Tuesdays Are Crazy Around Here

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

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

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

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, in preparation for final assembly

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

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Crossheads and Guides

The crossheads and guides are mechanisms that ensure that the piston rod only moves in the same direction of travel as the piston.  Since the rods are connected to the crank pins on the driving wheels, without the crossheads and guides, there would be excessive transverse force, which would cause wear on the piston, and create a great deal of friction.  This process is much easier to understand in action (click the image to activate animation).

The movement of the crossheads and guides can clearly be seen in this animation. Notice the two long rods to the right of the driving wheels (crosshead guides), and the mechanism that slides along them (crosshead). This particular image depicts a different type of mechanism that can be found on the Sierra #3, but the idea is simliar.

Much work has been required to refurbish the crosshead guides on the Sierra No. 3, including machining 4 new guides (the long rectangular rods the crossheads slide back and forth on).  Bob West is currently measuring to machine the new brass (yes, another bearing surface!) for the guides.

We have been very fortunate this past couple of months.  Mike “Tony” Stroud and Ted Bray , two Columbia area machinists, have been volunteering in the shop.  That has sped up the work and helped keep the project on schedule.

Volunteer Machinist, Tony works with George on the guide pins.

Tony's handiwork. Two new pins adjacent to the original.

Bob West and Rob Buchanan review numbers for crosshead guide measurements for a final time, in preparation for machining the brasses.

Checking the measurements.

Checking measurements against the guides themselves.

Bob discusses how measurements are taken of the piston rod diameters.

Citation for animationThe Sierra #3 is equipped with Stephenson-type valve gear, rather than the Walschaerts displayed.  We’ll explore these interesting adaptations in a future entry.

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Scenes around the shop last week.

Jim Bays demonstrates fit of the rod brass around the crankpin.

Rod brass fit up in the ends of the rods.

Rods laid out, waiting for pins and installation.

Distribution pipes, installed!

James and Kurt adjust the fit of the firepan.

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Scenes Around the Shop Today

The cab is sporting a new interior coat of green.

Phil uses the mag drill to drill hole for stud in backhead of the boiler.

James and DJ attach the running board.

Bob West finishing up the machining on the distribution pipes.

Jim, on loan from Sacramento this month, lays out the rod brass for assembly.

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Scenes around the shop this week

Lots of odds and ends being worked on this week, and still lots to do!

The #3 pilot being worked on by our Tuesday volunteer work crew. Wherever possible, hardware and lumber have been retained.

The cab was brought in this week in preparation for interior painting (green Imron).

Phil climbs into the cistern (air flow tube on the left), to apply the final touch-up after installation of the baffles.

Applying the final touch-ups inside water cistern.

Material is laid out for making spring stand parts.

Cab seats, with the upholstry removed, await clean-up and repainting.

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Happy New Year!

Thank you for your support in 2009!  From all of us, to all of you– Happy New Year! 

Railtown Staff, including CSRM Foundation Staff and the Sierra #3 staff: Norm Comer, DJ Ponder, Phil Hard, George Sapp, Kim Baker, Danny Taylor, Stephanie Shelman, Lisa Smithson, Shirley Rainwater, Kurt Anderson, James Judnich, Bob West, Rob Buchanan, Ray Harm, Wendell Cushman, Ryan Richelson, Lori Brandon Rainwater, Dave Rainwater. Not pictured: Ken Roy, Joe & Virginia Bispo.

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What is that loud noise?

Last week the top of the tender was finally put in place for rivetting.  We are preserving the original tender lid and coal boards, and marrying them to the new cistern bottom and sides.  It took a bit longer than anticipated, to get them matched up.  Then bolts were applied to the approximately 500 rivets holes, to hold it into position.  During the rivetting process, one worker climbs into the cistern (with a spotter and negative air-flow machine).  Then the bolts are removed in a coordinated pattern (to disperse the stress equally as the rivets are applied), and the worker in the tank watches in-the-blind as the red rivets to poke through, and applies the rivet snap with the pnuematic hammer.  Kind of like an industrial version of “Whack-a-Mole”  This work is being done in the roundhouse, you can’t miss it when its happening, it is loud!  Come by and hear it for yourself.  Hearing protection is strongly suggested. . .

DJ and Rob wiggle the coal board into place for rivetting.

Coal board is held on with bolts until rivets can be applied.

The crew waits for the next batch of rivets to heat.

The top is preserved from the original tender. Here the old rivets can be seen alongside the new.

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Brass

Used brass piled in shop can.

Newly cast brass set up in the lathe for machining.

Turn, turn, turn. . .

Viola!

Follow along as we assemble the rods in the next few weeks!

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Tender Update

This week, several coats of a high-tech epoxy-like paint (Ceramicoat) were applied to the interior of the water cistern, to prolong the life of the tank.  The exterior was also treated with a primer.  On Monday, the lid will be set in place, and then rivetting is planned for all day Tuesday, Wednesday and Thursday.  Visitors on the behind the scenes tour may be able to observe some of the final 400 rivets as they are applied, depending on the schedule.  It will be loud in the neighborhood!

The new tender sporting a new coat of primer.

Interior of tender, with first coat of the "ceramicoat" lining applied.

Damage to old tender, caused by years of corrosion.

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Sierra #3 on the Move

The modern equipment available at the Tri Dam warehouse has been essential for completion of this project.  The Tri Dam, however, is not equipped with a crane.  We’ve had some challenges with levelling the frame with the spring rigging, and it has become apparent that we are going to need to re-machine some of the parts on the front truck.  The simplest way to remove the truck is to use the drop-pit in the roundhouse.  So, today, the locomotive made its first trip back to the roundhouse in several years!  We probably imported too much signifigance to the occasion, but it was fun!

Norm Comer (in foreground) monitors the rigging as the #3 is pulled out of the Tri Dam.

George Sapp at the helm of the 45-tonner, (with flatcar as a "handle") pushes the #3 back towards the roundhouse.

James Judnich, Kurt Anderson, Norm Comer and Rob Buchanan-- the #3 crew on hand-- just couldn't resist the bizarre photo op of the "naked" #3 with the famous water tower.

The #3 is pushed back into the roundhouse.

 Visitors will be able to see the #3 on display in the roundhouse for the next couple of weeks.  On Monday, visitors may be able to observe the drop-pit in action when the crew is scheduled to remove the front truck for some adjustments necessary for levelling of the spring-rigging.  (Please, stay behind the fence, and do not feed the crew! )

On Wednesday, the 9th, the “Behind the Scenes Tour” will be offered.  Call 209-984-3953 for reservations.  In addition to seeing the work in progress, visitors will also see a slide show covering the progress to date, as well as historic photos of the locomotive over time.

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