September 2015

September saw progress in several areas, the roof, vertical tie rods on the ends of the car, needle beams and bolsters, and window frames.

The tie rods had to be cut and threaded in order to install as space is limited above and below the car.  This photo shows a coupler joining the pieces together after installation.

In this photo a nut is being placed on the upper end of a rod which is passing through the horizontal beam above the door.

Here Ron is placing a nut and washer on the lower end of a rod.  (I wasn't kidding about the limited space.)

The bottom plates for the bolsters were installed.  This photo shows the plate resting on blocks below the bolster which is at the top of the photo.  It will bolt to the end of the bolster and provide support to the sides of the car.  The pin for the trucks goes through the center of this plate, so it essentially supports half the weight of the car.

This photo shows the bottom plate against the (somewhat rusty) bolster with bolts in place but not yet secured.  The end of the bottom plate is against the truss rod bracket.

Meanwhile Jim and Craig  continued to work on the roof.  The curves on the ends of the car are complex and required considerable fitting.  Here they are installing a piece of "bendy" plywood.

To refresh our memories, here is a drawing of the support mechanism under the car.  The bolsters are near the ends of the car, and the needle beams are on either side of the center running across the width of the car and seen on end in the drawing.  The queen posts abut the needle beams and act as spacers between the tie rods and needle beams.  This provides support to the center of the car.  (Click on image to enlarge.)

Here Ron and Bill are preparing to raise the needle beam into position using an ingenious and one-of-a-kind mechanism to accomplish this.  The beam is surprisingly heavy, not your average 4x4.

Success!  Now to bolt it into place.

These are the bolt holes for the needle beam on one side of the car.  They look innocent enough, but much of the framing had to be removed from the side of the car to expose them.

Like so.

Work continued on the interior of the car as well.  Here Tom is working on the clerestory frames, pulling old nails, I believe.

Craig continues with the trim here on the end of the car as well as inside along the bottom of the windows.  (See previous post.)