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Messages - Harold Downey

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Work and Events / Re: Coach 9 - Official Work Thread
« on: February 26, 2020, 07:47:58 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, 07:58:56 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, 10:48:46 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, 07:24:07 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.

Work and Events / Re: B&SR Tank 14 - Official Restoration Thread
« on: August 15, 2019, 05:59:12 PM »
Wow.  It looks like the tank was holding the flat car together. 

How are the sills?  I see some already have scarf repairs.   There is a spec in the 1895 Car Builder's Dictionary on how to do these scarfs, and also the acceptable location.  They don't recommend repairing the center (draft) sills).   Since railroads interchanged cars, any RR could do repairs, but had to meet specs.   It is interesting that they also had a valuation method for charging back to the owning RR. 

Work and Events / Re: Coach 9 - Official Work Thread
« on: August 01, 2019, 08:33:15 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. 

Volunteers / Re: July 2019 Work Planning
« on: August 01, 2019, 08:27:05 AM »
About 140??

Work and Events / Re: Coach 9 - Official Work Thread
« on: July 31, 2019, 06:49:59 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):

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

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

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

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:

Here are a couple of shots of the fixture:

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.

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. 

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. 

Work and Events / Re: TCDA No. 65 (Reefer) - Official Work Thread
« on: June 26, 2019, 05:48:17 PM »
Here's our chance to add the missing period after ASS'N   . 

Work and Events / Re: Eames Train Brakes - Official Work Thread
« on: June 16, 2019, 04:35:24 PM »
You may be missing it.  Click on the double arrows in the top RH corner of the picture, then zoom way in and drag it to see the bottom left corner, just to the left of the brake wheel on the baggage car.  The truck is cut off, but peeking up above the side boards of the flat car. 

Work and Events / Re: Eames Train Brakes - Official Work Thread
« on: June 16, 2019, 10:00:53 AM »
Check out this photo of W&Q #1 Baggage and Mail car:

It's sitting on a standard gauge flat car, and at the left end of the flat car you can see one of its trucks.  Look closely and you can see the Eames vacuum brake pot is mounted on the truck. 

Work and Events / Re: Coach 9 - Official Work Thread
« on: June 12, 2019, 02:16:21 PM »
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. 

Work and Events / Re: Coach 9 - Official Work Thread
« on: June 10, 2019, 09:27:44 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. 

Work and Events / Re: Coach 9 - Official Work Thread
« on: June 10, 2019, 07:26:47 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. 

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. 

This is the rough cut stack of main deck carlines.

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

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