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!

 

 

May 2024

 There were two work sessions in May involving primarily fitting the new east end sill.  Some repair work was needed on the vertical framing that joins with the sill.  Work also continued on tie rods and cross blocks between the north outer and intermediate sills.

The new end sill was moved from the roundhouse into the car shelter and placed on a jack for positioning.  Dean, Mike and John are shown here.

This photo shows the south end of the new end sill with the tenons of the new outer (south) sill in the left of the picture.  The vertical framing tenons are above.  These ends will be removed and new wood spliced into the framing.

Another view of the new end sill.  The drill is for drilling holes for the tie rods, one of which can be seen toward the upper left of the photo.

The north end of the new sill.  The vertical framing in this corner is missing the ends and new ends with tenons will be spliced on.

Work progressed on welding the tie rods together as seen here.  Joe's helmet is on one of the cross braces and the welder just off the right edge of the photo.

One of the horizontal tie rods in the new north outer sill that has been welded and a nut and washer placed on the end.

Drilling for a vertical tie rod in the new end sill.

The new sill has been moved into place and is supported by blocks instead of the jack.  The bad ends have been removed from the corner framing.

In this view of the northeast corner the corner posts have been put in place.

The southeast corner with the corner post held by a come-along.

Another view of the northeast corner.  There is a gap between the corner post and the tip of the new end sill that will have to be dealt with.

Craig and Ron are checking the fit of the new sill.

Ron is fitting one of the vertical tie rods that will hold the sill in place.

The ends of the old tie rods are cleaned up with a grinder prior to welding on the new segment.

Craig and Glenn are fitting the corner post.

There were no work sessions in COS in June because of activity on the railroad.  The work on the baggage car will resume in July.

Thanks again to Don Atkinson for help with the photos.

April 2024

 The old east end sill of the car was moved into the roundhouse for use as a pattern for fitting the tenons in the floor sills and wall framing in the new sill.  Bolster bolts were installed in the new north outer sill.  Cross braces were fabricated and installed between the north outer and intermediate sills.  Two extra work sessions were held in April because of weather cancellations earlier.

The new and old east end sills.  The mortices will be cut into the new sill in corresponding locations to where they are located in the old sill.

Dean is giving Craig a break on the router.  John is holding the light.

Dean is trimming the edges of a mortice.

Dean, Craig and John at work.

The east end of the car was cleaned up, removing old nails, etc.  I believe this is Mike working here.

This side looks good.

Ready for the new end sill (new south outer sill on left).

Similar view of the new north outer sill.

This photo shows two horizontal bolster bolts in place in the new outer sill.  Cross bracing blocks are resting on the intermediate sill and bolster above.

Drilling for the vertical bolster bolts was more challenging (gravity, you know).  Dean is using a right angle drill which helps some.

Most of the work on the cross braces was done from outside the car.

Easier than bending over from inside but still awkward.

New door posts have been installed.  New cross braces are at the bottom of the  photo.

The new east end sill is getting closer to being fitted into place.

The big square nuts for tie rods have been countersunk.

Vertical tie rods were fitted for welding together in the north wall.