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Archive for the ‘Maintenance’ Category

Visitors Will See the Famous Sierra No. 3 Up-Close & Personal Plus Learn About Current Projects Underway

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 Railtown 1897 State Historic Park (SHP) will now offer special, behind-the-scenes Shop Tours on Tuesday mornings from 10 a.m. to noon on an ongoing basis beginning March 26, 2013. Interested visitors will be treated to an up-close and personal view of routine maintenance and specialized work happening on current projects in the historic Roundhouse as well as in the Tri-Dam shop (a Cold War-era machine shop used to repair, replace or service parts for operating equipment, cars, steam and diesel locomotives). Keep in mind, parts for steam engines — and sometimes vintage diesel locomotives — cannot be purchased and must be manufactured on-site making Railtown 1897 SHP one of the most accessible places around to watch this specialized work being performed.  Along with educating visitors about our fascinating rail history, maintaining and repairing steam engines and diesels is an important part of the mission of Railtown 1897 SHP.

The weekly two-hour Shop Tours begin with a brief slide show that provides background of current projects to date.   After the video, a knowledgeable volunteer host will guide visitors to the historic shops to meet and ask questions of skilled paid and volunteer staff who are actively working on projects and activities that keep the historic shops alive.

Open daily, Railtown 1897 SHP Shop Tours are included with Park admission, which is as follows: $5 for adults, $3 for youths ages 6-17 and free for children five and under.  More information about the Shop Tours or Railtown 1897 SHP is available by calling 209-984-3953 or visiting http://www.railtown1897.org.

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One of our most popular cars– the 599 Mountain Observation Car, presents maintenance challenges due to the same open sides which make it so enjoyable to ride in.  In the winter, it is almost impossible to keep the weather out, which results in peeling paint and requires a lot of upkeep.  Our amazing volunteers are giving it a cosmetic facelift– removing wooden seats for repainting, as well as patching and painting the floor.  It should be ‘back on track’ for our first wildflower train on April 14th. 

Volunteer Sam Cook unloads another seat from the interior of the 599 car in preparation for painting.

Volunteers Dave Deutsch and Dave Gibson with some of the bench elements for painting in the carpentry shop.

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One of our most useful pieces of equipment went down on us last year.  After many years of faithful service, the transmission gear box failed.   It is one of our new machines, housed in the Tri-Dam building, so most visitors do not see it.  Keep in mind that the term ‘new’ is relative, here.

The Cincinnati #4 Horizonal Mill with Powered Overarm, Circa 1954, is new, in comparison to the machines in our historic belt-driven machine shop, but in 2012, most folks would not consider it new.  This piece of equipment came to us around 1993, from miliary surplus at Rough and Ready Island.  It is heavily used in the shop, for everything from milling the crosshead guides on the No. 3 during restoration, to boring brake adjuster brackets, to re-boring couplers. 

Its a very useful light-duty powered overarm mill.  The overarm is an accessory which essentially converts the horizontal mill into a vertical mill, as needed. 

Our cohorts at the California State Railroad Museum picked up a heavy-duty overarm at the same time we aquired ours, and its been in storage ever since.  This one is about twice as heavy as our old one, but we were able to get our hands on a factory print of the circuitry.  Our district’s amazingly gifted electrician, Steve Spath, rewired the crunchy old motor leads, and designed custom electrically controlled circuitry.  In early February, Steve spent two days with George &  Phil, in the shop, where they installed and tested the new arm.  Just like new!

The old overarm attachment, ready for retirement.

Steve Spath puts finishing touches on the electrical for the "new" overarm attachment.

Voila! The replacemnt arm in position, and ready to go.

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Six sets of tall doors provide access to the south side of the building and are a distinctive architectural feature of the Jamestown roundhouse.

Maintenance records do not exist for the roundhouse doors, so we don't know if they have been replaced before, but its clear that they have faced hard use and have many interesting scars to prove it. However, by late 2010, damage caused by gravity and use resulted in many of the doors being closed for safety reasons.

 

Using the original doors as a pattern, the new set of frames was constructed by skilled volunteers, using specially milled fir.

The door openings are temporarily boarded over while the work is being done.

Once the doors are completed, they are hung "naked" (without the tin sheathing).

Installation of the "skins" is time consuming. Original sheathing is carefully removed from the original doors, wherever possible, and put into the same position on the new doors. Shortline Railroads like this one have been notorious for "making a penny squeal" and the judicious use of small pieces of tin on the doors is a symptom of this frugality. It would have been much easier to replace with new tin, or even used tin, but some history would be lost. The completed door will receive a final coat of paint, but otherwise, looks exactly like the original, and utilizes many materials from the original.

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The Sierra No. 3 ran on time last year, but there were a few minor details we had to defer.  For example, replacing the water delivery lines to the injector, which were getting very thin in places.  And repairing the whistle.

The iconic whistle from the No. 3, has become raspy over time.  The top is a cast iron five chime whistle, of unknown origin, with a brass base.  The original seat was cast integral with the base, and had become worn over time, as had the valve. 

Our crack team of locomotive artisans (Tony and Joe) got to work over the winter, and a new valve seat and valve were machined and inserted, restoring the “voice of High Noon”.  The locomotive was steamed up today, and we took the opportunity to put it though its paces.  Beautiful!  Hear it for yourself this season. 

Sierra No. 3 Whistle

Cast Iron 5 chime whistle, valve, pins and lever

valve

The original valve was cast, the replica is machined bronze.

top view

Top view of whistle, with casting number "2557"

bottom view

Base of the whistle (where it attaches). The original seat was worn, so it was machined out and a new seat pressed in.

whistle

The whistle in position on top of steam dome (whistle is on the left--in the steam, safety valve is on the right)

To see a video of the new whistle, see the Railtown facebook page.

The first official opportunity to ride the Sierra No. 3 this season will be Sunday, April 10th on the hour from 11-3, regular ticket prices apply.  Tickets sold at the window on the day of excursion.

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Tickets are now on sale for all 2010 Sierra No. 3 Excursion Rides, which include August 7 &  8, September 4 & 5, and October 2 & 3.  On each day, regular excursion trains leave the station at 11, 12, 1  & 2.  Sometime around noon the Sierra No. 3 will emerge and be on display, until the 3 & 4:30 PM excursions leave the station, pulled by the Sierra No. 3.  These rides will include a stop, a photo run-by, and refreshments will be served on-board.  Space is limited, and advanced tickets are strongly recommended, and are available online at http://railtown1897.org/railtown/doc.asp?id=551 .  Any available tickets will be sold on the day of the event, at Railtown. 
Currently, the maintenance work continues in the shops at Railtown, and can be observed in the Roundhouse during normal operating hours.  In addition to routine repair and maintenance to some of our historic cars, the Sierra No. 3 is also receiving some attention to repair a failed bolt at the connection between the distribution pipe and the valve chests (see photos).  The distribution pipes, which are made of cast iron, convey the steam from the boiler to the valve chests (to the pistons).  Even the slightest leak at this joint can result in a loss of power, which was what was experienced on the final run of the 4th of July weekend.  A cursory inspection immediately revealed the problem.  It also marked the transition from restoration to routine maintenance, which is constant in any roundhouse where steam locomotives are in service!  This is a relatively quick repair. 

This is the head-on view into the front of the locomotive (smoke box) with the front door removed. The curved pipes coming down from either side are the steam distribution pipes, which feed the valve chests, which in turn feed the pistons. They are sealed with a machined ball seal, and secured with bolts.

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Tuesdays at Railtown seem to get busier and busier.  There are many projects in progress, here’s just a few. . .
#3

Ron Sloan wraps wire around the boiler in preparation for lagging, with help from Dan Maher as Mike Warzee looks on

phil

Phil Hard trims studs mounting the bell.

John Stier replaces parts in the popcorn machine.

John Stier replaces parts in the popular popcorn machine.

paint

The Carriage Room floor received a fresh coat of paint.

Stan Eggink and Mike Warzee put final touches on the 1265 diesel.

Stan Eggink and Mike Warzee put final touches on the 1265 diesel.

david bradley

David Bradley refinishes a door from car 14

Judy Nordstrom takes a pause in cleaning the 14 interior

Judy Nordstrom takes a pause in cleaning the 14 interior

volunteer

A new volunteer works on the exterior of the 14 car

#12

12 car waits inside the Tri-Dam for wheel change

Tom Keys

Tom Keyes constructs new benches for caboose seating

lunch

Lunch awaits!

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Yesterday, Railtown was a veritable beehive of activity.  Paid and volunteer staff were working on an incredible number of projects including replacing the fence near the freight shed, moving the Sierra #3 to the roundhouse, mechanical work on the Shay #2, replacing staybolts on the Shay #2, finishing work on the Caboose #7, cleaning and repair of several cars, and repairing a broken irrigation pipe.

In addition, all of the locomotives were pulled out of the roundhouse for the electrical system work that is being completed by district electrician, Steve Spath.  No doubt about it, Tuesdays are an interesting day for visiting Railtown!

This rotten fence is being replaced by park volunteers

This rotten fence is being replaced by park volunteers

Sierra #3 passing by the water tank on the way to the roundhouse, where it will remain

Sierra #3 passing by the water tank on the way to the roundhouse, where it will remain

Volunteer David Ethier helps guide the Sierra #3 over the drop pit

Volunteer David Ethier helps guide the Sierra #3 over the drop pit

Three park visitors on a guided tour led by Leroy Bushart enjoy the roundhouse activity

Three park visitors on a guided tour led by Leroy Bushart, enjoy the roundhouse activity

A volunteer works on the main bearings for the crankshaft for the Shay #2

A volunteer works on the main bearings for the crankshaft for the Shay #2

Norm Comer inspects holes from staybolts he burned out of the boiler of the Shay #2

Norm Comer inspects holes from staybolts he burned out of the boiler of the Shay #2

The tender for the #3 now parked in view of the roundhouse

The tender for the #3 now parked in view of the roundhouse, in preparation for final assembly

interior roundhouse

A rare view of the interior of the rounhouse, locomotives 28 & 34 have been pulled out for electrical access

Electrician Steve Spath, and Railroad Restoration worker Jim Bays, both employees from Sacramento working at Railtown this month

Electrician Steve Spath, and Railroad Restoration worker Jim Bays, both employees from Sacramento working at Railtown this month

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“The Secretary of the Interior is responsible for establishing standards for all programs under Departmental authority, and for advising Federal agencies on the preservation of historic properties listed in or eligible for listing in the National Register of Historic Places. “ 

The standards were designed to apply to structures, however, we have found them to be useful guidelines for preserving and restoring railcars and locomotives. 

We currently have two restoration projects ongoing at Railtown; the Sierra #3, which could be classified as somewhere between a restoration and a rehabilitation, and the Caboose #7, which would be more accurately described as a rehabilitation. 

There are unique challenges to any preservation project, whether it is a building, vehicle, or other artifact.  Addressing those unique aspects with specific and creative solutions which preserve the integrity of the resource, is what makes this field and interesting and challenging one! 

Arguably, the structures at Railtown (the historic shops of the Sierra Railroad) are the greatest historic resource at the site, and of course, the Secretary of the Interior’s standards are applied in their preservation.  The site is not currently listed on the National Historic Register, however, it is clearly eligible (listing it hasn’t been pursued because our limited resources have been directed to more urgent issues, and because it is already protected as a State Historic Park).  Therefore, every proposed change, minor or major, is carefully reviewed by qualified staff, following  CEQA (California Environmental Quality Act) requirements.  This process can be tedious and time consuming, but is an important step to ensure that well-intentioned, paid and volunteer staff do not make changes over time that can impact the integrity of the site.  It is also an important step to document changes, over time, for future park managers and historians. 

For example, we will soon begin an electrical upgrade to the historic roundhouse.  These important improvements will (hopefully) reduce the fire hazards to the building.  Park staff propose to utilize existing conduit wherever possible, retain extinct hardware, and keep modern replacements out of the “historic viewshed” by placing them in hidden areas, or camoflaging them.  The upgrade is unavoidable because we wish to continue using the building, but we seek to find elegant solutions to mitigate changes, and document, document, document!

In many ways, the restoration challenges for the Sierra #3 are more complex.  Because we wish to operate the locomotive, we have taken a very different approach than if our intent had been to put it on display.  Much consideration was given to “restoring” the original boiler.  Contraints included cost, employee safety, and feasibility, as well as artifact preservation concerns.  In the end, it was decided that it would cost the same, be safer for employees, and better preserve the original artifact if we built and operated a new, welded boiler.  Critics would argue that it is no longer the same locomotive.  Others would argue that operation of the locomotive over the years, including repairs after wrecks, replacement of worn parts, wheels, tires, tubes and valves, new paint jobs for film shoots, and all of the minor tweaking over time, has caused cumulative changes that have been just as significant.  The curators will argue that the ”original” parts could be re-assembled for display at any time.   All of the arguments have their merit. 

Isn’t this fun? 

To learn more about historic preservation standards, and the recomendations of the Secretary of the Interior, please visit the NPS site

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Sometimes, despite the best planning, we have one of those crazy days where everything converges at once.  Today was one of those days.
We are preparing for the insertion of the crankpins (into the driving wheels) an operation that requires precision machining, coordination, and a bit of low-tech magic in the form of liquid nitrogen.  In order to insert the steel pins with the least amount of stress to the cast iron wheels, we are freezing them in liquid nitrogen, which shrinks them for a few minutes and gives us some time to insert them before they expand into place.  Today’s schedule called for double-checking measurements, and doing a practice run to get comfortable with the process.  Tomorrow is the big day for the actual insertion. 
Additionally, some of our key volunteer staff have stepped up to fill in the gaps left by our limited paid staff, and attempt to get the Shay #2 running again for the weekend.  A problem  with a cylinder lubricator was repaired, but another problem was discovered with the #1 piston.  Unfortunately, that issue will require more time to repair, so “another diesel weekend”, as the engine crew says. 
To top things off, we have added a documentary film crew to our menagerie.  The team from Kailuna Productions is producing a series of documentaries about historic restorations, and is shining the spotlight on the Sierra #3 restoration.  This requires a bit of effort on our part, to accomodate the extra folks in the physical space, as well as interpreting the project for the camera.   
We also had several tour groups in the park today, with volunteers Darryl Bramlette and John Stier leading tours (along with regular Thursday tour guide Ron Jeske), sent off the smokebox ring to Chelachtie Boiler Works for mating to the new boiler, and procured a hydraulic press rental for use on the project. 
We ended the day with the test run of the freezing process, with an impressive display of the physical properties of liquid nitrogen.  Whew.  Long day. 
Erik Young takes final measurements on crankpins.

Erik Young takes final measurements on crankpins.

While Kurt Anderson measures the crankpin holes.

While Kurt Anderson measures the crankpin holes.

The driving wheels sit in the warehouse, ready to go.

The driving wheels sit in the warehouse, ready for the procedure.

Railroad Restoration Lead Worker, George Sapp, squeezes in some time to help diagnose performance problems on the Shay #2.

Railroad Restoration Lead Worker, George Sapp, squeezes in some time to help diagnose performance problems on the Shay #2.

Volunteers Dave Tadlock and Warren Smith (along with Kevin Zimmerman and Ron Sloan), spent most of the day preparing for a test run of the Shay #2, in the hopes of operating it on Saturday.

Volunteers Dave Tadlock and Warren Smith (along with Kevin Zimmerman and Ron Sloan), spent most of the day preparing for a test run of the Shay #2, in the hopes of operating it on Saturday.

George Sapp spent time being interviewed by documentary film crew.

George Sapp spent time being interviewed by documentary film crew.

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