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Messages - Ron Ginger

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Work and Events / Re: Coach 9 - Official Work Thread
« on: August 14, 2022, 10:59:27 AM »
Eric and I have talked about the ceiling a bit and have a basic plan. We will remove the white painted masonite from coach 3 and see whats under there. We suspect the old decoration is there, based on some peeking Eric did a couple years ago. If its there we will probably do good photos, import that into some CAD program and try to reconstruct the image. From that we will likely create cut files and cut mylar masks on my CNC router (or use Alans if the images are to big for mine). We should then be able to stencil the layouts onto the oak veneer we will use for the ceiling panels.

Like all the tricky parts of this project Eric and I start to discuss them as we approach that work. By the time we get to it we seem to always get a plan ready and are able to move on. That is what has made this project so much fun, at least for me.

Volunteers / Re: PHONE LEFT AT PERCIVAL HOUSE - 8/6/22
« on: August 07, 2022, 12:41:40 PM »
Yes, it is mine. I did not even realize I had dropped it until I  saw the mail this morning.  I retrieved it this morning.

Thanks to all that helped get this back to me.

ron ginger

Work and Events / Re: Coach 9 - Official Work Thread
« on: July 27, 2022, 10:23:43 PM »
Eric and I are both boatbuilders, so we are not worried about bending panels. We talked about it some today and have a couple ideas for form bending some thin ply, then veneering it with oak as in the original. We are not artists, so the decoration may be difficult, but we have a couple ides for that as well. Currently coach 3 has Masonite bent over the original ceiling, and painted white. That is probably to  cover up a dark and deteriorating ceiling.

Today we put the second to last oak strip all around the car. Three molding strips to go and the interior oak is done up to the ceiling.

Work and Events / Re: Coach 9 - Official Work Thread
« on: July 25, 2022, 09:13:32 AM »
What is not very obvious in these photos  is the most recent work. The strip  of molding  above the windows is now finished and in place- not screwed down, but held in place by its close fit. This was probably the hardest  part we have made. It required about a dozen passes through the shaper and 6 or 7 passes over the table saw at an angle to make the relief curve on the backside for the window shade.

Eric and I had 8 foot long strips of the molding finished and Lou cut them to length. Tomorrow, when Eric remembers to bring back his pin nailer, we will glue the two pieces together.

It is interesting to me that all through this project we have faced complicated tasks. As we work toward them Eric and I talk them over while we are doing simpler jobs. By the time we get to the hard part we pretty well have it figured out and it goes well. The next tough job, at least to me, are the ceiling panels. These are thin veneer sheets, curved into the roof curve, and painted with  scroll work. I am confident by the time we get there we will have figured this out as well.

Work and Events / Re: Coach 9 - Official Work Thread
« on: May 22, 2022, 11:43:44 AM »
Eric hand carved all those blocks. They were the first pieces of the coach to be built, well before we started the frame. He was still making drawings while carving them

We next need a piece of molding to  go along the top edge of these. So far we have not found the right cutter, but Eric took a shot of regrinding one to the right shape. I have found a couple router bit that may work, so the job next Tuesday will be making the molding.

Volunteers / Re: May 2022 Work Reports
« on: May 04, 2022, 07:36:40 PM »
A crew went to Mass. To pick up a new shop machine, no… I don’t know what it is.
                   (Jonathan, Brendan)
I was along on that trip, in fact it was to pick up a new Hurco SM1 milling machine which I obtained through a friend in MA for FREE. This is a major step up from our old Bridgeport we have in the shop now. There is discussion ongoing as to replacing the Bridgeport with this or keeping both. There are uses for both.

Today I reassembled the machine and started a full cleaning.

Volunteers / Re: March 2022 Work Reports
« on: March 27, 2022, 05:28:36 PM »
*  Coach #9 assembly continues, looks like interior work done.  (Eric, Ron)

The interior is not nearly done. We do have the oak up to the bottom of the window sill, but now it gets a lot more complicated. Almost every piece that goes in now will have some kind of molded edge.

We are also looking into the interior hardware. I have made a few RTV molds and cast a few wax parts, and Tuesday Eric and I visited a foundry in Brownfield ME to check them out for making our interior hardware. It looks like they will be able to do all we need in the various brass latches, hinges, knobs, etc. I have a lot of mold making to do, in my home shop.

Eric is also looking for parts to make the hanging lamps we need. That will be a rather long project.

Museum Discussion / Re: Movie about #9: "The Nine Lives of #9"
« on: October 02, 2021, 10:22:20 AM »
Indeed, that is an excellent video.

Since I did not know about this place in Harrys time I enjoyed seeing that part, and Jasons connections. Now I understand Jasons wish to make the train more than just a ride.

I was a bit lost in the timing of Alices interaction with the damn project. Am I right that they were building the dam in the 30's and eventually agreed to let her stay on the farm the rest of her life. That must mean the farm was in the area reserved for overflow, but obviously not in the part that got flooded. She must have been at some risk that she might be flooded out in the event of a major storm.

Work and Events / Re: Coach 9 - Official Work Thread
« 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.

Work and Events / Re: Coach 9 - Official Work Thread
« 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!

Boothbay Railway Village / Re: Boothbay New Steam Engine Restoration
« on: June 21, 2013, 11:16:09 AM »
Unfortunately that project kind of died.

There were 5 or 6 volunteers that started it, with the usual great enthusiasm of starting a new project. It got just about totally torn down, then hit the point where only Brian could weld on the frame. Other work came along and this project got shoved to the back of the shop.

My big fear is that parts kind of got scattered around, and only Brian knows where and what they are. In another couple years it will all be just junk scattered around the shop.

Other Maine Narrow Gauge / Re: SD Warren Tank Engine
« on: December 15, 2009, 04:36:29 PM »
On Monday, December 14 the S.D. Warren engine at the Boothbay Railway Village was moved from its roadside display into the engine shop where a restoration will be started. The work will be a volunteer project starting right after the first of the year. Brian Fanslau will be lading the volunteers for this project.

It is not yet decided if it will be restored to its as new condition, or as it was in its last service days at SD Warren.

This will be a long project, there is no specific funding for it so work can only be done as volunteers are available and as donations come in. Obviously donations would be very welcome.

Work and Events / Re: WW&F No. 9 - Official Work Thread
« on: May 27, 2009, 10:09:20 AM »
Xray was contracted to a company that comes on site with portable equipment.

The main stress relieving of the entire boiler shell and firebox was done in Pennsylvania. Brian and Jason drove it down and waited for it to be done- an overnight process. There is no furnace big enough any closer.

For a small area of work, like in a repair we have ceramic electric heaters that can be placed on the surface. We have temperature monitoring equipment and a laptop program that collects the data and controls the rate of heat and cool.

Work and Events / Re: WW&F No. 9 - Official Work Thread
« on: May 26, 2009, 09:58:07 PM »
The hydro test is fairly simple.

Every external valve is attached and closed. Each of these valves is considered part of the boiler and must meet spec and be part of the test. The boiler is totally filled with water- no air space at all.  Nothing is connected beyond any valve except a water pump to supply the test pressure.  It is then pumped up to a pressure of 150% of working pressure- in this case 210 psi. It is held there while the inspector looks around for any leaks. He went over it pretty thoroughly, even crawling under it to get inside the firebox. After a few minutes at the high pressure it is lowered to working pressure- 140psi- and held there as long as the inspector wants, about an hour.

The boiler is required to be warm, as I recall over 70 degrees, We had a kerosene heater blowing into the firebox door for a couple hours to get the whole thing up to a suitable temperature.

The paper trail is extremely complete. Every piece of material that went into the boiler must have orders and invoices showing its exact origin, and each piece must have a certificate that it meets whatever spec is appropriate. Each piece of metal that came into the shop was logged in, and assigned a 2 character code. Each piece was stamped with the code. As a piece was cut off the stock to use it was first stamped with the same code, then cut off and used.

If you look at the boiler now you will see lots of yellow paint marker circles about 1" dia. These identify the code stamp. You can go back to a file and find the exact source of that item, and its certificate that it meets spec. Once the boiler has been approved and stamped these numbers are no longer important- the boiler now has a serial number and an S stamp that certifies all its pieces met spec.

Basically the inspector had to be satisfied that every item in the boiler was made from an approved material, with a clear spec. He actually did this review at several stages during construction, and initialed every order, spec sheet, and drawing.

He also looked at every test report, like the Xrays of welds and the stress relieving to verify the tests were done, and signed.

In addition BRV had to develop a written procedure for every operation. These procedures were part of the early work to get the certification. The inspector was frequently checking to see that these procedures were correct, and were performed correctly. It cost BRV over $30k to achieve this certification, including purchase of a set of spec documents that fill a shelf about 4 feet long. These get updated every 3 years, and more inspections, to the tune of over $10k.

Code work is a very detailed, and costly process. But in the end we have great assurance that every item in that boiler met all the specs needed to insure its safety.

Work and Events / Re: WW&F No. 9 - Official Work Thread
« on: May 20, 2009, 12:10:51 PM »
No, Serial Number 2 was already used for a major rebuild boiler for Boothbays #7.

Id like to see the next boiler be for the fire engine we have at BRV. Its fully restored, ready to run, except for a boiler. If some kind benefactor ever drops some money on us I think that would be a neat project.

But a boiler for a #11 would also be a great project. If we can just drag Jason a little way into the 20th century so it can be more welded and less riveted and threaded. :-)

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