August 2015

This month saw work continuing on the roof, mostly on the curved ends of the car, as well as working on the truss rod assembly under the car.

The finishing touches were put on the clerestory roof with the installation of the fascia that Craig had milled.  Bob is putting in the last fastener.  The windows will go in below and inside the fascia.  The frames have been made but not installed.

This photo shows the framing at one of the corners of the roof.  Note the curves in two directions in the lower area.  Covering this neatly was somewhat of a challenge.

The solution is "bendy" plywood.  Sheets of this material were cut into strips and  fastened onto the framing at right angles to the framing.  A second layer was added in the same orientation but offset a half strip width for increased strength.

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This photo shows the process.  As Craig says "You can't have too many clamps."

This photo shows the strips in place.  Filler was applied over the surface and sanded smooth to complete the job.The side of the clerestory also has been covered.

Meanwhile Craig was working on the inside of the car, installing the window sills and trim between the windows.  Oh to be left handed.

Here is the finished product.  Nice work, Craig.  We will get a better look at the panel between the windows later.

Work began on installing the needle beams.  They support the queen posts which extend down to the truss rods and provide support for the body of the car.  One of the two needle beams is shown on the ground here.  In the upper part of the picture just to the right of center are two bolts exposed to which the beam will be fastened.

Here is another look at the bolts for the needle beam that can be seen exposed at the bottom of the picture.  The heads of the bolts are behind the two 2x6's that abut each other, and outside the large 2" board that runs the length of the car inside the framing.  And yes, they both turn easily with no access to the heads.

So Ron and Bill L. are beginning to remove the rusty screws that haven't been touched for 126 years so as to remove the boards to gain access to the heads of the bolts.  Where is the impact screwdriver guys?

Earlier in August Ron and Bill K. were drilling bolt holes in the spacers that go between the truss rod bracket and the bolster.  Most of the steel came undrilled and was drilled on site to fit the holes already present.