Author Topic: WW&F No. 11 - Official Work Thread  (Read 376620 times)

John McNamara

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Re: WW&F No. 11 - Official Work Thread
« Reply #510 on: May 29, 2022, 10:09:59 PM »
Wow, just a few more pieces to fill in the gap between the rear tank frame and the cylinder half's and we will have a complete locomotive.  (He said with tongue firmly in cheek.)
I hope this is not what model railroaders call a "shake the box kit." We'd need a really hefty shaker.

Ed Lecuyer

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Re: WW&F No. 11 - Official Work Thread
« Reply #511 on: June 09, 2022, 10:53:41 AM »
[Moderator's Note]
This statement was authored by the Build 11 team in advance of the normal 11th-of-the month updates. Also, Stewart has posted some good photos of the frame being constructed on our Facebook page.



There was much excitement at Sheepscot on May 17, when just as the diesel locomotive was unloaded, a second truck pulled in bearing the two new cylinder half-saddle castings for No. 11.  A few days later, however, a detailed inspection of the castings revealed several flaws which rendered the castings unacceptable for use.

The foundry was contacted, and following some discussion, they agreed to manufacture two new castings and ship them to us, at no cost to the Build 11 Project or the WW&F. This process will take a couple of months, as minor modifications to the patterns are necessary and new cores for the patterns must be made.

While we were all disappointed at this turn of events, the final outcome will be satisfactory. More importantly, the long delay in receiving the cylinder half-saddle castings does not materially delay the assembly work now underway on the rear frame.

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Ed Lecuyer

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Re: WW&F No. 11 - Official Work Thread
« Reply #512 on: June 10, 2022, 07:03:42 PM »
Monthly work sessions have continued to be productive, with more progress on No. 11’s rear frame. Everything has been drilled and bolted together, and the large rear frame extension castings that will enclose No. 11’s firebox has arrived. It needs some machining before it can be attached to the rear frame, but it’s shown fitted to the rear frame in these photos:





There was much excitement at Sheepscot on May 17, when just as the diesel locomotive was unloaded, a second truck pulled in bearing the two new cylinder half-saddle castings for No. 11.  A few days later, however, a detailed inspection of the castings revealed several flaws which rendered the castings unacceptable for use.

The foundry was contacted, and following some discussion, they agreed to manufacture two new castings and ship them to us, at no cost to the Build 11 Project or the WW&F. This process will take a couple of months, as minor modifications to the patterns are necessary and new cores for the patterns must be made.

While we were all disappointed at this turn of events, the final outcome will be satisfactory. More importantly, the long delay in receiving the cylinder half-saddle castings does not materially delay the assembly work now underway on the rear frame.



Our fund-raising for No. 11 is making slow progress toward the $70,000 goal. Right now, we are focused on reaching the $25,000 mark in contributions. That will unleash a $25,000 matching grant from the Candelaria Fund, immediately moving our fund-raising total to $50,000, or 51% of our goal. Please consider making your dollar for dollar donation count right now!

http://www.build11.org
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Ed Lecuyer

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Re: WW&F No. 11 - Official Work Thread
« Reply #513 on: July 10, 2022, 10:20:08 PM »
Build Locomotive 11 - July 2022 Update

During the most recent work session for No. 11 (July 5-7), Gordon Cook, Harold Downey and Jason Lamontagne concentrated on making preparations for riveting the various components. Gordon was making tack sleeves to accompany the tack bolts. The sleeves fit in the reamed holes so that standard bolts can be used to hold the components firmly in position for riveting. Harold, in the meantime, began the task of disassembling the various components from the outside of the frame toward the center sills.

It’s expected this work will conclude in August, after which riveting will begin. The majority of the riveting will take place in September. (Want to help? See http://www.wwfry.org/volunteer for Build 11 work dates!)



Elsewhere in the shop, Alan Downey has been machining the large rear frame casting, using our H&K mill. Machining is a necessary process to properly fit the casting to the rear frame; then, the casting will be riveted to the rear frame.

On the fund-raising front, we have received a little more than $24,333 which leaves us just $677 shy of the $25,000 we need to raise to release the $25,000 in matching dollars from the Candelaria Fund. With those funds in hand, we’ll still need to secure another $20,000 in contributions to reach our $70,000 goal by the end of 2022.

Have you made your donation yet? Learn more and contribute at http://www.build11.org
« Last Edit: July 11, 2022, 09:01:41 AM by Ed Lecuyer »
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Wayne Laepple

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Re: WW&F No. 11 - Official Work Thread
« Reply #514 on: July 11, 2022, 06:11:52 PM »
I am more than pleased to announce that this afternoon, we reached (and surpassed) our initial fund-raising goal for No. 11 for 2022. With the support of many donors, we hit the $25,000 mark, which triggers a $25,000 matching grant from the Candelaria Fund. When we receive those funds, we'll have $50,907 toward the final goal of $70,000 for this year. That's $19,093 we still need to raise. I know we can do it! Thank you, thank you to everyone who has contributed so far. More donations and donors are welcome, too!

Gordon Cook

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Re: WW&F No. 11 - Official Work Thread
« Reply #515 on: July 30, 2022, 02:18:33 PM »
We will be having a No. 11 work session this coming week, August 2, 3, and 4. All who are interested are welcome to join us at Sheepscot. We usually start around 9.

The primary task will be to continue reaming the rivet holes in the rear frame pieces. Right now the frame is assembled with bolts and we have carefully adjusted the alignment of the pieces so the overall dimensions of the frame assembly are in spec. To preserve this exact position of all the pieces, the process is to remove one of the bolts that is holding two or more frame pieces together, match ream that hole to a precise diameter, insert a precision bushing and bolt it through the bushing to hold the pieces in alignment, then repeat for another hole in that assembly.
Once two holes in a joint are reamed and bolted, the remaining holes can be reamed.
When we have all the rivet holes reamed, the frame can be disassembled. The precision bushings and reamed holes will guarantee the alignment of the frame and proper fit of the rivets when the rivets are set.
After all the holes have been reamed, final assembly of the rear frame can begin. 
« Last Edit: July 30, 2022, 04:49:38 PM by Gordon Cook »
Gawdon

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Re: WW&F No. 11 - Official Work Thread
« Reply #516 on: July 30, 2022, 03:19:53 PM »
I'll be there, Gordon. Looking forward to it.

Bill Reidy

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Re: WW&F No. 11 - Official Work Thread
« Reply #517 on: August 05, 2022, 03:40:18 PM »
While at Sheepscot Wednesday, I was able to take a few photos of the August work session.  Gordon described the August plan in his July 30th post above.  First photo is of (left to right) John Kokas, Wayne Laepple and Rick Sisson drilling rivet holes in the rear frame pieces.


Meanwhile, Gordon Cook was milling bushings to align the rivet holes for now until the frame is later riveted.


You might notice the back of a sign on the right of the first photo.  This sign presents a Baldwin erecting diagram for WW&F No. 7--our future No. 11.  This helps explain the project to the public, and perhaps it's a handy reference for the Build 11 crew.
What–me worry?

Ed Lecuyer

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Re: WW&F No. 11 - Official Work Thread
« Reply #518 on: August 10, 2022, 09:57:25 PM »
Build Locomotive 11 - August 2022 Update
Riveting News!

We did it!
Thanks to your support, on July 11th 2022, we achieved the $25,000 mark in our 2022 Build 11 project fund-raising, releasing an additional $25,000 in matching funds from the Candelaria Fund. As of today, we have $52,378 toward our $70,000 goal. We need $17,622 by the end of the year. Can we make it? It’s up to you!



Over three days at the beginning of August, the Build 11 team made great progress. With the help of four new volunteers joining three regulars, we were able to match-ream nearly all of the holes in the rear frame of No. 11. The process involved removing each bolt one by one, reaming the previously match-drilled holes to size, inserting a sleeve to maintain the alignment and finally replacing the bolts. We did not expect to complete the work, but with the help of the new volunteers, we did it.



That left us time to explore our big Hanna riveter. You may recall the machine was overhauled over a year ago and was successfully tested by riveting the smokebox ring for locomotive No. 10. We experimented with altering its orientation from vertical to horizontal, figuring out how to perform that operation safely. Remaining work includes changes to air piping to more efficiently receive the air to squeeze the rivets and redirecting the air exhaust away from the operation.

Next month, we’ll continue preparations for riveting during the October Fall Work Weekend. The September work session is planned for Sept. 20-22 and may include additional work on the Hanna riveter, making test coupons for test riveting, and the actual testing of the rivet furnace. Work generally begins around 9 a.m., and new volunteers are encouraged to come by.

Want to join the crew? Sign up at www.wwfry.org/volunteer



So now we need rivets. We’ll eventually need a lot more — maybe a thousand of them — but right now we need 146 in several sizes. Your donation of $11 will buy four. If 37 of the folks who read this each send us $11, we’re there!



We recently took delivery of 10 new bronze replica builder’s plates, which we are offering upon request as a premium to folks who contribute $1,100 or more in a single donation to the Build 11 project. We also have 3-D printed miniature builder’s plates, in return for a $110 donation to the project. Build 11 challenge coins - with the infamous typo now corrected - are available in the WW&F Gift Shop for $11.
Learn more and contribute at www.build11.org
« Last Edit: August 11, 2022, 11:14:53 AM by Ed Lecuyer »
Ed Lecuyer
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Ed Lecuyer

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Re: WW&F No. 11 - Official Work Thread
« Reply #519 on: September 11, 2022, 04:36:01 PM »
Build 11 September Update: Ready to rivet.

The Build 11 work sessions that occurred on Aug. 23-24 continued the prep work for riveting No. 11’s rear frame. A  few test rivets were heated and installed in test plates to determine the correct lengths, and Gordon is working on a fixture to allow precision cutting of rivets as required. The big electric compressor was wired in to provide air to power the Hanna riveter. We’re just about ready. One more work session on Sept. 20-22 should do it.

Want to come and help? Sign up at www.wwfry.org/volunteer


All the silver bolts and nuts seen here will be replaced by rivets.


Harold looks over the Hanna riveter positioned to drive a rivet in the frame

On the fundraising front, the magic number is $13,333! ("Three, it's a magic number." Thanks, Schoolhouse Rock!) That’s what we need to reach our stated 2022 goal of $70,000. That’s right – our current 2022 total stands at exactly $56,6667, or just over 80% of this year's goal. Can we make it by the end of the year in three months?

You can donate via our FundRazr page: build11.org, by credit card directly to the museum through the museum store, or by check. Let’s do it!
Ed Lecuyer
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Ed Lecuyer

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Re: WW&F No. 11 - Official Work Thread
« Reply #520 on: September 21, 2022, 06:40:34 PM »
Special News Update!

Following weeks of preparations and tests, today the first rivet was driven into the frame of Locomotive 11.

Ron Ginger captured the historic moment:
https://fb.watch/fHmz6mlWHs/

Eric Schade documented a subsequent rivet:
https://www.facebook.com/100005420616816/videos/1219623585559320/


Thank you to all who have contributed to this project with their time, expertise, and donations. Learn more (and get involved) at www.build11.org
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Mike Fox

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Re: WW&F No. 11 - Official Work Thread
« Reply #521 on: September 24, 2022, 06:43:27 PM »


Mike
Doing way too much to list...

Ed Lecuyer

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Re: WW&F No. 11 - Official Work Thread
« Reply #522 on: October 11, 2022, 06:00:18 PM »
Build 11 - October (Video) Update

We have some great progress to report this month. During the September and October work sessions, the team, along with some additional volunteers, essentially completed riveting the rear frame extension together. The big Hanna riveter was used for about 85 percent of the work, while hand riveting finished the job. More than 70 rivets have been installed. In locations where it was impossible to drive the rivets properly, fitted bolts will be installed.

Here's a video showing the Hanna riveter at work, with Rick Sisson operating the Hanna and Jeff Schumaker assisting.

We are pleased to report that the 2022 Build 11 Project fundraising has reached the 85% mark. We’re less than $11,000 from our goal of $70,000. Have you made your contribution at Build11.org yet?
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Ed Lecuyer

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Re: WW&F No. 11 - Official Work Thread
« Reply #523 on: November 12, 2022, 09:44:25 PM »
Build Locomotive #11: November Update!

Fitted bolts was the name of the game for the work session held Nov. 2-3. Gordon Cook made the bolts, and he and Rick Sisson were able to install five bolts in the frame. These special bolts are necessary to protect cast-iron components from potential damage during the riveting process.

On Tuesday, Gordon and Jason took the cylinder half-saddle castings to Mountain Machine Works in Auburn, Me. This firm has the capabilities to machine the mating surfaces between the two castings, plane the valve faces and bore the cylinders. In addition, the large rear frame casting will be taken to Mountain Machine for final machining. We expect these pieces to return to Sheepscot early in 2023.

Over the next several months, the pedestal binders and cross frame braces will be made. When the parts are returned from Mountain Machine, the three major frame components and the cylinders will be united into a single unit to support the rest of the locomotive.


Gordon cook carefully hammers a fitted bolt home. At the left side of the photo, two completed fitted bolts are circled. Photo by Rick Sisson.

On the fundraising front, we are just $2846 short of the overall goal for the year of $70,000. We're grateful for your continued interest and support.

We’ll start a new round of fundraising for No. 11 on January 11, 2023 with a goal of $50,000. To all the folks who have contributed to the Build 11 Project over these past years, we thank you. Thank you for sticking with us as we strive to make this happen. We’ve raised three-quarters of the final goal of $350,000, and at every work session, No. 11 becomes more of a reality.
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Wayne Laepple

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Re: WW&F No. 11 - Official Work Thread
« Reply #524 on: November 12, 2022, 10:31:19 PM »
And just like that, now we're only $2,777 from the goal!