be confusing, but this is correct. The wood pattern is what we want to end up with. Each pattern gets a frame ("flask") on top of it which is packed with casting sand. When the pattern is removed, the sand will hold the reverse image. The two halves ("cope" and "drag") are brought together to form a complete cavity into which the metal is poured. Since the sand image was reversed, the metal will be the "correct" way 'round, the same as the wood that initially formed the mold.

Title: Re: Coach 9 - Official Work Thread
Post by: James Patten on August 20, 2018, 10:08:33 AM
Harold, your name as pattern maker should be somewhere on that casting too.
Title: Re: Coach 9 - Official Work Thread
Post by: Carl G. Soderstrom on August 20, 2018, 03:21:56 PM
For sure Harold! WW&F too?

Is this something that could be sold to other restorers?

I did not mean the pattern but the finished casting.
Title: Re: Coach 9 - Official Work Thread
Post by: Bob Holmes on August 20, 2018, 07:41:20 PM
I would think so. How about MNG and their coach restoration?
Title: Re: Coach 9 - Official Work Thread
Post by: Duncan Mackiewicz on August 22, 2018, 08:02:28 AM
Thank you Benjamin for "waking me up". I wasn't thinking about using the wooden pattern to make a sand casting. My bad, should've put my thinking cap back on.
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on June 02, 2019, 09:15:43 PM
Hey all (or should I say y'all, being from Texas), I am going to post a series of updates on what I've been doing for the Coach 9 project.  I've got a lot to cover, so this may take me a few days to post it all. 

First an update on the seat patterns.   There are eight patterns required to make each seat, and I have completed all of them.  You've seen the main aisle side frame previously.

This is the finished window side frame pattern, top view:
(https://lh3.googleusercontent.com/kqmCB5F1xrpdpC_Sav1_-dHbJp_seTFxx8B7krLspinMOLBCMXZMIVRxGTvRjZrXUd4Rlq7gueiKKBUO7V_5vUQV2ZLKMG8nwBLaYBxPV7Bzikk2pTNp4WLwUKu1l7dhd0xbLdirOg=w1200)

Here is the bottom side core box, side by side with the bottom view of the original casting:
(https://lh3.googleusercontent.com/lRskmgQIMo-j3-oVQXT5bbnkAxOzJbsK3cgdjy7eGa0CcTW1kJNsygZ6L-nnBXuDVc39hNljWoCXQKSyjbqmtzdOzw-n95lFiExy3AV_rSqqfHuqT3hFhfm2If2fX5z2qa22Tme9Dg=w1200)

The seat back flip mechanism is a four-bar linkage.  Three of the links are the same for aisle and window side, with the base link that attaches to the seat frame being different. 

This is the pattern for one of the long links.  I did this on a mold board in a 2-up configuration, to help with production costs.  There are 2 per seat, and 24 seats per coach.  The other reason for a mold board, is that the pattern is split in the middle and each half is only 5/32" thick.   

First the top view of the link:
(https://lh3.googleusercontent.com/HtVCvZKbSs5TpeY1j44Xf_q7TBkusyFZStRpkJIP1CFNGGObGoRApxIR7zRddjJIb59eLR-oWx5l-EQ94h_xeIlvFDnYHqXZ8zfgVHSxppqCaMc86iiKQaSb99dTLaa5AQ9fWF01hA=w1200)

Then this is the bottom of the same pattern.  It looks like two pieces, but they are really for one link.
(https://lh3.googleusercontent.com/syB021t7cSXtYrmigsxWItlHdmU4T4wWJKkz4RJ6Y5EG5F0joc9cgh-outC-WhgAYzqr9PoPSNex4bknBBvzK1O1eiZ09zFQpoq1FGJZwB02_Rii_he83yV5Gshs1nY5_S8PjAH2xA=w1200)
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on June 03, 2019, 09:37:45 AM
This is the pattern for the seat back portion of the mechanism.

Top view:
(https://lh3.googleusercontent.com/gq_QXXHPCHkRnLrmZx8dQrx4dPigyluSUtloyW0t5lLuLzYbr8uGPYZv3VA13Y2dvcjpqEWQ1HJ1otljMpgElHDgrO7uGWsragOdsaPWqcQJrXoiQeSXgiraBHAcRVnbcBX9MlK45g=w1200)

Bottom view (this is the reverse side of the same mold board):
(https://lh3.googleusercontent.com/_fe1t4X9RazQYt5m9y16mHf3m80eUDl0JFd09XKw78-v-NcrEorAnlSX5GfSYoZFu8z0i7YLXc_k8TQMr6D9Fv2BUcGEugufxe2f62AvKlXHKNQjcs00IpcxYEHHP9HlSMrZCNwSRw=w1200)

The bottom links, that attach to the seat frames.  This is the reverse side of the links on the actual mechanisms in the picture.
(https://lh3.googleusercontent.com/E667IC_GGNefI9q7E0Nfp92fuVVEIi4ZHI0cGL51hUeZb3U9w9hgDgAf0VPRU72MP7HVN3o--DLTkonWNpOKab_3KuN6JAbIhwPkGpDAbBovJBvtWpEeJxAG0CUXUt3Jdo1kFZaqjQ=w1200)

And the last piece, the armrest.   I made two patterns and one corebox. 
(https://lh3.googleusercontent.com/-VYLhkyylmwUsUvADXCXGE8K-OYo1KwAZyV68iGCuMWlXwiMktnOOUiRdmIdaKh5069_HKHFdCsxsOmC6SWQ76fqgSdJGTwIpf9l0caFuT4vnaOityIooF4F-9kmmanFlapwvwNNHg=w1200)
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on June 03, 2019, 09:45:24 AM
Now some patterns for the coach.  These are all the castings required for the base frame.

From left to right:  Three core boxes and the pattern for the bolster truss rod casting, the center plate, the body support casting, and the queen post casting.
(https://lh3.googleusercontent.com/db9p0NRvTs8cyR-f6aju_EVtcDdwQOmO8zfL30PpCBblg9HotvpAvWGqR58WZiu-37OUIe-Ruped2mr-sXDmhIQCb-dfXFOigsGb1ah5k-vi6luF7vAMK-xmBNdaHREVpcCBKBXhdA=w1200)
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on June 03, 2019, 09:51:20 AM
Very nice Harold. More show pieces for future display.
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on June 03, 2019, 10:18:19 AM
But wait, there's more!

Now we need a few castings for the Jackson and Sharp reproduction trucks. 

From left, going clockwise:   The core boxes for the journal box, the journal box (this is a top-opening version as on coach 3), the female center plate for the truck, the bearing wedge (or shim), the bolster spring seat (locates the elliptical leaf springs top and bottom), the transom truss rod end plate, and in the middle, the transom truss rod seat.

(https://lh3.googleusercontent.com/WF4MaT6JqmPlSIQYJ4ohK1enxNUrRMHVN4WMA7eJpQCPcV8K16vcYuxiAOb5T8TLhRnvtaU2tTFfZUGhk1sGPKp276Jd1r18YnxaH_BLtsH9RFX8061oHiwrszXzOeP1MNCjRyFPNw=w1200)

The journal box lid (right) and its core box:
(https://lh3.googleusercontent.com/YgZHEdVCkLl90XuQGuL4PLJgEowQpce5mDjsN4uhD0LYa9UWebTncR-LqDp5yUjkMV8yxYCEwrtX9l835WnqhoarNJZrxgdUkwpJQZkUaDFY3r1eh7GeYQVxfwfPjZObu0V5EaB9_A=w1200)

Since we are reproducing the J&S trucks, we are using J&S brake heads and shoes, thus new patterns for those are needed. 

The brake head (top side of the mold board, note the 2-up configuration):
(https://lh3.googleusercontent.com/dHYe5jSeCc61S9dTmklxvhxCDlkSvy6lvJZfds-3FY7l7GQInEDE8TbIuTlyngjSc4-5DtP8bcGlINHHyN6X8inufP65rEG_Ch0uDeKq5G7cEhtVIhJ9Yrp7p2Vtn295HyEUoVvFAQ=w1200)

The bottom side of the same mold board, which forms the curved bottom surface and a pocket to accept the bolt head:
(https://lh3.googleusercontent.com/YX-VoEhTP0MMQhb_PXaE3ptRs0CpVrMO-MDY9E8tVzeE0AmiByZVs_5mMsmBKKqEFo_n0Cu2ORD1pLHVuELbKYQJzViop3HKdhLZiv2n_wr0yctzonOiPFvqxIqlz0K4hAP0O44oDA=w1200)

The brake shoe pattern is confusing.  This top side view forms the features above the back of the brake shoe, two locating ridges and a loop for attaching it to the brake head.  There is a core required to form the hole in the loop -- that's the wing-like thing going across.

(https://lh3.googleusercontent.com/jqYryH4tiqrhMWOJ-nM0x5tM7-KwbqYMfVrIwkZlYOuYBYi71ymMaKPRjTWNTHnUnxLXsxGfI3LgHjHP0URpH-fCcvhDCu-sQ9oxa3VKQBjCCDr-cpAimMPGCxmubd6txym47woUWQ=w1200)

The bottom of the same pattern -- this is the actual shoe portion.

(https://lh3.googleusercontent.com/cL0yNaS2TbnGuxNXDbrunVoDLkE3HI4msbADhDwN64LjCw08oRBPsDm4HNmFYlz8pT_sZckai-X0OLp5gybo_0wnfU_QdZSvfQgEbau5A1mnLwFfOdkHJa8sZQ48eQbALSNE86R3Dg=w1200)

There are two more patterns I intend to do for the trucks:  the truck side bearings and a new 2-up pattern for the brass bearings. 
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on June 03, 2019, 10:45:37 AM
Truly artisanal work.

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: Bernie Perch on June 03, 2019, 12:37:30 PM
Harold,

I am just blown away by your work.  It is difficult to imagine all the hours you have in your patterns.

Bernie
Title: Re: Coach 9 - Official Work Thread
Post by: Dave Buczkowski on June 03, 2019, 03:02:31 PM
Harold;
I think Bernie's comment says it all and is very, very high praise from a master patternmaker himself. We are not worthy!
Dave
Title: Re: Coach 9 - Official Work Thread
Post by: Wayne Laepple on June 03, 2019, 03:39:21 PM
I'll second Dave's and Bernie's assessment. Lovely work, Harold, just lovely. Cannot wait to see these patterns put to use.
Title: Re: Coach 9 - Official Work Thread
Post by: Carl G. Soderstrom on June 03, 2019, 04:24:59 PM
This is art that should be under glass!

As Mike said I hope there will be a display of all the patterns that are used.
Title: Re: Coach 9 - Official Work Thread
Post by: Bob Holmes on June 03, 2019, 07:43:17 PM
I would hope that we can market these castings to other heritage railroads replicating Jackson and Sharp coaches....
Title: Re: Coach 9 - Official Work Thread
Post by: Jason M Lamontagne on June 03, 2019, 08:29:24 PM
An issue and common misconception is that these seats aren’t necessarily “Jackson and Sharp” seats, they are Hale and Kilborn seats.  Both Jackson and sharp and Laconia bought Hale and Kilborn, the problem here is that this particular model of H&K seats are very unique in that they were only produced for a few short years, which happen to include 1894.  The more common H&K seats can be found in F&M coach 2, the Bridgton coaches, and pretty much all other Maine two foot walkover seat cars.

What we have here is the ability to recreate a very rare, intricate seat design.  Unfortunately, rare also likely means the demand is very limited.

Harold, the patterns are, of course, beautiful looking.  I’m sure they’ll work as well as they look!

Thanks
Jason
Title: Re: Coach 9 - Official Work Thread
Post by: Ed Lecuyer on June 03, 2019, 08:51:39 PM
Isn't there a larger-but-still narrow railroad out in Colorado doing some interesting coach rebuilds? Would the 1894 H&K seats be appropriate for those cats?
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on June 03, 2019, 08:58:26 PM
On to the next thing.  We have the J&S build orders for coaches 5&6 (1901) and the material specified for the body framing, as well as the sills and floors, was yellow pine.   Since yellow pine is not readily available in Maine, other than pressure treated, I decided to source the material here in Texas.   Eastern Texas and Louisiana are a major source of yellow pine from managed forests.    My plan is to prepare all the material for the body framing here in my shop, and then make a road trip and bring it all up to Maine this summer, along with the patterns.     

I special ordered #1 grade yellow pine 2x12's in 8', 10' and 12' lengths.    The reason for getting 2x12's is that they need to come from the best and biggest trees. and #1 grade to minimize knots.  None of the body framing is standard dimension lumber, so all of it will need to be sawn, surfaced and other milling done.    I picked up the order on May 17th. 

Here is the trailer load when I got it home:
(https://lh3.googleusercontent.com/a0xSfdaDnnGWtNfNKONDp4g0yyaxn915_owdnO09a7fbOnCr2_lHjsnKEiC7M4NWQLy2IAt5RAD5RELr4K4u8dpi8Q9fjBD4_KQbT-N-BPVpMLzlmyrHtQxsyfT4qbzJp8R-JtgAHw=w1200)

All the eight footers became this stack of 72 vertical frames (studs).  The final thickness is 1-1/8", and there are 9 notches milled in each, plus a tenon on both ends.   
(https://lh3.googleusercontent.com/HE6PLFEti_SHUQOP1jyo_VXjVqZD0irPj5_MjSajeocuHLR6rhM6s7WKqFRf2LggyU9TREiEVwCyCA3yTafKwwz6hFI-sDf4TCrULtHrZP4IEWBNJXPDqW3gmUTzpDXB5k6xRjN0LQ=w1200)

The studs are assembled into pairs with 5 spacer blocks between them, drilled for the vertical tension rods at each location.  There is one pair between each window, as well as one wide pair at one end of the coach.    After completing 160 spacer blocks and 320 holes, I started assembly of the stud pairs.  I used #12 flat head slotted wood screws to fasten them together.  I am thankful for modern cordless drill/drivers!

You can see the first few here:
(https://lh3.googleusercontent.com/ns5QJMqxNuN9VBqXp_tJr9SuHRxWzA-bV_Cd08--nxlpTMG40Scmn6jjAhE8wnTaOSsTqa_eRCzKODYFGpIcCf8nYiv3DQpVdLYC-4C-FlAc4eLH_WFrLJaKi4BwiOo9R3XsjLAVog=w1200)
Title: Re: Coach 9 - Official Work Thread
Post by: Bill Baskerville on June 03, 2019, 09:18:45 PM
Harold,
Most of us are still catching our breath from the professional, and artistic work you have completed on the seat patterns.  Then you come up with what looks like a laser cut kit for a J&S coach like we would put together for our model railroads.  I echo the previous remarks on your patterns, and I hope we can find a place in our new museum display area to show off your excellent work.
B2
Title: Re: Coach 9 - Official Work Thread
Post by: Stephen Piwowarski on June 03, 2019, 10:16:44 PM
Really fantastic looking work Harold! I'm impressed by the output and consistency. Did you make up a set of jigs for producing those studs?
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on June 04, 2019, 07:09:43 AM
What do you do in your spare time? Sleep? It seems like last month we (the board) just gave the green light for the wood order, and here you have the studs done, looking ready to be installed. Very nice work.
Title: Re: Coach 9 - Official Work Thread
Post by: Joe Fox on June 04, 2019, 07:14:01 AM
Such amazing work. Very impressive stuff, well done.
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on June 04, 2019, 08:08:17 AM
Fantastic work!

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on June 04, 2019, 08:11:37 AM
Isn't there a larger-but-still narrow railroad out in Colorado doing some interesting coach rebuilds? Would the 1894 H&K seats be appropriate for those cats?

Cats usually sit anywhere they want, so I doubt they would prefer one type of seat over another.  ;D (Sorry, I couldn't resist.) ::)

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on June 04, 2019, 09:33:04 AM
From Stephen P:
Quote
Did you make up a set of jigs for producing those studs?

Not really jigs.  Each cut was done with a fixed setup, then I would do all 72+ pieces.   The dado cuts used a sort-of jig:  the blade only cuts about 3/4" wide, so I made a spacer block just the right width for each setup.  I set the table saw fence so that the left edge of the desired notch was aligned with the left edge of the blade, and then made a spacer block the right width to go between the fence and the stud to put the blade at the right place to cut the right edge of the slot.  So I would do it with this sequence: first cut with spacer block (right most chunk), remove block, make second cut (left most chunk), then free hand the middle out. 

It still took a total of 16 hours to make all the cuts.  14 setups including the first length cut.   So it took just over an hour for each setup and running all the pieces through. 

Pattern making has really forced me to up my game for accuracy in woodworking.  I just take that to this job too.    I also spent a lot of time tuning my machines to be super parallel and square.  That really helps. 
Title: Re: Coach 9 - Official Work Thread
Post by: Steve Smith on June 04, 2019, 12:05:32 PM
Harold, the Museum is WWF.......wicked WICKED fortunate to have you doing this marvelous work!
Title: Re: Coach 9 - Official Work Thread
Post by: James Patten on June 04, 2019, 02:24:19 PM
The walls will be ready before we have big timbers to attach them to!
Title: Re: Coach 9 - Official Work Thread
Post by: Paul Crabb on June 04, 2019, 09:46:15 PM
Harold's work is just amazing!!!! As Steve Smith said the Museum is fortunate to have him doing this.
Title: Re: Coach 9 - Official Work Thread
Post by: Paul Uhland on June 04, 2019, 11:22:00 PM
This is super-precision factory work, right?  ;)
Amazing quality wood. Can't wait for assembly.

Go for it!

BTW, when will boxcar 67 get its metal roof?
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on June 10, 2019, 08:26:47 PM
Latest progress.   The curved roof beams are called carlines.   The top part of the roof is the "main deck", and the outer section is called the "clerestory deck."     

We need 41 main deck carlines, and 78 clerestory deck carlines.    I made a template for each of them out of 1/4" marine ply.  First I just traced the template on the stock (planed to 1-1/8" thickness) and cut them out about 1/8" outside the line.   Then the next step is to use a router with a top bearing flush-cutting bit to trim each one to the template.   

Here is the first one with the template attached, ready to trim and next to the stack of rough cut clerestory deck carlines. 

(https://lh3.googleusercontent.com/0MJdJEzU0F5I1S9gbX4PLAzVWtC_ME2lBuiRGAhgjCPvB7gOThT3ZvyqvrYUkin04vMH7LEzpm5Q8JymeVNsMKqc3EqwYcB1j1lg7ApzDl0_4ngjqSiqf4qofuHw-PzFLHUhbufxkQ=w1200)

The finished stack.   I started with 85 and ended up with 78, due to some of them warping too much after rough trim, and some due to router tearout.   I will need to make a few more to make sure there are some spares. 

(https://lh3.googleusercontent.com/_DkXLOsIzGVHGKWw0OzNKqrN8AWImzuxzHn1shLHUZS1Y78a6FRzbNAg_a2OxfxGUvXWVg7ktp41pFXYRtt30oRo2y8nQBSx1_saJFOmJS_YVSWH-_czLWCXoO99xuicQPsuwqycWA=w1200)

This is the rough cut stack of main deck carlines.

(https://lh3.googleusercontent.com/nC6WyO384VCihaMb3M5vJIQVKmmHSPp8shDxrFWB0MKw8QGoFiGS8zafrCyqUcoxxGFgsFhysu35dLjEeojRDg5KnKY5h6ywfFZCWLzunksyYbgbNDhq_bm9gT8lvLmSL_cZxhhL8g=w1200)

There was a bit of waste after cutting out the carlines.  This is what the pile looked like around my bandsaw when I finished. 

(https://lh3.googleusercontent.com/-9YX6LaUO36aHIDVBj4d4wp5Ms6o6KFy7PhLw-OaMUmyKVvkjbZqPd2X8x2MBgX62nCBRZ__RlW0B9mpXTOLKOk59BnnUOavz1e5wfLmjNVnlxDUtlTbnqxjBVTj8FD1fLJZcDgilQ=w1200)
Title: Re: Coach 9 - Official Work Thread
Post by: Wayne Laepple on June 10, 2019, 08:46:33 PM
Harold --

Will these main deck carlines be sistered to flat bar stock bent to the same curvature?
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on June 10, 2019, 10:27:44 PM
Wayne,  basically yes, but not every position.  There are "iron carlines" at every second window post.  The wooden carlines are spaced one at each window post and one in between  Thus, every fourth position gets an iron carline.  At that position, two wooden carlines sandwich the iron carline, and there are bolts holding them together.   

While the originals were probably wrought iron, and forged, we will most likely deviate and have them waterjet cut from hot rolled steel plate. 
Title: Re: Coach 9 - Official Work Thread
Post by: Joe Fox on June 10, 2019, 11:21:01 PM
Harold this is amazing craftsmanship you are performing at a remarkable pace. Keep up the good work. Very fascinating reading how each piece is made. You have really done a thorough job researching and documenting the process.
Title: Re: Coach 9 - Official Work Thread
Post by: John Kokas on June 12, 2019, 08:09:34 AM
Harold,

I will start off by saying this is only a theoretical question:  Using your process, how much of an effort would it be to create parts for two or three additional coaches?

Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on June 12, 2019, 03:16:21 PM
John,
I am not sure how to answer this.   The quick snarky response:  two to three times as long.     It is already as efficient as I can make it, since the setup time is minimized when you then run 40-100 pcs for each setup.   My planer is small and therefore slow, so that could be improved.  I think the RR's planer could do stuff faster.

Mainly it would take more volunteer labor to make it happen, which is the strength of this museum.   We need to capitalize on that.   I am enjoying doing this, but I underestimated how much work was involved.   It seems fast because I am working on this nearly full time.   

Once we complete coach 9, I think we will be in a better position to plan the next one.   We are learning many lessons already.   By then we will have worked out the best suppliers for raw materials, and probably will be able to improve things a lot. 
Title: Re: Coach 9 - Official Work Thread
Post by: John Kokas on June 12, 2019, 03:45:09 PM
Harold,  maybe I worded that a little obtusely, but you got the drift.  I can see a lot of sub-assembly work being accomplished in the "new" wood shop.  It becomes mostly a "right equipment and right people" to make it more of a production versus a one-of type of job.

BTW - I would have been disappointed if I hadn't gotten a "snarky" comment - this can be a rough crowd so I need to keep sharp on my correspondence.   ???
Title: Re: Coach 9 - Official Work Thread
Post by: Bill Baskerville on June 12, 2019, 04:34:54 PM
Harold,  maybe I worded that a little obtusely, but you got the drift.  ...BTW - I would have been disappointed if I hadn't gotten a "snarky" comment - this can be a rough crowd so I need to keep sharp on my correspondence.   ???
John, you are one of the more clever wordsmiths on the forum. We expect obtuseness from you and you are always sharp and don’t disappoint.
Title: Re: Coach 9 - Official Work Thread
Post by: John Kokas on June 12, 2019, 08:15:09 PM
Thank You Bill for your kind words,

I will continue to attempt to expand linguistic horizons of those who read the forum but only as long as my proclivity for profundity does not go to the point of being verbose.


That being said, I'll just shut up!  :o
Title: Re: Coach 9 - Official Work Thread
Post by: Bill Baskerville on June 13, 2019, 04:37:03 AM
...I will continue to attempt to expand linguistic horizons of those who read the forum but only as long as my proclivity for profundity does not go to the point of being verbose. ...
Eschew obfuscation.
Title: Re: Coach 9 - Official Work Thread
Post by: ALAIN DELASSUS on June 13, 2019, 12:05:28 PM
 or an issue of obfuscation  OK I get the hell out of that forum;
Title: Re: Coach 9 - Official Work Thread
Post by: Bob Holmes on June 13, 2019, 08:50:15 PM
Yeah, let's refocus on Coach 9...
Title: Re: Coach 9 - Official Work Thread
Post by: John Kokas on June 13, 2019, 09:03:12 PM
To get refocused, is there a particular piece of equipment that we still need in the wood shop to really help make it more productive?
Title: Re: Coach 9 - Official Work Thread
Post by: Ted Miles on June 16, 2019, 03:38:43 PM
This thread has mainly been about the wood parts of the new car. But what about the wheels? Does the project have a source for the wheels the car needs?

I follow the doings of the Friends of the Cumbres & Toltec Scenic Railroad in Colorado. They seem to be buying a lot of new wheels to go into their new or rebuilt trucks. They may have a good, that is reasonable source. My guess is that the eight wheels will cost $14 or $15,000? 

Ted Miles, WW&F Life Member
Title: Re: Coach 9 - Official Work Thread
Post by: John Kokas on June 16, 2019, 03:47:06 PM
I know both Wayne and I are constantly on the lookout for wheels and axles, but 20" wheels are a bit of a rare commodity.  Any help in locating stuff like this is always appreciated.  BTW - couplers, we're good on.
Title: Re: Coach 9 - Official Work Thread
Post by: Rick Knight on June 23, 2019, 12:53:20 AM
When Old Edaville quit there was a pallet In the Agway building where the big lathe was of new wheels and axles. I think I remember 8-10 new wheels and five new axles. That pallet made it to the MNG and I had is stored in the museum. Where is that pallet now, I don't know, but someone should ask around. Rick.
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on July 31, 2019, 07:49:59 PM
A few pictures to show some of the interim progress.   

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

(https://lh3.googleusercontent.com/r2pskZCshg1FJcMSsP7uX_itPgfTyGRd3_P-1EeZuEoNgaOjMY58wjgo-tt08aDo3JP4qc6otzBh3i8tLi_vwsPRv6wgXMNFdaQt4CyqhB_c2k1WVCX5NIm2MQefELsWgMGvR3ERvw=w1200)

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

(https://lh3.googleusercontent.com/E2Y1_bcP-nh2tIkzaEJsADjSvyDt5ZNbaWlNyCBmbZMaR0q8ugihZfE2vx8w02tBwObZIMqmnFo27xNlVbVLdxQ8-81xksmVOZUM2QRB8Ud0V0bWCw7pqpRLvNNagBqG6--X4V5FAQ=w1200)

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

(https://lh3.googleusercontent.com/CGWd_70eWKoxAqBK4zcJBpR927z8J76YjZc6mjtp3GybfF6JRpLN3kkWVsuouliwhcrDjFwTOUmohjRR5sUhA14mBepwMnMGKrR8xByhms2P411f77YXAeH9JfJoenkRaqAhQ2EP0g=w1200)

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

(https://lh3.googleusercontent.com/Vqs-OW214hsWSLDwIHF2wg82IgmMUMACqNQ-h1bxmO58T0DzHaQGjJrnx1-mxJcGRI3GQAw2cC6RbcSf9E0t87OI8so_wemAWVPnbx_6s6D1Ct4S9Mpb4pg-v6nygf0ohIUkegp_jQ=w1200)

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

(https://lh3.googleusercontent.com/LYZPFDQr4NgYcV-9u-cTf18TGeit2cmKde9-OhhGa2paZn6yyeYgbnFF8LDXiME0YpCDY3_fdZ_VIqZrO4278irqpuQsVdXnBG-iyETcbfCPmDz6qNtyW9pf9V0koZzorPQzwICbCA=w1200)

Here are a couple of shots of the fixture:

(https://lh3.googleusercontent.com/9bK_Vx_fp-Odl6HNFx6fslMIrWT47dzN9p9xRlUzrH-l8XWefnSIGZUIJJOoWS5l_SEhHnMGHvdUcuSjL_EqadM7bjD7VO85HjcXNd5KkMZYKmTlGFrpxIPZTVfh6XUMbtPRctuBiQ=w1200)

(https://lh3.googleusercontent.com/TVVMiarSkfcZxye7UXHkt9FcIRohqrRFd3cgsPvZhy6iczZpGQOWe83gPyg_HgndGoXU7eykYwUyRGC3VbvmBzivONqPxxB15-POGXbAPomfFL2h0XjBwgvqdicH1L7SQHHL2_Rimw=w1200)

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

(https://lh3.googleusercontent.com/R0OBPktgrn5qq8BaK1oKKKR9jRxgRMGOEygpfmkQBZ-PPhH0KStcxU30-FVxz-g6oRKCu6L6_M9oebK29YdpdOa4WM9jRo_GCPIzLdTSDPUcKeazdz6PJeEY6mvuRQwBsYNt9z3JkQ=w1200)

(https://lh3.googleusercontent.com/TE4ZJDQXem_CAYAD6QS-AKVNphAzImd8E6m9d5Kq7epZ0R30U30Sqoe69XB31kAhe4Dwnn2Hnfc6F63BiDIHzmhOcnwGerK3-8TljIH7Mcq2qFuysP5RlLHJWt9J90B8VdvVof1ViQ=w800)

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

(https://lh3.googleusercontent.com/Xtm_FOKF74SiuAeMiVrlfnQcErjMrgwsHTOUtPw5Ay8jG0Mk5G3KwvnbP47QdwibuZ9ogKjYG8HVsNLLSeOgZDewE19hcXGJiu_RZ0dZ4iM6qhHyFbyAtZQ0grQkdcgEwnOW1B9MDA=w1200)

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

(https://lh3.googleusercontent.com/erjZzloy7k9A34NHRF4kugCNUolGDtZ2GhRXBQvDaEoLgLMcDgKWZ9fdZEpfRdQBbNOUbSeyStNb6z7FhIDCK6urfS73qBy689Q49_Bqp9jd2jGmrKwgbIcLDgZyh8nGuNDgUEuyAQ=w1200)
Title: Re: Coach 9 - Official Work Thread
Post by: Wayne Laepple on July 31, 2019, 08:56:19 PM
More fabulous work.
Title: Re: Coach 9 - Official Work Thread
Post by: John Kokas on July 31, 2019, 09:04:38 PM
Wow!  For modelers this is kit-bashing to ultimate level, except this is the makings of a real kit!  Can't wait to see this go together,  :D
Title: Re: Coach 9 - Official Work Thread
Post by: Paul Uhland on July 31, 2019, 10:37:46 PM
The equivalent of fine cabinetry work.
Masterful!
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on August 01, 2019, 06:28:06 AM
We have seen that type of joint used in repairs of main stringers also. It holds very well.

Great work as usual Harold.
Title: Re: Coach 9 - Official Work Thread
Post by: Bill Baskerville on August 01, 2019, 06:35:10 AM
And I thought making the baggage doors for coach 8 was complicated. Well done Harold! You make it look so easy.
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on August 01, 2019, 08:25:15 AM
You are an artisan, Harold.

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on August 01, 2019, 09:33:15 AM
Thanks for the kind words.  I am enjoying it.   The weird thing is how accurate it needs to be.   Unlike house framing, where window openings are called "rough in" for a reason, the window openings in the coach framing are the actual window frames.  The window sashes are 1/4" narrower than the nominal openings, and there are leaf springs on the sides to keep them from rattling.  So at most there is 1/8" to play with -- over a 40 foot length. 
Title: Re: Coach 9 - Official Work Thread
Post by: Eric Schade on August 01, 2019, 02:01:36 PM
Very Nice Harold!  Looking forward to delivery of long stock for the car floor, should be soon!
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on November 27, 2019, 09:19:11 PM
According to a Facebook post, the long timbers for Coach 9 have arrived and are stored in the shop, between bays 2 and 3.
Title: Re: Coach 9 - Official Work Thread
Post by: John Kokas on November 28, 2019, 09:39:47 AM
Sounds like seat frame casting will have to come to the fore shortly.  Do we have a foundry in mind yet?  Also, do we have passenger car trucks for it or do we need to build those also?
Title: Re: Coach 9 - Official Work Thread
Post by: Bill Baskerville on November 28, 2019, 10:27:15 AM
We have a set of passenger trucks on the woods track, or set off the woods track beside the garage.  Although they may be earmarked for another project.
Title: Re: Coach 9 - Official Work Thread
Post by: Ed Lecuyer on November 28, 2019, 10:51:19 AM
We are building new trucks for the new coach 9.

There are plans for the "extra" trucks - which need to be rebuilt before use.
Title: Re: Coach 9 - Official Work Thread
Post by: Wayne Laepple on November 28, 2019, 12:54:23 PM
Harold Downey delivered a number of patterns for truck components to Cattail Foundry in Gordonville, PA shortly after the FWW. I expect a call any day now that they are finished. I believe Alan is to transport them back to Maine.
Title: Re: Coach 9 - Official Work Thread
Post by: Alan Downey on November 28, 2019, 04:32:01 PM
Oh yeah! I forgot that I was going to do that. Thanks for the reminder!
Title: Re: Coach 9 - Official Work Thread
Post by: Bill Baskerville on November 28, 2019, 07:10:21 PM
If you don't need them before spring, I can pick them up on the way.
Title: Re: Coach 9 - Official Work Thread
Post by: Alan Downey on November 28, 2019, 10:59:46 PM
Thanks Bill, but I've been meaning to get down and meet the folks at Cattail for awhile, and I set this up to finally make it happen.
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on February 26, 2020, 08:47:58 PM
While Eric is busy in Bay 2 starting the frame, I have been making the window sashes.   There are 30 sashes needed for the side windows, 4 in the ends that are narrower, and 30 clerestory window sashes.   In addition, I assessed the state of the windows in coach 3.  None of the main window sashes are original, and most need repair.  Not only that, they are either the wrong type of wood, or don't have the correct design features.    The end windows do appear to be original -- they are made of quartersawn white oak, and have the original anti-rattle springs on the sides, as well as a number stamp on one edge. One of the end windows is in poor shape, in the end where there was a fire at one point.    So we decided that as long as I was to go into production on one set of windows, I would also add 30 new window sashes for coach 3 sides, one end window, and 15 clerestory windows.   That led to a grand total of 110 new window sashes. 

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

(https://lh3.googleusercontent.com/U6wPG7sv6AaR6Sa5BJP04uB6fhsaf8V27Dd5qgUlOcR3op9y-tOL6sMctqfkOJb30k4zoIb17rtFqX63vqSNyNzSjTF_N52nguJYr55wJ4DouHv4iJgVjDAGvRztpd6nZfOIZe9aMgR9WihJbBm-qKviqgLakU5y6EIXs-UNs1o6fMVHLeHilknairZm6uJFLNUlegBJ3QMJFeQC4aAPhgYAxwWgf-6X5MmxrcOh8Tvt4c_1XoxFMml3JjvULjH3Q8K6QBWJ9VKELctKPinkOm74PaG70SUL2-d-YMAK5y3iepOqapW23NlDskA0L7deEe8QNv4jZ82iAod25OHck9xUg7zuPqU_U5z5tx-DZr-VuZJnc7w8tPeMY_ge9Qzozz0l4V1GQ8y9MXUT3Bl-2MBIHNwQSuiXY1YZSEFmhe1qVmU0jr2Kss2JKKpExRBRDD0fZlDt6MESbRaBTnCqhPTrolDMOgRiS-Dpgt6Kstk5bgyDbI81kCwK6fcw-A6_-5_nUjgE7l5pnbYZjM-fXP13CXBUcZck3BBBpfw6BQv-ebe13ZQADmIAjRPHyx-K4zLVk7jMi7AKJX7uRcE9dUFg1jX8mV5krQF9FBou8MtCJNcx2Jq1mky-L0uiX5Xoq1LjF9mt6gJWS_U6FpbJYOC8zUr_zRUKJu0TQ36-wS3zzU-Sw4cVy4WOMJw29bLnq8F3CjODDErvELtFr-0x9Qkyt6kCqfRb-sTP14Pl5A4HrI5F=w1429-h844-no)

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

(https://lh3.googleusercontent.com/thFAAI0YqcD0FPPGvW_LN2ASBDMx2AtmNmmFEcBUPnWQeelXpNPDUXo0z_S6BmO4L02npWgKUqwnpQB8Fg4VErOLONyhBsKaaRwdluzVdJCmnmQ9Tdd2p2AejUMjCPPlLPc8cQ9tj-sHJI3Xfw187mPU-TB6Zdo8VQZDmmX0wN3DOzTPO1HSP76-X8_4kgwggvHAG7SjFlldB8NqD18ZQ_CtWo5Pb4ry-fl0AdzUDp03nRtXVMiYjTrt3RoklrxLK9AVjeBVm0w7OKXJt1G99gHveobrNA-pkMSBznYCy1AOGJC_opiTOoE9cxB4v-arNxiKOzneX2j5ftMEq8XFh4UWGj1HLAng8wAg0fYNJd6R2sR-tkT2_HtQjI_7cwCVuQtDXrN6dra9FVbL_Z1NjRnXw5DZXaWr_cG28kdU6UtftwH0TAkXVQFHtY4cziKatbeS02i-pHqUY9cO1V_UnJ_-sxGvkSJozZm8n4J_VZPpa4b4sGhpev_NKeFAKC7GMbZyTtMTQzn9LxbhaLdB706BRODbzacgV5xgm2ALjJWl7gW0mT-xzhyuiewri4x21x4uqWZ7NmEDr1adWGYOr-4D1EC0-SRs1XYH5IA3ODLtHaw4vpm3FX-jDg-h5xTbHt4bKiEgLRY9A_QE08VSyxS6UG3_MBjIroF22xpSsw3e22KQHR7V0cXIvi6nJrzMW3eI2A2b3QhB8lh2ongRN0QXuDyjd11krJXYdNqCgLPp2vEK=w1031-h773-no)

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

(https://lh3.googleusercontent.com/4KG7FS7aJ3SbqaBue1a2LlC_NRxQBQRTXIfRrzUG8obvP0TFQz-H7cgrLUyXgWfVB0MZ6ZgiecLNrFE-0-9CwS94bhjoeGxpUuSYVy44vldCEbYZdHbB2fWzm-uqyM_bD5yI30HqKBWLjm0QzdcrM6RJsEM6RoMeJDIXb6TKrvgcw5LZQxUP0czySkbi71rJBAVSzdGxTggNoQLXFXfjGClyXGV4M1GLjrVoasOl2OmUShhZsdpMXVM75M7n_MhhM6ykkpmUNmdU0cZAPSZpVGpFkcPnTK7IK44vAyspDEnhq7odGw2C9_rofGdLsIMHcq2Tz9IWRQOlYenU-HwQ61YIr6335v9EHITiBs4dO7YD1LRKhn7OE-h-RDJtpSRmGT2VRwNnelB0Z_YeBJjUSpDOW4RX_mJhmF618KiAvpxe4dZkP36fSbnrGwBtU_oYZZ9oGtHcuyH6364YGKnnEvYIFID7cPVTTyhOyOzuWz4enfpvepX0Zhdhl2iWH84sr7uou4yTrAGi87a1cV1bYMa_tKrU-BExhGB-9wy_HqQKcl2PGE8mGybf81FfvbNrruVO5FxCsM0QjOZz4txOBK-mC5fOR9Jg65Wui8WUTlTN9r_-0NdFNM5olcA8juZb7F6HCQ1h0gjZJklsUdLxRtire4Nh7jQysvhyW2EHoCkUOUXzoOr3mGgVsPg8wySNOxNW-s5iA2yX9TYIFQiF5W5d0u8vUHGUTgc9rQX60_Tksv9y=w1288-h966-no)

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

(https://lh3.googleusercontent.com/aP55C6Bv19O7ScDOXjv7TmoKf_ajg00DRSLbEg4inf2-3t1QFJ1sN1GfJPG20MGypa2i0JTl09OSaI5d-fhqkAcGxFwXYQfeziktstiaq89QZ-hGzkybeeXYdP0IjloQJqFB5g6XXlO_1c2bw0vbt4N8ae8a9GDym4-bSGG-5xIz0oMGxEuUB4ra3XDVp034JH3YJrCb_PJp5efLOyi98pW6xt5kv6Ybl69Nt0sxtN1ZDz0DulHAyrvkupUruVaJgbZC4hD1EbEvDtjFZeWdExDCsTB6EiWb3312Hwv1-z3FfFCBtL4-iovqRNhGl2GnMcbcqPVlwrFYltAo9CcUrwrMI9aMVmi_mdBo1yr8EGnx1hjS-Yh8BaWRe1D8mGt_YNra-JxANn8w_duxBuCr5Fv5YoN4F4zPUf_Q4iQP9SgeItOUMCn03CySNsy7TxeTSfama4j2fm8qq8-Dc2YnVHW5foI-nm_weB5CDJ4uqRl4pYMKVilU4v9QGy6v2J7my0G2o31-UQ5DTV2b_lzm4KrrzfmZCq2fT2ygWdpn7YIGAmFSE_x36rfz0VMkzX9Ple_gSYNo9tBQ6rathkOZYNkzayPK59dKEfCRDpIqmnU1X9IF5I9B-VrCIKg_k5xHdTbCg7iSHQv7iIwpZR6T0FfaoiX3vL5hgudHE8gq-ec-WbK-Lg4jQInb5oDaNaUOWphxwtBTqfTNhh6NskbHX0eePpaVWZUK3-9_e_6C-liufz1K=w1031-h773-no)

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

(https://lh3.googleusercontent.com/w9GytUbp5WeOsAr_6nb-F2Lyr5Jbpve-RA7OLS9BMMss8J2acS6W3PcBBs1PE2YLSU87Ug7gg0YF_QvA_AyJtI5vARdE94ojzV1Cd3VnHymKxz2iVNbYzGe-G0bswI1GZmbv1QJsyjz3jF-Mt4nPgKDQrTkYFC48nFsY35vgHsnxltMNOdGOXqUoMMpLbBw0J2OEehxrw6m4-0IkprrgIwOG4HTN2nlEsUHAZLBjpGt2GiI6564vYowbOujZNZDWkGCm5M3YRg55MsLnUBLv6bEzAoj4takLBQls0Go5KK2Yfbs3Ra1OgWLub-H5rMkCH_2aS5kcfRPGIGxi0qJyDD0yXSZpL11pqP1WeuhT9fzQYk7TbmMPqEd-_JixD_V9OBlzvYHkjLeIaQgTcM8JtmaLOW2rKgNP5KLecoue5olbypnvB47y6G5_GYf-QPsyrG8Zq9jS11NEYYlIz4NCynuAcUplnLO16FmaS3n8gm_EU0sR51z229PhTZLgTUE_Bkxk5EXwadfqndRud4HOSlHrvT5orXCmUECYHQvJPsqNf1QTXEdHmV0wIzCCTA7ZKSr5qqUOLPyXLYUeFz_Nj2_Bk9K0UVEXtYbOI0OjLXarRTx11AeSeoE8jra2hXRq7KGqsUhhX7xt7LKw2XKpcJ7HjFVp3a-Gf9pMAh0ODBKrzEde3lZa4P5V87cD-FmUatVRImmoUU7q5fdjfe4A1RcdZV-DwT-PzuSaolrykvYcGasv=w1031-h773-no)

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

(https://lh3.googleusercontent.com/O6ihZJoGGJCo9TwKxjy4ZQJc_jYCU3E919zHEpQfkTifBRQNmVsoBRuynKcrJdlLm2nOGNQx3_iwP2v7gSDoR5IbZvpWgjID9r-820F7RkN6jkmDOja-quWAivoPgY8c44DkACOdPgpJibXtN23tarnn-snKTsMwgTHfpEP7D_kmvSP1_u4QUNeIeR8Xi8RSvGcOegImxTCiZ8RJ2N_5OcKGPRXA8zwylQgO9toO6_NoC4iXUMSsTF_ZYVZSPuuTWKYkMgRFnIebXYwEXUgcOxASfHaMkH9CbdF8RYn7tW6ok6fyW9OqeIeAFsupIFl_wb0ukiGtXxizANSFpTEfp8bHm_vgpNhjnCgxDmzcOGJ8AhK1ci4IlbKov_ODAKyfK-YR9hfWbuEaPpBBSYAgaZfJeD36vtarX8_AzKnnsnUpKyaF8pv5TMHMo7gPiruD-nfAFc9cMiCfWO5c9WcjnXb2tsO9D6OF0Sy0ifrfo_LUYDWHM0-X6EAK7zHPhLC-TQEJhl2GnWWaHBIMc4EUwx484Idcqyl9nXe0_QqxlYnAJW6FDO9kafiNw-l7eMhAZlWRfcHjY_Vqtuu-A1k1c_1SI5zPvxkcm18qRv0AThpOz9NgxvvGqFEhklH8BAVrEFs3u4JWc0ZfuFyh0hIG5NkzEGQl1vZoKw024cePL36GhLuyZbDUUZJJbBm9qPwBrejEooPDZstQE8kYtOdxaRXbt2tSXPUEtLHdwLP7Fy6tBLmj=w1031-h773-no)

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

(https://lh3.googleusercontent.com/w5WYFvT0hwSpcop3Ef4gpWeXBonLPEs6g-80_INLfgWMEhKTgFF-xPra9TNeM8vU74T7jiTO2JuAbwWG4nH_OH7rl29whopv-JYH8YzXI4WIif27IYHI9SuoaWOzT8fc5F4feIEAl1-a8e_bEGQIeFLIxrSLZi4_8wQeWm8z8kesxbb4hiwaLc2WK1Wqeo5pj4TC1ncJCLT4M2R13oTtYByfssK9MBTb5Tdkrtp2ZBFMLFHghluDjwfXuaGSXIVfcKZgc1S-0gZd8U4rdvmAa1zq2fWUBcLEhp5RbLPmzaHkaXbleNU3Xn6PvhrEIqOYREZHxQ2JaUCTQQgfXfRyL7UCwDd58EfU6XFrdaquPrANQNrrxPZPuwjFHhh5dOHlrwyIyjIAZsrjWyipcJU4X0lQM4C4CMlKde0-OVbqunr0n645nexbT51WMKzUm2pr8OkIsrej43CUs9MtGhtEcfCXiP9dLunsQ6QYtETNkuuByGkWOIv4kM6RQct1a067zOWN9LlvXMTI9gD6lywinisk2Lbmhdj6u7HHH2a8LNaKmZLcoYfsQYtgkfaSwEKYntN9t0UAZw-arjv07QXSChIaaY0ipjfxs7m7WaJl8JjjhcP7VjfUrEhZ2iXm_RSYX3aruN9xNPRmcXd3JCi6QQyGasik3CE_KKi0_1fVf6hn9o0bugZD7Td9dbO0dfzWxkIJT0u4o0v0MRuIv8JYpeZsPp37oKyVHQtOx0jTNIG4fJIX=w1288-h966-no)

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

(https://lh3.googleusercontent.com/DsTfdG-X_P6d3w2WRO3Z6bVNQ7VhD_z_IfXXKrBOfgeux1CaVV9YQTzJvsc2uLzOtQL8HQNZHu5GumPYFulccIRbyIs5VJPQIGL1atvcFq_Qo9xgQFd6R-eiMURmOAAu5Vo0cEPu0xT7XL_V05fMSB1jLZsP84BRdLRtO80vdkobfilGMrTZdD6urqPxByifF2QOCVatvby6Y1CG9UNxJEDAuREgO_8LvY9cXhkeughYgsYr0oF9hhhbGtBPjr4BT-4dB0zy-gsvMy8UQ0CAUsox4ipwupzp_4rQd-eGMfHw3FGRIx84w3NY1H9dlpsEHrYqHw31VlvQ-1TcP_kfYHicygYvGH_agYWjTskkPBx_YKOEtudA0F1YkLUgmi5fwiCXb7VB9Tbro-kCr-p94UXRBRNP7h76bGO1-_NSJZ6a0AHai743O1RZLE_3fibLIoJICaXOwW4HT-jp_MXrYOTR_PJ0erXKlQgnmazDSDsdQXSxbzN9A5Ljhsf4tfJhSogRvq5egONs2RJ_Xn_NLGVo2iEEIzSHeyOZYWA0r6yGTiKYoyt4lh3fgFdKvAxt8tQS9Olhm-57IgF4XEHQwzG1Tgm4hWFp6Z1ZN7S1pxCtUBBE8E7Vrd5XU3qvut33vp8d0QRr2DEYP4fGJJaflFdtgcZuAJWdNpi4Lfe-gMQIYIUjaZQgn9EQ7l_FIDCajLXY5DcYHPMh0kxahYuFo9bRPhumsHCp0jqdj8QhJg6Ocij5=w1288-h966-no)

Moving on next to the main doors....








Title: Re: Coach 9 - Official Work Thread
Post by: Gordon Cook on February 26, 2020, 09:17:48 PM
I was excited to see that Harold had posted an update, but then discovered I don't see the pictures.  :(

Is it just me or is anyone else able to see them?
Title: Re: Coach 9 - Official Work Thread
Post by: Wayne Laepple on February 26, 2020, 09:25:57 PM
No pics here, either. Of course, yours from the other day didn't appear either, Gordon.
Title: Re: Coach 9 - Official Work Thread
Post by: Gordon Cook on February 26, 2020, 09:27:33 PM
No pics here, either. Of course, yours from the other day didn't appear either, Gordon.
I was afraid of that. It worked for me but it was from Google pictures and that has happened before. I will see if I can fix that. Thanks.

(Clock ticking...............)

OK, I put the picture on ImgBB and I think it works now.
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on February 26, 2020, 10:08:32 PM
I think it's fixed now.  Other than the large size...
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on February 26, 2020, 10:16:00 PM
You certainly have been busy, Harold. It's impressive.

In the first photo, the edges of the boards are painted. Did they come that way, or did you mark them?

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: John McNamara on February 26, 2020, 10:16:29 PM
Gasp! The pictures are stunning!
-John M
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on February 26, 2020, 10:22:06 PM
Quote
In the first photo, the edges of the boards are painted. Did they come that way, or did you mark them?

Jeff S.

Jeff, that's how they came from the lumber supplier.  They paint the ends to keep them from checking (drying and cracking from the ends).
Title: Re: Coach 9 - Official Work Thread
Post by: Graham Buxton on February 26, 2020, 10:35:32 PM
Aside from the excellent work on the window frames, the next most remarkable thing I noticed was the [lack] of sawdust on the floor!  :)

Tip: if the right edge of larger  photos seem to hit the right margin of the forum frame, with many browsers typing [Control]- (hold down the Control key and then press the minus key and release) will reduce the size of the image and text. Repeat that process until all the photo is visible.  [Control]+ is the reverse (makes it bigger).
Title: Re: Coach 9 - Official Work Thread
Post by: Bill Baskerville on February 26, 2020, 11:16:46 PM
No pics here, either. Of course, yours from the other day didn't appear either, Gordon.
  I can't see the pix either.  just a big minus sign.  Any ideas?  I am using google chrome.
Title: Re: Coach 9 - Official Work Thread
Post by: Graham Buxton on February 26, 2020, 11:30:18 PM
While the other day Gordon's post in the February Work Reports thread did display a big 'minus' in place of the image, its working for me at this point. Link:  http://forum.wwfry.org/index.php/topic,3614.msg45044.html#msg45044 (http://forum.wwfry.org/index.php/topic,3614.msg45044.html#msg45044)

  If that is what you can't see, perhaps its a cache issue. Clearing your browser cache may fix that.   Or here is a screenshot ...
(https://i.postimg.cc/RNRKjD5x/Gordon-Screenshot-from-2020-02-26-22-20-20.png) (https://postimg.cc/RNRKjD5x)
(click image  to see larger)
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on February 26, 2020, 11:35:27 PM
It's acting weird.  I can't see them in incognito window, but can as guest in normal chrome window.  Let me try to fix it another way.   Sorry about that.
Title: Re: Coach 9 - Official Work Thread
Post by: Wayne Laepple on February 27, 2020, 12:14:51 AM
It's fixed for me, Harold. Gordon's is fixed as well. Great looking work. Will you deliver the sash in April?
Title: Re: Coach 9 - Official Work Thread
Post by: ALAIN DELASSUS on February 27, 2020, 01:51:03 AM
Well done Harold; All this woodwork must have taken you busy for a while, looking at your beautiful pics it seems to me  I can smell the nice fragrance of fresh sawed oak.
Title: Re: Coach 9 - Official Work Thread
Post by: Bernie Perch on February 27, 2020, 11:07:53 AM
Harold,

I am amazed at how you attack your projects.  Do you have time to eat and sleep?  The WW&F is blessed to have you as one of the amazing volunteers that are recreating the best part of the "good olde days" in Maine.  I wonder if in a previous life you worked for one of the car builders that made some of the varnish for the original two footers.

Bernie
Title: Re: Coach 9 - Official Work Thread
Post by: Joe Fox on February 27, 2020, 12:33:00 PM
Absolutely amazing work Harold. The countless hours that you, Eric, and a few others have spent in planning, studying, and now executing for this project is simply amazing. Well done to everyone involved. It is very amazing to see things starting to shape up.
Title: Re: Coach 9 - Official Work Thread
Post by: John Kokas on February 27, 2020, 02:29:20 PM
The next question is, after the learning curve of this project, how hard would it be then to construct another car or two?
Title: Re: Coach 9 - Official Work Thread
Post by: Anthony Vo on February 27, 2020, 03:47:29 PM
The next question is, after the learning curve of this project, how hard would it be then to construct another car or two?
more like why not construct another while y'all are at?
Title: Re: Coach 9 - Official Work Thread
Post by: Ed Lecuyer on February 27, 2020, 04:02:27 PM
The next major coach project is to do a full restoration on Coach 3. It is really way overdue for an overhaul.

After that, there have been various other proposals to construct replica coaches. However, these all pre-date the collaboration between the WW&F and MNG. Even with the new expansion of the car barn to an exhibit space, indoor storage will remain a premium. We may be better off focusing on non-coach projects for a little while.

Title: Re: Coach 9 - Official Work Thread
Post by: Graham Buxton on February 27, 2020, 04:31:49 PM
  ;D  Hmmm . . . The Pavilion roof isn't finished yet, but I seem to recall Mike saying that the Pavilion 'floor' hadn't been decided yet.   Is it time to consider a poured concrete floor with 'embedded' rails?  :P


Use the Pavilion for Events in the operating season, and car storage in the off-season.


 8)
Title: Re: Coach 9 - Official Work Thread
Post by: Ed Lecuyer on February 27, 2020, 04:59:41 PM
Dual use of the pavilion was considered, but deemed impractical - mainly due to placement constraints.

There have been some ideas floated around - but nothing is in the immediate works (except, of course, the roundhouse - which will help alleviate the storage crunch.)
Title: Re: Coach 9 - Official Work Thread
Post by: Wayne Laepple on February 27, 2020, 05:31:49 PM
There certainly are a multitude of non-coach projects waiting in the wings.
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on February 27, 2020, 06:35:45 PM
We could build a building a year and not have enough storage. Excellent work Harold.
Title: Re: Coach 9 - Official Work Thread
Post by: Fred Morse on February 27, 2020, 06:37:34 PM
We're not all COACH-men.
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on February 27, 2020, 07:06:31 PM
Merci, Alain!

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

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

Oh, and I won't be there for SWW this April.   I don't think the windows will be needed that soon.    I also want to complete the salon (toilet) walls and door as well.    Then I should have a big enough load to justify the drive again.   Or maybe I will just crate it all up and ship it freight. 
Title: Re: Coach 9 - Official Work Thread
Post by: John Kokas on February 27, 2020, 07:43:46 PM
Harold, sounds like you need some minions !!!  Beautiful work even if its a slough.
Title: Re: Coach 9 - Official Work Thread
Post by: Stephen Piwowarski on February 28, 2020, 10:29:27 PM
Harold- first and foremost great work and thank you for sharing an update on your progress.
Interesting about your trouble finding quartersawn white oak. In organ building we use quite a bit of white oak for casework, but also in the windchests and smaller dimension wooden pipes, because of it's strength. We used white oak specifically because it has closed capillaries which do not allow air to leak readily as opposed to red oak, which could leak air readily.

As for the quartersawn oak, that was specifically sought after for casework due to the appearance and aforementioned rays. Leonard Lumber, in Durham, CT was our supplier and we had good luck with them, but it's a bit far for you. Surprised it is hard to come by your way.

Steve
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on February 28, 2020, 10:58:20 PM
Stephen - they have q-sawn oak, but only in 4/4" thickness.  The selection in 4/4 is great.   In the rift sawn stacks of 6/4 and 8/4, I have been able to select what I need that is effectively q-sawn.  I should ask for a discount, because the folks that want true rift sawn don't want the rays, so what I take would not normally be desired. 
Title: Re: Coach 9 - Official Work Thread
Post by: Stephen Piwowarski on February 28, 2020, 11:15:18 PM
Ah, I understand! Not a bad idea to ask for a discount! ;)
Title: Re: Coach 9 - Official Work Thread
Post by: Pete "Cosmo" Barrington on February 29, 2020, 12:13:32 AM
BOO-NERDS!!!
BEEEEWWWWW!!!  :-* :-* ;)

(Sorry, ... had to)
Title: Re: Coach 9 - Official Work Thread
Post by: Philip Marshall on February 29, 2020, 12:40:15 AM
We used white oak specifically because it has closed capillaries which do not allow air to leak readily as opposed to red oak, which could leak air readily.

These structures are technically known as tyloses. They're lateral ingrowths of xylem parenchyma (often from the rays) that fill up the conducting vessels over the course of the first growing season after each growth ring is laid down. Tyloses are also why white oak is used for barrels and casks, which are never made from red oak if you want them to hold liquid, and why white oak tends to be more decay resistant than red oak - which is almost certainly the value of tyloses in term of evolution. You will often see old red oak trees with rotten hollow trunks, but white oaks are almost always solid even at hundreds of years old.

Harold, I'm amazed at your craftsmanship. Bravo!
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on February 29, 2020, 08:09:54 PM
Meanwhile, back in Sheepscot, this is the current condition of the frame. Marcel has also been working on the truck assemblies, but I did not get a picture of them.

(https://i.postimg.cc/D0p4zYh1/0229201457.jpg)

(https://i.postimg.cc/fW895kdk/0229201458.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on March 07, 2020, 09:15:12 PM
Marcel and company have been working on the truck frames..

(https://i.postimg.cc/vTnKShV7/0307201533a.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: Ted Miles on April 04, 2020, 04:14:10 PM
I just read in the newsletter that Harold Downey moved from Texas to Maine in order to be closer to the museum! Now that is what I can a dedicated volunteer!

Harold, Thank you so much for all that you do; the new WW&F #9 should have a brass plate somewhere to thank you. I know it would have been built later; but thanks to your shop and your skills it will be much sooner!
Ted Miles, WW&F Life Member 
Title: Re: Coach 9 - Official Work Thread
Post by: Keith Taylor on April 04, 2020, 04:46:58 PM
I just read in the newsletter that Harold Downey moved from Texas to Maine in order to be closer to the museum! Now that is what I can a dedicated volunteer!

Harold, Thank you so much for all that you do; the new WW&F #9 should have a brass plate somewhere to thank you. I know it would have been built later; but thanks to your shop and your skills it will be much sooner!
Ted Miles, WW&F Life Member
Ted...Harold’s son Alan moved to Maine...not Harold.

Keith
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on April 04, 2020, 06:10:05 PM
Yup, I'm still in Texas.  I completed the doors (two of them), here's a couple of pix:

(https://lh3.googleusercontent.com/MAeIJrl9BtfN2IGSuWUyLwNq0uIYkLSIoO5tlrRNbCRTkFSMvG639Yyigox6_hqveCXxlFUqy6ZLzNsDIDN5O-8W39y58iR8D4pA71jFCWushCeOe9ZrJJ2VGXJdVTSBocFet94oGbA8LwF-xfIJQVbDdhQgPWPKhzRptnJYjle5VkMXS4xwMj4Q_OZZexAcCz30fgQap8unx3HUUKUHWhvGW80nW1tgMEiZgsMn8EODYH2_oZ5_x4bSefGoUV5i1kQflSIDFywrU761EK2zVxojyw1Os4D1kjUqEP0YJYvqWs6c2wc8vcHuzzwEPWExnXPqhei74Enu5xyfv85kJxApc_l_Ds4YsQy3HneJTLmFSlsgYUdezqyf2Sa6M7oVHgHFj_7WUXBzFDdXSWEBSQ4-zHeyBwezosZmTLgswGN6BSNgp3SPDhkcNQvGCF0m3Ri5fvGjPERBStMk4InR0vIvATLRAym7dkSpBK3HgRJ2H6Zb4iiMZqBR5jz3ZRgTiMGePOL8AdTzKatTaK93n3SDHqoTU9PrdhN0KmYOJcFqNeQcIx6nGxV6m-HN5ZUYHoFif8xINyqVGUcqtwGpQqzQd-EDlFv_5Ig49xmAibiafTl-bztJWOiA7j48KtN2_kEVxLBxKvoBGt0ClwlKNwdIix12aaFV-4YOfBq-a7u6i6DvcJ-YTo2xSF4PErTxWy5wzCTjJ_XFzi_wjejSYPTg7DjWrdovjOmTzUOm9m7KN3fql4CoHw=w211-h586-no)

(https://lh3.googleusercontent.com/FdEPBCLDSd4eZY1ZgrCtLFS7wa4Jjr_ANOxWJyVDQsppi1e-o00I-zoW3q1DhNK4_QAM2_aHhqu9JPcHKSyjCFJsutbTVIi7V5ZOXMxz7qU8WrDBsnY5JrJNFddsalEMDWzaKAl1EBgnpbh4d4gdBZis6mtg409Q6Sg8FhBRfg121azV1uGRixaKkqixwA6SGxkgoT17xqRt5cquD18u9_PgOfbf9z9IhiPZ3m8Y3-Sn_YrKvmqoWd0LowQNhBq-_F9CmdAmjACskcBQctArrdoUqBTbNjLqGK05AcPFlzeVLreWgVOcP4_MzLRI3bih2ljuUcKOqd5gha37d0C9cm_JVmTJwv6AgjfW_Ax06TTYhdV5wNlsoHLlYFhEnOGrI0Kc6tTIyMf-hHkbjSFcWeem6xrQ1pFCZhRH8L7lzcXl_xHk_JMsRLebTbIczbSoilUPchyZW1QlNiqAVubNXZ2Bc02caplI2cf-jHETxvoYfC_9KDcN0fpM6__FfDIFykJqytRh6flYBv4ZZmPsF8sKLOTm3Q_V-gQub14yZ6UtfJJdJqU-ZR9QpEbc1O0fMwLOb9k_998NfrjXQBno4BWiuFmEgxVBSW8SElp8mf1QU5r_njoTTBVhu0z62_wPgkzHHEY6oKwwBtVi5i1W9BmEoDqpV5I1TEOp_8vEkwc1MUiSnLxLpXgIbYFAvP-MPJkf2FGI73n-_vYoOon4ZUGmVY0-PamAO4DOc0qQwGVTGczUPPwB4A=w1278-h586-no)

(https://lh3.googleusercontent.com/u5URpW2UZ_YtV9gPJeHTTKoAgZ90I0O4D7wjdDnFXbdJR8vNJp3Y7ykdthswh2ZLOigQ2V6t4D0nMEOqx2ebSrn2SN8lFSTVhduI504XV8kh5KZQXDvoXubBdwc0U5-mP_sPI5njAePGpUG0GkR6xXcRh-ciV9JtuRqty7i6LVDWCHBn5j1UZWN42PKuqn7TMx7Pj2wXn0EERTlrDKKx6-2FcN3j0wvpyehshsqrTzbZYSDfyhWw_AWPc43ekoeMJk340_cwqLn9ALCfwlJocCL4wF4OCJjFvQlayHEaA2OGUyEIS6YbCtpM23fyAPrwxzuZrv_cgDCCGD4TnZF0uqTU70Lbnk0Z_1CC0e39yI1Y9iDZFlhupUbmwrFgrhPLN9mVGwdiSxb6XF4ZdI27xOVHWQ28mKGRzMtoLo2JqBQwTTIXxSa-B3-UtfgE8EO8vcVZV3KghJDLgGYbVXSpQA2EEZA-IXKeq4dKj0zQ59DxLLNRUt3jtxYlMf28tZapoSvG6r_dyLoxpYB5Qta6M_ADlrovDlhToIpKWlQvuBjdNAd5YLYi6w6iKCxPeyYQZXZ7_NUsSsQa2SLV4DREE9to9joNl9TTvUckGrsvtxTLBmw1vKFb4bMQrPip6RjUfQHbctEOKzRobFJ2zFPgRT1ILbdJliPeJakimhUfg82IoQ_mpzROxLQPh6SjMMsOglVNiQj1krPAp0xUNUPv5zs8nG_1kqbgrpIGVHzSs77B13RD094LDQ=w1395-h482-no)

Title: Re: Coach 9 - Official Work Thread
Post by: Bill Baskerville on April 04, 2020, 06:12:47 PM
Harold,  You are truly talented, dedicated and a boon to our museum.  Thanks for all that you do.

Title: Re: Coach 9 - Official Work Thread
Post by: Bill Reidy on April 04, 2020, 06:48:43 PM
All I can say is WOW!

Thanks Harold.
Title: Re: Coach 9 - Official Work Thread
Post by: Stephen Lennox on April 04, 2020, 07:14:26 PM
Double wow! Harold those are some damn fine looking doors..... Thank you.

Steve Lennox
Title: Re: Coach 9 - Official Work Thread
Post by: James Patten on April 04, 2020, 07:26:39 PM
The door seems narrow - is it the camera distorting the image somewhat?
Title: Re: Coach 9 - Official Work Thread
Post by: Mike the Choochoo Nix on April 04, 2020, 07:58:00 PM
Those look nicer than store bought ones for a house.
Title: Re: Coach 9 - Official Work Thread
Post by: Graham Buxton on April 04, 2020, 08:14:54 PM
The door seems narrow -
Not to worry - its designed to go in a narrow gauge car!  8) ;D
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on April 04, 2020, 08:43:33 PM
Quote
The door seems narrow - is it the camera distorting the image somewhat?

The camera does make it look narrow, but it is certainly not wide.  21-7/8" to be exact.   Not quite up to ADA standards, I'm sure. :)
Title: Re: Coach 9 - Official Work Thread
Post by: John Kokas on April 04, 2020, 09:01:52 PM
Think of the bright side, it's about an 1 1/2" wider than the economy seats on some of the discount airlines.  :D
Title: Re: Coach 9 - Official Work Thread
Post by: Jeremy Jordan on April 04, 2020, 09:21:06 PM
That is some amazing workmanship!
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on April 05, 2020, 11:54:06 AM
Beautiful work, Harold.

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: Paul Uhland on April 05, 2020, 05:21:29 PM
Premium quality workmanship!!
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on April 05, 2020, 09:31:39 PM
Looking good
Title: Re: Coach 9 - Official Work Thread
Post by: Duncan Mackiewicz on April 08, 2020, 10:46:24 AM
Harold, as one who has done this sort of carpentry, I find the level of workmanship you have created to be nothing short of amazing. Your joinery on those doors is superb! I can't wait to see the whole project once it is at the museum where we all can see and enjoy your handiwork up close and personal.
Title: Re: Coach 9 - Official Work Thread
Post by: Ted Miles on June 22, 2020, 06:02:12 PM
Harold,
           If I recall correctly, the toilet room in the W & Q#3 is missing. But I have a drawing that calls for a toilet room in the #2 and #3. Are you planning to put them into the old and new passenger cars?

Ted Miles, WW&F Member 
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on June 22, 2020, 07:42:07 PM
Ted, you must be referring to the Salon (as shown on the J&S drawings).  It is definitely still there in #3, just no fixtures.  We are planning on replicating it exactly for coach 9.
Title: Re: Coach 9 - Official Work Thread
Post by: Carl G. Soderstrom on June 23, 2020, 12:25:10 AM
Exactly?
Title: Re: Coach 9 - Official Work Thread
Post by: Ted Miles on July 24, 2020, 05:11:26 PM
That picture on the museum's Facebook looks great! All the sills really look good; it is not easy to find top quality lumber these days; Is it yellow pine?

Ted Miles, WW&F Member
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on July 24, 2020, 07:05:35 PM
The sills were special order clear douglas fir from Viking lumber.  They had the wood shipped from the west coast, then milled at their location.
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on August 02, 2020, 07:33:36 AM
A shot of the framework as of yesterday.

(https://i.postimg.cc/25PkMzgX/0801201433.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: John Kokas on August 02, 2020, 08:03:52 PM
I hope a couple good coats of wood preservative goes on that frame before things get covered up....
Title: Re: Coach 9 - Official Work Thread
Post by: Paul Uhland on August 02, 2020, 09:17:42 PM
Good to see Coach 9 underway.
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on August 29, 2020, 11:28:27 AM
Current progress as of today, 8/29

(https://i.postimg.cc/446yvBpy/0829200754a.jpg)

(https://i.postimg.cc/JznhL8vH/0829200751a.jpg)

(https://i.postimg.cc/8CfP7H11/0829200752.jpg)

(https://i.postimg.cc/ZRrbc5B2/0829200752a.jpg)

(https://i.postimg.cc/kGs70Yyy/0829200753.jpg)

(https://i.postimg.cc/yYfVn5x1/0829200753b.jpg)

(https://i.postimg.cc/R0t4SZRh/0829200754.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on August 29, 2020, 07:00:25 PM
Simply impressive.

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: John Kokas on August 29, 2020, 08:31:49 PM
I assume wood preservative and/or primer paint will be applied prior to flipping the carbody and starting the upper works.
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on August 29, 2020, 08:59:06 PM
Fred was saying something about using the Copper Napth before flipping.
Title: Re: Coach 9 - Official Work Thread
Post by: Bill Reidy on September 27, 2020, 09:34:23 AM
Eric and Ron have been busy.  Here's a couple of photos of their work on the platform extension at the south end of the frame.
(https://i.imgur.com/MzXAH5h.jpg)

(https://i.imgur.com/pXGQFbs.jpg)
Title: Re: Coach 9 - Official Work Thread - Eric's video of the frame being flipped.
Post by: Stewart "Start" Rhine on October 29, 2020, 11:26:16 AM
https://www.facebook.com/eric.schade.186/posts/1462675090589831
Title: Re: Coach 9 - Official Work Thread
Post by: Bob Springs on October 29, 2020, 12:25:00 PM
NO WONDER y'all get so much done!
I watched the Facebook video and I have NEVER seen anyone work this fast!
LOL!   ;)
Title: Re: Coach 9 - Official Work Thread
Post by: ALAIN DELASSUS on October 29, 2020, 01:48:30 PM
That funny  and nifty video of course reminds me of the Mack Sennet ,Charlie Chaplin ,and Laurel and Hardy movies I enjoyed watching when I was a kid but  first and foremost it proves that the dedicated and skillful  WW&F volunteers in charge of the project work fast and efficiently.
Title: Re: Coach 9 - Official Work Thread
Post by: Brendan Barry on October 29, 2020, 02:07:07 PM
Pictures from yesterday.

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_2665.JPG?width=1920&height=1080&fit=bounds) (https://photobucket.com/u/bbarry74/a/5eea03cf-9481-491b-9315-6b0eef26b083/p/f000977f-c4c4-42e1-986e-a3ef236ca0ef)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_2669.JPG?width=1920&height=1080&fit=bounds) (https://photobucket.com/u/bbarry74/a/5eea03cf-9481-491b-9315-6b0eef26b083/p/87a059e0-ed73-4bc8-96f2-4b9e25d03f60)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_2673.JPG?width=1920&height=1080&fit=bounds) (https://photobucket.com/u/bbarry74/a/5eea03cf-9481-491b-9315-6b0eef26b083/p/dbe377a2-4250-4b46-9ab5-f43553019c0b)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_2675.JPG?width=1920&height=1080&fit=bounds) (https://photobucket.com/u/bbarry74/a/5eea03cf-9481-491b-9315-6b0eef26b083/p/6ec22afc-a4d1-4dc3-8c1e-48339de5af72)
Title: Re: Coach 9 - Official Work Thread
Post by: Ted Miles on October 29, 2020, 04:54:30 PM
What are the 1"x4" pieces next to the sills for? I would think they would be a water trap and cause the sill to rot.

Ted Miles, WW&F enthusiastic member!
Title: Re: Coach 9 - Official Work Thread
Post by: Stewart "Start" Rhine on October 29, 2020, 06:17:12 PM
They are nailer strips for the under sheathing.
Title: Re: Coach 9 - Official Work Thread
Post by: Brendan Barry on November 10, 2020, 08:33:15 PM
Walls started going together this week.

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_2755.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/5eea03cf-9481-491b-9315-6b0eef26b083/p/6bf5b43b-3757-4e9f-b3c6-d2666ef87201)
Title: Re: Coach 9 - Official Work Thread
Post by: Bob Holmes on November 10, 2020, 08:47:16 PM
WOW, thanks to Harold, it's now a kit assembly project!
Title: Re: Coach 9 - Official Work Thread
Post by: John McNamara on November 10, 2020, 09:25:51 PM
WOW, thanks to Harold, it's now a kit assembly project!
"Ages 40 and up"
Title: Re: Coach 9 - Official Work Thread
Post by: John Kokas on November 10, 2020, 09:38:40 PM
I think when this one comes together we (museum), are going to want another 2 or 3.  Better get those production lines ready Harold.  :)
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on November 11, 2020, 11:05:29 AM
Very impressive work.

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: Brendan Barry on November 13, 2020, 11:45:42 AM
More wall framing was up Wednesday.

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_2762.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/5eea03cf-9481-491b-9315-6b0eef26b083/p/21030f6b-a2a0-48a1-b64c-b91b82611dd4)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_2764.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/5eea03cf-9481-491b-9315-6b0eef26b083/p/d8c7439c-d7bf-4de6-b42d-6675ab6b1a38)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_2770.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/5eea03cf-9481-491b-9315-6b0eef26b083/p/df8e0948-4477-4349-bf8f-4cba7c1fa07a)
Title: Re: Coach 9 - Official Work Thread
Post by: Dave Crow on November 13, 2020, 11:58:52 AM
Are the top plates just temporary, as I thought the hood beams were continuous with the carbody?
Title: Re: Coach 9 - Official Work Thread
Post by: Bill Baskerville on November 13, 2020, 12:03:24 PM
Great work, it is really beginning to look like a coach.  Will the particle board floor stay or is it temporary?
Title: Re: Coach 9 - Official Work Thread
Post by: Brendan Barry on November 13, 2020, 12:17:57 PM
Are the top plates just temporary, as I thought the hood beams were continuous with the carbody?

I believe the top plates are permanent. The compression rods in the walls run through them.

Great work, it is really beginning to look like a coach.  Will the particle board floor stay or is it temporary?

The particle board is a temporary work floor.
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on November 13, 2020, 03:02:22 PM
It's coming along nicely. Bill B. beat me to the coach comment.

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: Brendan Barry on November 22, 2020, 10:42:00 PM
As of Sunday afternoon.

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_2824.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/5eea03cf-9481-491b-9315-6b0eef26b083/p/25327941-0ecc-4297-bf10-85521afe528e)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_2825.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/5eea03cf-9481-491b-9315-6b0eef26b083/p/7c0d1d69-8439-4d4d-9ac7-37fce983ee0a)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_2826.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/5eea03cf-9481-491b-9315-6b0eef26b083/p/cec126f4-c497-42c0-a111-f113e18bb887)
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on November 23, 2020, 05:52:56 PM
Simply impressive.

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: Brendan Barry on November 26, 2020, 09:01:23 PM
More framing done on the coach body.

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_2843.JPG) (https://app.photobucket.com/u/bbarry74/a/5eea03cf-9481-491b-9315-6b0eef26b083/p/a57e718e-5a98-4365-920f-8670fb5739bd)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_2844.JPG) (https://app.photobucket.com/u/bbarry74/a/5eea03cf-9481-491b-9315-6b0eef26b083/p/e0801558-217d-4105-b123-f5d958dac280)
Title: Re: Coach 9 - Official Work Thread
Post by: Bill Baskerville on November 26, 2020, 10:01:48 PM
That is an amazing amount of very fine craftsmanship and detailed work.  it seems a shame that we will cover it up with sheathing. 
Title: Re: Coach 9 - Official Work Thread
Post by: Bob Springs on November 26, 2020, 11:52:57 PM
Am I seeing a steel subframe for the roof structure?
Title: Re: Coach 9 - Official Work Thread
Post by: Carl G. Soderstrom on November 27, 2020, 02:29:57 AM
A B&W photo of a side view would be Fine Art.
Fine Art of Fine Art?
Title: Re: Coach 9 - Official Work Thread
Post by: Graham Buxton on November 27, 2020, 09:05:21 AM
Am I seeing a steel subframe for the roof structure?
Yes, here are comments by Harold on that subject:

Wayne,  basically yes, but not every position.  There are "iron carlines" at every second window post.  The wooden carlines are spaced one at each window post and one in between  Thus, every fourth position gets an iron carline.  At that position, two wooden carlines sandwich the iron carline, and there are bolts holding them together.   

While the originals were probably wrought iron, and forged, we will most likely deviate and have them waterjet cut from hot rolled steel plate.
Title: Re: Coach 9 - Official Work Thread
Post by: ALAIN DELASSUS on November 27, 2020, 11:46:37 AM
 The skill you display and  speed you are working are both downright amazing. Thanks Brendan for the pics.
Title: Re: Coach 9 - Official Work Thread
Post by: William Simonton on November 27, 2020, 06:42:03 PM
Now the WW&F needs to start planning to frame another Coach for display without the sheathing so that visitors can see the expertise and craftmanship that went into late 19th and early 20th century passenger cars.  That would fascinate almost all visitors (except those under 4 or 5).
Title: Re: Coach 9 - Official Work Thread
Post by: John McNamara on November 27, 2020, 06:54:07 PM
Now the WW&F needs to start planning to frame another Coach for display without the sheathing so that visitors can see the expertise and craftmanship that went into late 19th and early 20th century passenger cars.  That would fascinate almost all visitors (except those under 4 or 5).
Maybe a digital slide show of Coach 9 construction  broadcast by our on-campus WiFi?
Title: Re: Coach 9 - Official Work Thread
Post by: Bill Baskerville on November 27, 2020, 06:55:47 PM
William has a great idea.  Perhaps we don't need to build a whole coach, but just from the platform back to just behind the truck at that end.  That would show the more complex parts.  Most of the rest is just a repeat of that section.
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on November 28, 2020, 08:48:59 PM
(https://i.postimg.cc/qRSRwpzc/1128201626.jpg)

(https://i.postimg.cc/mZ1hD15m/1128201626b.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: Brendan Barry on December 11, 2020, 06:14:15 PM
Coach 9 progress.

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_2864.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/5eea03cf-9481-491b-9315-6b0eef26b083/p/98b03f47-f2a4-4e35-9056-c010e53108b4)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_2868.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/5eea03cf-9481-491b-9315-6b0eef26b083/p/be3ddcbf-f56d-443a-ad4b-0bb507edd749)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_2870.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/5eea03cf-9481-491b-9315-6b0eef26b083/p/f2cae019-b342-46f2-85b0-48a60677c9e0)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_2903.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/5eea03cf-9481-491b-9315-6b0eef26b083/p/cce21c9a-6d71-40d8-ba69-ae033e7aa970)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_2906.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/5eea03cf-9481-491b-9315-6b0eef26b083/p/85cf90c6-f437-4a83-8d74-eb77fb4d80a3)


Title: Re: Coach 9 - Official Work Thread
Post by: Bob Springs on December 11, 2020, 06:28:39 PM
WOW! 
Just, "wow"!





















Title: Re: Coach 9 - Official Work Thread
Post by: Bill Baskerville on December 11, 2020, 06:54:28 PM
Impressive!!!!
Title: Re: Coach 9 - Official Work Thread
Post by: ALAIN DELASSUS on December 12, 2020, 03:29:22 AM
Mind-boggling progress.
Title: Re: Coach 9 - Official Work Thread
Post by: John Kokas on December 12, 2020, 10:44:37 AM
Where can I order at least two or more of these "kits".  Beautiful !!
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on December 12, 2020, 03:24:32 PM
Simply amazing. How much more framework is there to do?

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: Ted Miles on December 13, 2020, 11:40:14 PM
Jason,
          Will the new passenger car get vacuum brakes? Or is that just for the #9?

Ted Miles, WW&F Member and narrow gauge fan.   
Title: Re: Coach 9 - Official Work Thread
Post by: Graham Buxton on December 14, 2020, 12:21:26 AM
Jason posted this several weeks ago ....

Eventually all cars will be vacuum brake equipped.  There are no specific plans for 67 right now.  We are focusing on the most frequently used cars first- and even that comes after system testing and refinement, which is what we are doing now.

Thanks
Jason
Title: Re: Coach 9 - Official Work Thread
Post by: john d Stone on December 15, 2020, 01:54:44 PM
Absolutely beautiful!
Title: Re: Coach 9 - Official Work Thread
Post by: Brendan Barry on December 19, 2020, 05:48:48 PM
Pictures from this afternoon.

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_2955.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/5eea03cf-9481-491b-9315-6b0eef26b083/p/29d677b5-abac-4916-898a-3710aa4c53d7)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_2959.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/5eea03cf-9481-491b-9315-6b0eef26b083/p/75e3ccf7-e90f-4709-99d8-b3135138bc20)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_2960.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/5eea03cf-9481-491b-9315-6b0eef26b083/p/ed2b888e-ec00-4b4d-954b-41e4b9d402f1)
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on December 19, 2020, 07:29:16 PM
A couple more I took this morning. Showing some detail..

(https://i.postimg.cc/pr7WGP5z/1219200806a.jpg)

(https://i.postimg.cc/8knzPmXc/1219200806b.jpg)

(https://i.postimg.cc/yxW6yDx7/1219200807a.jpg)

(https://i.postimg.cc/76KYz3xB/1219200807b.jpg)

(https://i.postimg.cc/ZRb507hB/1219200807c.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on December 20, 2020, 11:14:18 AM
Impressive.

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: Mark Spremulli on December 20, 2020, 06:57:18 PM
Are you going to make molds of original seats and use them or build new ones of your own design? Anyway great work.
Title: Re: Coach 9 - Official Work Thread
Post by: Graham Buxton on December 20, 2020, 08:05:06 PM
Are you going to make molds of original seats and use them or build new ones of your own design? Anyway great work.

There are photos of Harold's great work in making casting patterns for seat parts earlier in this thread here:
http://forum.wwfry.org/index.php?topic=2944.105
(scroll down slightly after that link loads)
Title: Re: Coach 9 - Official Work Thread
Post by: Benjamin Richards on December 21, 2020, 10:29:36 AM
Looking through these photos, there's something very poetic about one car taking shape for the first time, while another is being disassembled for the first time, simultaneously under the same roof.
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on December 22, 2020, 09:22:54 PM
(https://i.postimg.cc/4yPwBgvX/1222201449.jpg)

(https://i.postimg.cc/9XYxWG6s/1222201450.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: Bill Baskerville on December 23, 2020, 01:42:35 AM
The assembly of the coach 9 kit continues to impress!
Title: Re: Coach 9 - Official Work Thread
Post by: Keith Taylor on December 23, 2020, 01:20:53 PM
The assembly of the coach 9 kit continues to impress!

Wow! I didn’t know La Belle made them quite this big!

Keith
Title: Re: Coach 9 - Official Work Thread
Post by: John McNamara on December 23, 2020, 02:07:23 PM
Wow! I didn’t know La Belle made them quite this big!

Keith
"For ages 50+"
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on December 23, 2020, 05:04:05 PM
A real Craftsman's kit.

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: John Kokas on December 23, 2020, 05:18:14 PM
And folks wonder why I said to purchase (2) two more kits.  This car is going to look magnificent when completed.  In fact I wouldn't be unhappy if we ended up with a fleet of 6 based on future expansion and ridership increases.
Title: Re: Coach 9 - Official Work Thread
Post by: James Patten on December 23, 2020, 07:00:59 PM
Jason's hoping for the "matched set" - Coach 3 and 2/9, and a replica of the baggage/mail/express car 1.  Put a bathroom in express car for longer-distance trips.

Another replicated pair of 2 and 3 makes sense.

Eventually we should build our own parlor car.  Why?  A) save the Rangeley for special/historical events, and B) people want a special/premium experience.  And, C) eventually the Rangeley will go back to Portland.
Title: Re: Coach 9 - Official Work Thread
Post by: John Kokas on December 23, 2020, 09:12:47 PM
I would agree with a "Rangely" style parlor car.  For simplicity, use the same shell as 3/9 and just modify the interior.  The only thing we would need to pattern is the parlor car seat frames from the Rangely and find similar light fixtures.  But before we take on a car of this type we should have all our "standard" cars completed first as they will be used on a consistent basis.
Title: Re: Coach 9 - Official Work Thread
Post by: Ted Miles on December 26, 2020, 06:36:57 PM
folks,
         The clerestory roof frames look very close to the bay ceiling. Are you going to be able to finish the roof planking in the Engine House? I assume it will be stored in the Car Barn, when not in use?

Ted Miles, WW&F Member
Title: Re: Coach 9 - Official Work Thread
Post by: Bob Holmes on December 26, 2020, 08:14:02 PM
Way back in my modeling days, I built a whole San Juan Express from La Belle kits!
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on December 27, 2020, 02:34:12 PM
Way back in my modeling days, I built a whole San Juan Express from La Belle kits!

That is an impressive accomplishment, Bob.

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: Brendan Barry on December 27, 2020, 06:53:56 PM
Pictures from today.

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3029.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/5eea03cf-9481-491b-9315-6b0eef26b083/p/fcb7ba1b-d598-4309-a233-524182e4dcdf)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3032.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/5eea03cf-9481-491b-9315-6b0eef26b083/p/3f80618c-cdf7-4f5b-88a2-75278090c4c1)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3036.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/5eea03cf-9481-491b-9315-6b0eef26b083/p/dcd2390b-1cf1-4107-94b5-0bbf70b8868d)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3039.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/5eea03cf-9481-491b-9315-6b0eef26b083/p/941b8fb3-f67a-4e2a-9401-a9d24a8e293a)
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on December 30, 2020, 09:17:46 PM
Eric and Ron working on the window framing. This will run the length of the carn

Eric working inside

(https://i.postimg.cc/BvWN0fTB/1230201401.jpg)

While Ron works outside the car on the other piece.

(https://i.postimg.cc/tCM2Bx7f/1230201401c.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on January 05, 2021, 08:04:29 PM
A few shots from today

(https://i.postimg.cc/j5chpM3b/0105211345b.jpg)

(https://i.postimg.cc/Hk8Br4nw/0105211345c.jpg)

(https://i.postimg.cc/2jTHMSgZ/0105211347.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on January 06, 2021, 10:03:08 AM
Simply impressive.

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: Ted Miles on January 08, 2021, 04:51:55 PM
Folks,
         The top  of the car looks to be close to the ceiling of the shop in the pictures. Will the car have to be moved outdoors to get the roof installed? And what size will the new wheels be?

Ted Miles, WW&F Life Member
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on January 09, 2021, 09:45:51 PM
Hi Ted.
The car will fit. It is sitting slightly higher on the blocks than it will on the trucks.
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on January 14, 2021, 08:34:57 PM
Looking to see what I could find to take a photo of on coach 9, and found these corners. Note the block plane. I think these are all done by hand.

(https://i.postimg.cc/rppqKNRy/0114211047.jpg)

(https://i.postimg.cc/HLPd58bw/0114211047a.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: Stephen Hussar on January 15, 2021, 06:45:11 PM
What else is there to say, but wow! Thanks Mike and Brendan for taking and posting these great pictures!
Title: Re: Coach 9 - Official Work Thread
Post by: Bob Holmes on January 15, 2021, 08:04:31 PM
Maybe a post from Eric about how they actually did these to such perfection??
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on January 15, 2021, 08:30:03 PM
They did a 45 deg cut, then two passes at 22.5 degrees on the table saw.  Followed up with jack plane to bring down the peaks.  Finally, sanding with a form at the correct radius. 

ETA:  That clear douglas fir makes some real pretty corner posts. 
Title: Re: Coach 9 - Official Work Thread
Post by: Graham Buxton on January 15, 2021, 09:28:56 PM
I'll admit that I wondered if a "jack plane" was some kind of specialized plane for rounding corners.  :)

But no, a jack plane (https://en.wikipedia.org/wiki/Jack_plane) is just an ordinary flat bladed plane. 


So, between the jack plane and the curved sanding block, a lot of plain ordinary hard 'hand work' to get the right curved profile. ;D   Nice job!!
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on January 16, 2021, 07:19:52 PM
Here is the answer to the question how the shape was achieved. The block on the top is a sanding block.

(https://i.postimg.cc/cCGNTj0s/0116211251.jpg)

And here is a before planing piece.

(https://i.postimg.cc/sXhrYyF6/0116211252.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: Bob Holmes on January 16, 2021, 08:59:44 PM
Mike, you are always so helpful at revealing WW&F mysteries...

Thanks.
pg
Title: Re: Coach 9 - Official Work Thread
Post by: James Patten on January 16, 2021, 10:17:11 PM
There was a question as to whether the car would fit inside Bay 4 for work once it got on its wheels.  Zack did some careful measuring and he thought that it would - but without the smoke jack.
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on January 21, 2021, 06:53:11 PM
Test fit of the quarter round door trim..

(https://i.postimg.cc/Mpmwh7qm/0121211302.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on January 22, 2021, 10:51:48 AM
Looks like they fit pretty well. Thanks for the continued photo update.

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on January 29, 2021, 08:10:59 PM
Headache boards being fitted..

(https://i.postimg.cc/Y9B9dgTF/0129211506.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on February 05, 2021, 08:58:34 PM
End framework and pieces . top photo is one end glued and drying

(https://i.postimg.cc/Mp9R8R9Q/0205211057.jpg)

(https://i.postimg.cc/ZKh6PJ9C/0205211058.jpg)

(https://i.postimg.cc/DydLBRs5/0205211058a.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: Ted Miles on February 14, 2021, 04:59:06 PM
While all this great wood work is going on; is anything happening about trucks for the car? I guess patterns for Jackson & Sharp trucks will be needed. And then there is the matter of new wheels.

Ted Miles, WW&F Member
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on February 14, 2021, 09:16:24 PM
Wheels have been ordered, and axles have been completed, just awaiting pickup. Steel to complete the trucks will be ordered soon. Trucks will be completed before the car is, which is expected to take the rest of the year at least.
Title: Re: Coach 9 - Official Work Thread
Post by: Wayne Laepple on February 14, 2021, 09:39:41 PM
Castings for the truck frames were made at Cattail Foundry using patterns from Edaville/Maine Narrow Gauge.
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on February 27, 2021, 09:02:18 PM
More progress. Not as impressive as seeing it in person.

(https://i.postimg.cc/YS5WvHfY/0227211404.jpg)

(https://i.postimg.cc/RhVVFs8w/0227210749c.jpg)

(https://i.postimg.cc/kXHXJyyt/0227210749b.jpg)

(https://i.postimg.cc/T172WjMF/0227210749a.jpg)

(https://i.postimg.cc/wTMjYrDp/0227210749.jpg)

(https://i.postimg.cc/NGpjVt9D/0227210748.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on February 27, 2021, 09:22:55 PM
Looks pretty impressive from here.

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: John Kokas on March 01, 2021, 08:52:36 PM
As the car interior is being finished, has there been any decision whether the interior lighting will be original style oil lamps or electric ?  If it's oil lamps, do we know what manufacturer / style that was used on the original cars?
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on March 06, 2021, 10:05:03 PM
More sheathing of the roof..

(https://i.postimg.cc/dQTzww3w/0306211523.jpg)

(https://i.postimg.cc/15Dhcs1J/0306211524a.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: John McNamara on March 06, 2021, 11:26:10 PM
As the car interior is being finished, has there been any decision whether the interior lighting will be original style oil lamps or electric ?  If it's oil lamps, do we know what manufacturer / style that was used on the original cars?
Did any of the two-footers use Pintsch gas?
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on March 13, 2021, 10:03:00 PM
More roof sheathing done..

(https://i.postimg.cc/gJRnRD42/0313211817a.jpg)

(https://i.postimg.cc/q7NtB03n/0313211822c.jpg)

(https://i.postimg.cc/cJPvrjRz/0313211822d.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on March 14, 2021, 10:40:34 AM
Fantastic work!

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: Brendan Barry on March 14, 2021, 05:10:13 PM
Eric and Ron at work last week.

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3324.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/221b530d-2521-4f37-b301-0e1bb1a682cd)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3341.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/2671314d-497e-4145-b12a-f155e5d5a4bf)
Title: Re: Coach 9 - Official Work Thread
Post by: Bill Baskerville on March 14, 2021, 05:29:33 PM
Oh Eric, please don't make the head knocker so strong.....
Title: Re: Coach 9 - Official Work Thread
Post by: James Patten on March 14, 2021, 06:32:35 PM
Oh Eric, please don't make the head knocker so strong.....
Too late...
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on March 14, 2021, 06:35:19 PM
How do you know this, James?

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: James Patten on March 14, 2021, 08:31:04 PM
I tried talking Eric into a higher head piece.  He said actually our station platforms are too high, these cars were built assuming that people would step up into and step down out of them.  There's plans (not very far along) to lower the Sheepscot platform.
Title: Re: Coach 9 - Official Work Thread
Post by: Ed Lecuyer on March 14, 2021, 08:49:39 PM
I have concern that heads will get bonked when stepping between coaches. My head appears to be within striking distance of the vestibule overhang. I'm 6'.
Title: Re: Coach 9 - Official Work Thread
Post by: Wayne Laepple on March 14, 2021, 09:12:33 PM
Even though I am not at Sheepscot often, and work the passenger train even less, I can recall two occasions when a passenger bonked their head when getting off the train.
Title: Re: Coach 9 - Official Work Thread
Post by: Ed Lecuyer on March 14, 2021, 09:15:49 PM
Eric (and James) are correct. The proper answer is to lower the Sheepscot platform so that the vestibule stairs align properly. This is the source of the "bonk" when de-training.

I remain concerned about traversing between the coaches.
Title: Re: Coach 9 - Official Work Thread
Post by: John McNamara on March 14, 2021, 09:48:18 PM
I can tell you from experience that with age, one gets shorter, so this problem will go away.
-John M
Title: Re: Coach 9 - Official Work Thread
Post by: ALAIN DELASSUS on March 15, 2021, 01:39:44 PM
 Well done you both. Your amazing skill and steadiness in work have the building of this magnificent car come along very fast. BTW well  it's  surely a stupid question but have you counted the number of pieces of wood you have put together so far.
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on March 27, 2021, 07:20:46 PM
Plywood has been removed, reay fo the floor to go down

(https://i.postimg.cc/25JGv08M/0327211228.jpg)

(https://i.postimg.cc/vmDXcJM5/0327211228a.jpg)

Copper Napth has been applied generously to the framework

(https://i.postimg.cc/rFLhQZCL/0327211228b.jpg)

Roof has been sheathed, including the vestibules

(https://i.postimg.cc/m2RwQzBL/0327211228-HDR.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: Bill Reidy on March 27, 2021, 09:17:19 PM
I noticed today a large plywood box (foreground) near coach No. 9.  The information on the box indicated the box had been shipped to our Museum by Harold Downey in Texas.  I asked Alan what his dad had sent.  The box contains the pre-cut southern yellow pine for the floor of coach No. 9.
(https://i.imgur.com/ayewlXg.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: Bill Baskerville on March 28, 2021, 10:45:14 AM
I noticed today a large plywood box (foreground) near coach No. 9.  The information on the box indicated the box had been shipped to our Museum by Harold Downey in Texas.  I asked Alan what his dad had sent.  The box contains the pre-cut southern yellow pine for the floor of coach No. 9.
Ya gotta love that Harold.  When it comes to "Coach in a box" kits (trucks and couplers not included), he thinks of everything. 
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on March 28, 2021, 10:49:14 AM
Trucks and couplers not included - love it.

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: Harold Downey on March 28, 2021, 02:51:40 PM
It was quite a bit of work to make the flooring.  Over about three weeks, visiting about 6 different Lowes and Home Depots, picking through the 2x10x8, 2x12x8, and 2x10x16 stacks, I selected only boards that were perfectly clear.  I needed about 70 eight foot equivalent lengths.  I got really good at sorting through and restacking the bunks of wood.   

After that, all were cut down the middle, jointed one face, and planed to 7/8" thick (turning 5/8" into chips).  Sometimes they needed re-jointing as they warped after planing, during the process.   Then joint one edge, cut to final width, and finally tongue and groove every one.    I made sure for the last planing pass, that every board went through without touching the planer setting so that the thickness were all the same. Oh, and then I cut off about 16" of each board, since we only needed 78" lengths.

All that because no-one makes 7/8" thick T&G yellow pine.  It is all a 32nd under 3/4".   

We did get a quote from a custom milling shop for this and it was around $5k.  I think it was about $1200 for my raw material.  So the quote was probably very reasonable, considering the effort it takes. 
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on March 28, 2021, 07:28:13 PM
Great work Harold as usual.
Title: Re: Coach 9 - Official Work Thread
Post by: Bob Holmes on March 28, 2021, 07:34:36 PM
So much to appreciate about what you have done, but the detail you describe to achieve perfect floor boards is just astounding!!
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on March 28, 2021, 07:37:30 PM
And I can picture that 5/8ths of sawdust and shavings. Hope you found someone that needed them.

Title: Re: Coach 9 - Official Work Thread
Post by: Bob Springs on March 28, 2021, 08:12:15 PM
As a life long cabinet maker I feel I have some idea of how much work goes into building this coach. 
Careful SKILLED work.
Seeing this project come together is an absolute JOY!
Title: Re: Coach 9 - Official Work Thread
Post by: Graham Buxton on March 28, 2021, 08:56:37 PM
All that because no-one makes 7/8" thick T&G yellow pine.  It is all a 32nd under 3/4".   
There was a time when 'standard lumber sizes' really were by the full 'inch'.  :)
It seems reasonable to think that when those cars were 'floored', standard lumber sizes were likely used.

In the USA lumber marketplace, there has been a difference between nominal and actual lumber dimensions for more than 100 years, according to this US Forest Service document: "History of Yard Lumber Size Standards"
 https://www.fpl.fs.fed.us/documnts/misc/miscpub_6409.pdf (https://www.fpl.fs.fed.us/documnts/misc/miscpub_6409.pdf)

Here is a thumbnail snippet from that USFS document mentioning pine from North Carolina in 1906:
(https://i.postimg.cc/bdyQgsrX/Lumber1906.png) (https://postimg.cc/bdyQgsrX)
(Click image to enlarge)
(The sizes mentioned in there are in "1/4 inch" increments, so 4/4 = 1.0 inches, 6/4=1.5 inches, etc)

So by that 'standard' 1x pine lumber from those 1906 Southern producers would be 7/8" thick. 
 
 Back when most lumber was cut from trees near the building site, regional preferences in the finished size of boards developed. But when the growth of the national railroad network allowed relatively 'cheap' long distance transportation of lumber (and other goods), standardized lumber sizes across the country became common.
 
 As railroad transportation typically was billed by weight, 'planed' boards (less weight than 'rough') gained a transportation cost advantage, and the actual dimensions of lumber were gradually reduced over a period of multiple decades.
 
 That Forest Service document was published in 1964, and at that time a 1x10 was 0.75" by 9.5", but since then it has shrunk to 0.75" by 9.25"
Title: Re: Coach 9 - Official Work Thread
Post by: Brendan Barry on April 01, 2021, 04:52:44 PM
Flooring being put down and receiving a coat of varnish.

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3399.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/9ed5faef-469d-4f3e-bb3b-760c9bf639e4)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3409.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/7949ae22-04c9-43c7-a245-f8adb6d2d77b)
Title: Re: Coach 9 - Official Work Thread
Post by: Hunt Dowse on April 01, 2021, 05:19:14 PM
Beautiful!
Title: Re: Coach 9 - Official Work Thread
Post by: James Patten on April 01, 2021, 06:01:39 PM
Wow.  I see the coach gained some lights.
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on April 01, 2021, 06:25:56 PM
Dance floor for Saturday night?
Title: Re: Coach 9 - Official Work Thread
Post by: Bill Reidy on April 01, 2021, 07:07:51 PM
Dance floor for Saturday night?

I can hardly wait to see Dave trip the light fantastic.

Brilliant progress.
Title: Re: Coach 9 - Official Work Thread
Post by: Bob Holmes on April 01, 2021, 07:25:23 PM
Whoa!  Unbelievable!
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on April 02, 2021, 08:36:18 AM
Fantastic!

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: John Kokas on April 02, 2021, 08:48:42 AM
What is the plan for interior lighting?  Oil lamp sconces or battery powered reproductions?
Title: Re: Coach 9 - Official Work Thread
Post by: Graham Buxton on April 02, 2021, 09:12:06 AM
Regarding the lighting, James posted this at the NGDF forum earlier:

Quote
The new coach  will be number 9.  We'll have all the Victorian accoutrements: brass luggage racks, ceiling hung  kero lanterns, gold leaf, etc.


Thread link:
https://ngdiscussion.net/phorum/read.php?1,414443,414445#msg-414445
Title: Re: Coach 9 - Official Work Thread
Post by: Bill Baskerville on April 02, 2021, 10:44:44 AM
Coach work continues with the usual high WW&F standards. 
Title: Re: Coach 9 - Official Work Thread
Post by: Brendan Barry on April 09, 2021, 05:03:16 PM
Eric and Ron installing one of the truss planks. The truss plank bolts through the side sill with hook bolts. The plank has steel bar stock inset into the top of the plank to give the hook bolts a solid surface to pull on.

Truss plank laying on the car floor while the steel strip is installed.

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3458.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/fb7b2254-1bbb-49ef-b4a1-bae207acfddd)

Steel strip being bolted on.

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3460.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/36615ffa-42a2-49f7-86ef-6c9bda25f1c2)

Plank stood up against the wall.

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3461.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/15b34882-3966-421f-b5ea-b1a3f700dfb8)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3469.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/ab88a8d0-7120-4cae-a002-914cea2bdefa)

Hook bolts being placed into the side sill.

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3463.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/36acd6d8-9d3a-4255-9775-170702b1c8e5)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3467.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/a8fa7cc8-7d16-4980-948f-cb8dada7595a)

Ron installing a hook bolt in the plank.

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3473.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/9d83a3ec-5bca-45b3-85bd-b00387b629e1)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3475.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/e8b3dce6-2a97-4393-99c7-b87c106fe723)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3476.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/6d3b2ee2-b3ac-4fae-8a77-c662ea0969b5)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3479.JPG?width=590&height=370&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/74023aa0-72ab-4ec0-a84e-27f5941cca9a)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3480.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/4b17a934-a94b-4d5f-bde9-38736b2ebbd3)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3482.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/c7c5342b-6b24-4996-a43f-668b1d261b6b)



Title: Re: Coach 9 - Official Work Thread
Post by: Dave Crow on April 12, 2021, 09:26:03 AM
Very nice work, Eric and Ron!  And Harold, for the amazing amount of prep work on this kit!
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on April 24, 2021, 06:24:57 PM
(https://i.postimg.cc/wBc8jsGb/0424210741b.jpg)

(https://i.postimg.cc/3wHQhZnv/0424210741a.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on May 01, 2021, 08:04:38 PM
Letter boards have been planed this week.

(https://i.postimg.cc/FzkJ0vZW/0501211351.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: Graham Buxton on May 01, 2021, 09:35:05 PM
With regard to Mike's photo of those loooong letterboards above, the two photos of those loooooong boards getting 'planed' (in a different thread) deserve to be part of this permanent "Construction" thread.

Here is the caption snippet:

Work completed  Wednesday 28 April 2021:

*  Coach #9 Letter boards planed, these boards are 40 feet long.
    (Eric, Fred, Brendan, Bryce, Dan, Randy, Leon, Jacob, Steve L, Jason)

The two photos are linked from the quoted thread, below:
(https://forum.wwfry.org/index.php?action=dlattach;topic=3985.0;attach=2279;image) (https://forum.wwfry.org/index.php?action=dlattach;topic=3985.0;attach=2279;image)
(https://forum.wwfry.org/index.php?action=dlattach;topic=3985.0;attach=2281;image) (https://forum.wwfry.org/index.php?action=dlattach;topic=3985.0;attach=2281;image)

Note that there are 10 people listed in that caption, although not all of them are necessarily visible in those photos.
Title: Re: Coach 9 - Official Work Thread
Post by: Brendan Barry on May 08, 2021, 04:55:40 PM
Seat castings arrived at Sheepscot last week.

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3580.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/13b1318c-2e57-45de-8833-1ca1affc6959)

Another photo of planing the letter boards.

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3556.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/7b0bd50e-963c-4296-8f63-eb12805763b3)

Eric working on the roof trim.

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3582.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/353e4060-ddab-4f5d-acc7-ba3389e060ed)
Title: Re: Coach 9 - Official Work Thread
Post by: Bob Holmes on May 08, 2021, 07:39:01 PM
Those castings are to die for...simple amazing.
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on May 09, 2021, 09:53:21 AM
Those are beautiful castings.

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: Ted Miles on May 10, 2021, 01:04:12 PM
Those seat casting are wonderful. They are some piece of pattern making. I hope there are a couple of spares for damaged or missing seats in the W&W #3. I am looking forward to seeing the green plush part of the seats. My grandfather was a pattern maker and he would have approved, I am sure.

Ted Miles, WW&F Member
Title: Re: Coach 9 - Official Work Thread
Post by: Brendan Barry on May 20, 2021, 05:07:39 PM
Eric and Ron installed one of the letter boards today.

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3728.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/0ee9b696-f126-4c51-a130-691899cb9fd3)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3726.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/8cb4bcd6-27f5-4a20-b328-bb25d7406aad)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3731.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/39008f1c-8b40-44e6-9136-301c88256c6d)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3735.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/ca953233-e3af-4c50-b62d-d839c1b15b19)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3737.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/e306c86f-7704-4744-8de5-c63df3ae5fc8)
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on May 30, 2021, 03:19:11 PM
Progress as of 5/29/21

(https://i.postimg.cc/8P58GH3N/0529210815.jpg)

(https://i.postimg.cc/htNRpd2g/0529210815a.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: Dave Crow on June 01, 2021, 09:31:50 AM
Wow!
Title: Re: Coach 9 - Official Work Thread
Post by: Brendan Barry on June 01, 2021, 05:08:33 PM
Ron trimming around the window openings.

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3818.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/2cd2b08a-4196-4d13-a787-20d75bb34386)

Eric putting on the boards at the top of the window openings.

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3820.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/4cbeba7e-1d6b-4e6d-9f14-9abe97f4d103)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3821.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/ab5ab96f-f9e6-405e-9efb-9096029792f5)

Letter board installed.

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3849.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/2766e9db-2456-47c8-8294-cfd29d3b623e)
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on June 02, 2021, 09:05:24 AM
Very impressive work.

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: ALAIN DELASSUS on June 02, 2021, 12:41:09 PM
Thank you so much for the pictures and report. Work is going on steadily and smoothly week after week and that is what most surprises me as a French person.
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on June 19, 2021, 06:39:40 PM
Went in to check on Coach 9. Looking good..

(https://i.postimg.cc/X7JgRH73/0619211300.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: john d Stone on June 20, 2021, 10:23:17 AM
Beautiful!
Title: Re: Coach 9 - Official Work Thread
Post by: Brendan Barry on July 02, 2021, 11:13:48 PM
Coach as of last Wednesday.

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3951.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/70bc2873-e8b5-4747-bb6e-5dc4ec60cfd5)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3953.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/7386c657-fde0-4cf6-a4cc-b4aed08f371f)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3945.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/ea39e8a5-07ab-46fa-ae48-9b91907e9e71)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3949.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/7c3fd681-fd9d-43c1-bc70-3508a6e45a61)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3954.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/cdcb46fe-d4c5-43f8-82ba-b8e2ce3974bd)
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on July 03, 2021, 10:20:28 AM
Beautiful.

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: Bill Reidy on July 10, 2021, 09:54:22 PM
As James mentioned in his July 2021 Work Reports here (https://forum.wwfry.org/index.php/topic,4054.msg51448.html#msg51448), Alan Downey started the setup to machine the pedestal castings for coach No. 9's trucks today.  A couple of photos I got today, sans Alan except his elbow in the second photo:

(https://i.imgur.com/J2YRQOm.jpg)

(https://i.imgur.com/2XAFO65.jpg)

Compare the pedestal photos with the first photo Brendan recently posted on wheel replacements for historic twin coach No. 3 here (https://forum.wwfry.org/index.php/topic,3941.msg51405.html#msg51405).

Nicole was preparing the next new axle for journals, to be ready after the wheels are pressed on:
(https://i.imgur.com/ChpYdbP.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: Brendan Barry on July 11, 2021, 05:36:28 PM
Siding progress on the coach.

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3962.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/97e82c5b-c3eb-45e1-b1a0-2668efa6fe91)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_3982.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/4811ba8c-d306-405d-82a4-ab81f1483582)
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on July 17, 2021, 09:21:36 PM
As of today..

(https://i.postimg.cc/mr5QL2sB/0717211559a.jpg)

(https://i.postimg.cc/Gp2FnT6X/0717211559b.jpg)

(https://i.postimg.cc/JnHjGVrJ/0717211600.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: Ron Ginger on July 19, 2021, 06:22:58 PM
I did  not get a photo, but Lou hung the last piece of siding on the coach today just after noon. A couple pieces of trim to go and the exterior is done.

I hope we can get a coat of paint on the exterior before we move into bay 4. But I really hate to put paint on all that nice clear fir siding!
Title: Re: Coach 9 - Official Work Thread
Post by: Bob Holmes on July 19, 2021, 07:19:52 PM
Make sure everyone that we have a great set of photos before painting.  We know and are proud of our LaBelle kits before painting!!
Title: Re: Coach 9 - Official Work Thread
Post by: Brendan Barry on July 20, 2021, 05:25:03 PM
Coach siding done.

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_4023.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/308775ec-6e08-4802-b6d3-2f0592b51212)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_4019.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/c681b2a8-f7ea-4e8b-b2f5-5663f7ef0405)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_4144.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/283a4686-c13a-48f5-82cf-2a262f26af77)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_4155.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/14f6b0a9-6f4d-4e51-9e89-8b6310551e42)
Title: Re: Coach 9 - Official Work Thread
Post by: Bob Holmes on July 20, 2021, 08:52:37 PM
Just super!
Title: Re: Coach 9 - Official Work Thread
Post by: Russ Nelson on July 21, 2021, 01:28:03 AM
My wife and I will be in town the first week of August. You're going so fast, please leave me something to do on the coach Tue, Wed, or Thu! I know which end of a chisel or screwdriver to hold, so I can be useful.
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on July 24, 2021, 07:05:22 PM
(https://i.postimg.cc/ryg0ytpL/0724211715c.jpg)

(https://i.postimg.cc/CL1ZRLZn/0724211715.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: Wayne Laepple on July 26, 2021, 02:15:44 PM
Here's a recent article with a few photos of the Cattail Foundry.

https://goodsstores.com/blogs/a-good-word-blog/cattail-foundry-casting-iron-in-gordonville-pennsylvania
Title: Re: Coach 9 - Official Work Thread
Post by: ALAIN DELASSUS on July 27, 2021, 08:24:09 AM
Just amazing. Come to think the framework was being assembled in July 2020.
Title: Re: Coach 9 - Official Work Thread
Post by: Ted Miles on August 08, 2021, 03:37:50 PM
Job H. Jackson and Jacob F. Sharp would be amazed that one of their designs was built in the 21st century. They sold their plant to A,C & F in 1910 and the plant built the last passenger cars in 1930. It built small navy craft in WWII and closed forever about 1950.

Ted Miles, WW&F Life Member
Title: Re: Coach 9 - Official Work Thread
Post by: John Kokas on August 08, 2021, 04:34:30 PM
Does anyone know if the J&S buildings still exist?
Title: Re: Coach 9 - Official Work Thread
Post by: Wayne Laepple on August 08, 2021, 04:36:46 PM
I believe at least some of the J&S works is now occupied by Delaware Car Co. It's visible from the Amtrak line.
Title: Re: Coach 9 - Official Work Thread
Post by: Brendan Barry on August 14, 2021, 03:17:50 PM
Progress pics as of last week.

(https://hosting.photobucket.com/images/s5/bbarry74/DSC_0056.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/9ca065b7-8980-4b59-b7d3-c21a244fa273)

(https://hosting.photobucket.com/images/s5/bbarry74/DSC_0058.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/5e3e5193-22ef-47f7-aa12-fb217cef1394)

(https://hosting.photobucket.com/images/s5/bbarry74/DSC_0061.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/9fa4270d-0062-402b-8ebd-29d1edd2de52)

(https://hosting.photobucket.com/images/s5/bbarry74/DSC_0064.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/48a43c2d-3439-4a7e-991f-26e1e698cc8f)

(https://hosting.photobucket.com/images/s5/bbarry74/DSC_0068.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/dfb59822-6fba-46e2-8ee1-c04af580e4a3)

(https://hosting.photobucket.com/images/s5/bbarry74/DSC_0077.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/b273d0dc-da66-4c58-a3e2-e34826f0b296)

(https://hosting.photobucket.com/images/s5/bbarry74/IMG_4236.JPG?width=1920&height=1080&fit=bounds) (https://app.photobucket.com/u/bbarry74/a/58e384d0-fdec-4da1-9e1e-c14e3edadb0c/p/c23605c8-40ae-4910-bf14-87510fe1526d)
Title: Re: Coach 9 - Official Work Thread
Post by: Jeff Schumaker on August 15, 2021, 10:28:43 AM
Great shots, Brendan.

Jeff S.
Title: Re: Coach 9 - Official Work Thread
Post by: Ron Ginger on August 16, 2021, 10:32:19 AM
I don't think Brendans photos show it, but Lou got the last pieces of trim on the 4 corners last Tuesday. I think the entire outside of the coach is now finished, except for the platforms. Lou also got some of the plugs into the truss planks inside, so the work on the inside has started.

We will have a lot of detail sanding and filling to prep the outside for paint.

We are taking a bit of time off now, Eric has another course to teach at the Woodenboat school, and I am catching up on some CNC work on a lathe for Maine Locomotive and Machine Works.

When we return we have a big pile of rough sawn oak waiting for us to start milling for the inside work.
Title: Re: Coach 9 - Official Work Thread
Post by: Mike Fox on September 18, 2021, 09:10:35 PM
Coach 9 truck pedestals were getting some attention in the machine shop. Alan and his father Harold are discussing what Alan just milled on the little mill while Nicole is talking with Scott while she tends to the end mill

(https://i.postimg.cc/PrSYH06B/0918211235.jpg)

I returned hours later and they are stll at it. Alan jumped onto the larger Mill and was cleaning up the side of the pedestal. Nicole is in the background making an adjustment to the end mill.

(https://i.postimg.cc/ZKbp1JL8/0918211705.jpg)

(https://i.postimg.cc/d3vrQFcK/0918211706.jpg)
Title: Re: Coach 9 - Official Work Thread
Post by: Alan Downey on September 19, 2021, 09:43:19 AM
Yesterday was either a first, or a very rare moment for the WW&F shop- in which we had both large mills working at the same time! Nicole has been a great addition to the shop and we've been thrilled to have her help. The coach pedestals are fairly simple parts, but with 9 to do (we ended up with a spare casting which we'll machine to completion), any step takes a while to work through the lot. Nicole and I came up with a good system to break this job up into a "production" system to kick parts back and forth between each machine, doing one operation at a time. For this instance, changing out workpieces instead of tools let us tag team the work and really keep things moving. Most of the operations are pretty simple, but there's a lot of different steps to these parts. Over the next few Saturdays we should be able to finish them up.
Title: Re: Coach 9 - Official Work Thread
Post by: Stephen Hussar on September 23, 2021, 09:26:28 AM
Damn this looks NICE. Beautiful work. Great pictures. Wow.

SH