January 19, 2009

Progress on frame & cylinders

There are several activities shown below.  Work on the cylinder castings, frame, drawbar center casting and shoes & wedges.

Pilot holes drilled in cylinder saddle.  The smoke box bottom liner will be fabricated in Muscle Shoals.  Later, the liner will be welded to the boiler.
Photo: Steam Operations Corporation
   
The project requires new upper frame rails that secures the cylinders to the lower frame and engine truck center casting. (During disassembly of 786, one of these frame rails had to be cut away to free the old cylinders from the frame.)

Prior to burning the new rails a paper template was drawn on CAD and printed to ensure accurate cutting. Paper template is shown on old frame rail.
Photo: Steam Operations Corporation
Two new upper frame rails on the floor with one old rail. Next steps are to stress relieve new steel rails and then machine to fit.  Once machined, fits in cylinder castings are completed.
Photo: Steam Operations Corporation
Ronnie Jones laying out for the slot where the upper frame rail fits to the cylinder casting. 

This will be an unusual machining operation for modern times.  An old metal shaper (rarely used today) will be pulled from storage and set up for this operation.  The photos of this process will be interesting.
Photo: Steam Operations Corporation
Ronnie and Tyler weighing new frame rail.

Since much of the original spring rigging will need to be replaced, weights of the major components will have to be determined in order to complete the new spring rigging design.
Photo: Steam Operations Corporation
   
Terry Allen burning off bolts on drawbar center casting.
Photo: Steam Operations Corporation
Tyler Poss drilling out drawbar center casting frame bolts.
Photo: Steam Operations Corporation
1100 pound drawbar center casting  on layout table after removal of 38 frame bolts.
Photo: Steam Operations Corporation
Drawbar center casting. 

Note that the areas where the drawbar casting was bolted to the frame shows no sign of long term deterioration.  This means that when the casting & frame were bolted together, there was an excellent water-tight joint.  You can see other areas of deterioration & rusting on the casting, as one would expect after 90 years of exposure.
Photo: Steam Operations Corporation
After removal of drawbar casting it was cleaned as was the frame fits. It was then set back in to see how it fits in the frame rails.
Photo: Steam Operations Corporation
   
Shoes and wedges after cleaning.
Photo: Steam Operations Corporation
Old shoes and wedges after cleaning are installed on the frame with the pedestal binders in place.
Photo: Steam Operations Corporation