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Messages - Harold Downey

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Yes, that is definitely coach 3.  All the details are correct.  Still has hat racks and shades; the ceiling has been painted white, the center lighting is gone.

Here is an exterior shot that sure looks like #3 as well - nice that it shows the original steps/platform.

Great quality photographs, with high resolution scans.

Work and Events / Re: Coach 9 - Official Work Thread
« on: April 04, 2020, 08:43:33 PM »
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. :)

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

Work and Events / Re: WCSH's '207' visits the WW&F
« on: March 03, 2020, 04:18:17 PM »
Wow, that was an impressive segment!   

Volunteers / Re: February 2020 Work Reports
« on: March 01, 2020, 11:03:04 AM »
Mike Fox: I grabbed a shot of Carlos working on the repair for the big riveter today.

And in the foreground a sneak peak at the vacuum brake controller.   :)

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

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

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

Work and Events / Re: Coach 9 - Official Work Thread
« on: February 26, 2020, 10:22:06 PM »
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).

Work and Events / Re: Coach 9 - Official Work Thread
« on: February 26, 2020, 10:08:32 PM »
I think it's fixed now.  Other than the large size...

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

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

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

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

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

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

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.

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

Moving on next to the main doors....

Work and Events / Re: Car Barn Extension - Official Work Thread
« on: February 05, 2020, 08:58:56 PM »
Wow, we can't even get the roof on, and it's filling with rolling stock already!

Two Footers outside of the US / Re: New sugar 2-footer in Australia
« on: January 15, 2020, 11:48:46 PM »
I calculate their cost is $428k per mile. 

Sign me up for joint tightening crew. All days as required.

Work and Events / Re: B&SR Tank 14 - Official Restoration Thread
« on: August 16, 2019, 08:24:07 PM »
This is from the 1909 Car Builder's Dictionary, under Interchange Rules.   This governs repair splices to sills.   1895 edition did not allow center sill splices, but now they are allowed with a reinforcing timber as shown in figure 9A.    But I read from this that center sills can't be spliced right in the center.   Cross tie timbers are also known as needle beams. 

Rule 65. Draft timbers must not be spliced. All longitudinal sills may be spliced once, with the exception of center sills, which may be spliced at both ends.
Not more than two adjacent sills may be spliced at the same end of car.  The splice may be located either side of body bolster, but the nearest point of any splice must not be within
12 inches of same, excepting center sills, which must be spliced between body bolster and cross-tie timbers and not within 24 inches of either. Longitudinal sills other than center sills where less than 12 inches in depth, the plan shown in Fig. 8 is to be followed. When the sills are 12 inches or more in depth the plan shown in Fig. 9 is to be followed. When center sills are spliced the plan shown in Fig. 9a is to be followed. The size of horizontal or cross bolts shown in Fig. 9a should be 5/8 inch.

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