Ready to weld - February 15-27, 2014

The last pieces of steel to be fitted will brace the upper corners of the car and add stability to this area.  One end is bent at a 90 degree angle and will be welded to the inside of the plate secured to the end of the car, and other end will be welded to an angle piece bolted to the upper sill where Lenny is securing a clamp.

Grooves were cut in the framing so that the steel can be recessed allowing for the interior finish material to be flush over it.  Bill is working on one of the corner notches.

This photo shows one of the corners with the steel strip in place abutting the end plate to which it will be welded.

The other end of the steel strip will be welded to the angle piece which can be seen just below it.  This is a view from the inside of the car.

Here is a view from the outside of the car showing the angle piece that will be bolted to the sill above.

These pieces had to have the paint removed from the areas to be welded.  Thanks to the Trolley Museum I was able to use their wire wheel.  And thanks to Tom for taking this photo.

Meanwhile, Bob and Lenny were finishing up drilling the plates that will go under the pivot blocks where the trucks are attached.  These will be welded to the large angle pieces that are attached to the inner sills.

Rich joined us 2 weeks ago - some people have day jobs, I guess.

We received some vital hardware from Russ Hanscom who fabricated these in his shop.  These are fittings for the truss rods that run the length of the car.  Please see the photo of a diagram on the posting Sept. 7, 2013 showing where these are located.  Many thanks, Russ.

Finally, in the photos below, Craig has been busy in his shop as well.  He sent pictures of pieces he has made that will be needed to install the trucks.

Truck brake beams.

 

Truck bolsters.

 

 







Windows and steel - January 18, 2014

 Craig, Bob, and I fitted window frames that Craig had made in his shop.  The windows are in  two pieces, a fixed upper pane and a lower one that can be raised and lowered for ventilation.

The upper frame rests on a molding that is fastened to the frame of the car.  The lower pane rests against this molding as well, and can slide up and over the upper pane.

There was some trimming that had to be done, and we broke out the table saw for the first time.  In the lower right of this photo a pressure clip can be seen in another piece that is fastened to the framing that holds the lower pane in an open position.

This photo shows an original upper frame with a peg in place that fits into a groove in the wood above.  The upper frames are put in place by inserting the peg in the groove, then pushing the lower part in over the shelf in the molding along the side of the window.  They can be removed if needed to replace glass by reversing the process.

Meanwhile Tom is preparing for adding steel to the ends of the car by cutting out notches in the framing with an oscillating tool.  Each end will have a steel "cage" that will be welded to the steel below for added stability.  More details on this later.

Lenny was using the magnetic drill to drill steel plates that will go under the car at the pivot points of the trucks, and will be welded to the angle steel that is fastened to the inner sills.  The large hole is for the pivot bolt, and smaller ones for bolts to secure the plate.  We are hoping to complete the welding soon, weather permitting.

Last session of 2013 - 12-21-13

On this chilly December day we removed the cross pieces of steel from the ends of the car and welded the other side of the joints, that is, the side toward the car.  The ends of the steel have been beveled in preparation for the welding.

Mike, on the left, has agreed to help us with the welding, thanks to Lenny and Sarah for being in touch with him.  He is a professional welder, and here he and Tom are getting started.

Mike works quickly and does an excellent job.  He did all of the joints of the steel cross pieces at both ends of the car.

I got to bat clean-up, grinding the welds smooth so the steel would fit snugly against the framing.  Thanks to Tom for taking this photo.

 After the welding was completed the steel was raised up and slid into place under the overhang.

Meanwhile, Craig was working on the letterboards.  He had to replace part of the board on the end of the car because it was badly deteriorated.  Note how the end and side boards are dovetailed.