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!

 

 

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.