November 2024

 November was a transitional month with the lower framing largely complete.  Preparations were made for work on the upper part of the car as well as continuing with installation of floor spacers and tie rods.  New plates were fabricated to attach to the inner sills on the west end.  Those on the east end are still usable.

This is a view of the inner sills on the east end showing the plates extending from the end sill toward the center of the car.

A closeup of the east bolster area.  One bolt is still present in the side plate on the left.

Cutting the new plate to size.

Cutting a notch for the horizontal tie rod.

One new plate in place.  Notches were made for the bolster in the upper part of the photo and the horizontal tie rod in the lower part.

This shows the tie rod better inside of the end sill.

After the side plates were installed spacers were placed which were a different size than in the rest of the car.

Another view of the spacers.  They were made by laminating 2 inch boards.

Platforms were planned along both sides of the car to work on the upper part.  First the car was centered in the structure using pipe rollers.

Not sure what the outer end of the come-along was attached to...

Care was taken to insure the care remained level and square.  In this photo they are measuring a diagonal.

Fitting of the fascia board over the east door.

Work was begun on the side platforms by installing temporary rails on the side of the car.  These are at the same height as the horizontal pipe of the shelter behind John so that the platform will be level.

Yup, it is level!

Craig has made the platform supports that will attach to the car rail and rest on the shelter pipe.

This photo shows the platform supports in place.

The platform supports are hooked onto the rail by beveled surfaces.

Work continued on the plate on the north side of the west end center sill.

Again, notched out for the bolster as well as the tie rod.

Looks good!

The plates were then attached to the center sills with lag bolts.

September-October 2024

The four outside sills have been replaced and the first work session in September was spent squaring and levelling the car prior to tightening the horizontal tie rods.  Installation of the cross bracing between the sills continued as well as replacing the ends of the vertical tie rods.

Installing cross bracing.

Joe is welding a new end on one of the vertical rods.

Grinding the welds on a vertical tie rod.

More holes were needed in the new sills for the vertical tie rods which extend from the roof sills through the floor sills.

Replacing the end of a vertical corner post.

Glued and clamped.

The work platform at the west end can be removed and the stairs replaced for easier access to the car.

One more look at the end sills.  This is the East end with one horizontal tie rod in place in the north corner.  The board at the south end holds a cable which I believe was used for squaring the car.

This is a closeup of the northeast corner.  The end sill is laminated and this can be well seen in the angled cut.

This is the southwest corner with the corner trim post in place over the sill joint.

Levelling the car required jacking and blocking.

Blocks had to support the car while not interfering with the tie rod ends.  These are near the center of the car to prevent sag.

These supports are at the east end.

This is the northeast corner.  Sometimes all it takes to level is a piece of plywood (a little below and to the left of center).

 

July-August 2024

 During this period the west end sill was replaced.  The steps leading up into the car were removed.  A new sill was prepared using the old for a pattern.

This was the situation a few weeks earlier with the steps in place.  Note the deterioration of the end sill on the right of the steps.

The steps have been removed and a work platform is being installed.

The end sill has been disconnected from the side sills and wall framing on the left.  The wall to the right of the door remains connected to the sill and has been lowered with it.

A close up view of the right end wall and end sill.

 

A view of the west end with the sill removed.  The tenons on the right wall framing have been cut to release the sill.

Concurrently the north side sill bolster bolts were installed.

Looks like Dean is trimming the tenons on the center sills.

Measuring and drilling the new sill.

The mortices need to fit the existing tenons on the walls.

But where do you measure from/to??

Looks like drilling for a truss rod.

The sill tenons and wall framing have been cleaned up ready for the new end sill to be installed.

Notice the two mortices in the end of the side sill where matching mortices on the end sill will be located.  Wood plugs will fasten the two together.

The new end sill with the two plugs in place in the near end.

Drilling for a truss rod.

Mike is cleaning up the recess for a truss rod plate.

This one fits.

There are four altogether on the two end sills.

Ron is moving the sill from the roundhouse to the Friend's shelter.

A jack will be used to position the heavy sill on the car.

The beginning of the fitting.

Getting close.  The new north side sill is on the left and the end sill is on the right.  The wall framing at the top of the photo needs to fit into the mortice to the right of of it.

Nice work, guys.

Everything seems to line up.

Looks good!