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Messages - Harold Downey

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Work and Events / Re: B&SR Tank 14 - Official Restoration Thread
« on: August 15, 2019, 06:59:12 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, 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. 

Volunteers / Re: July 2019 Work Planning
« on: August 01, 2019, 09:27:05 AM »
About 140??

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

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, 06:48:17 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, 05:35:24 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, 11:00:53 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, 03:16:21 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, 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. 

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

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. 

Volunteers / Re: June 2019 Work Reports
« on: June 10, 2019, 07:58:06 PM »
Paul, that looks like the hydraulic power unit for the flanging machine.

Work and Events / Re: Coach 9 - Official Work Thread
« on: June 04, 2019, 09:33:04 AM »
From Stephen P:
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. 

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

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.   

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:

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

The journal box lid (right) and its core box:

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):

The bottom side of the same mold board, which forms the curved bottom surface and a pocket to accept the bolt head:

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.

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

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. 

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

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