Summer 2017

We had no formal work sessions in June as many of our crew were attending work sessions in Chama and Antonito.  We resumed with two sessions in July.

It was noted that the inner sill on the north at the west end of the car showed evidence of dry rot with the bolt heads and washers sunk into the wood as shown here on the right side of this photo.

Repair was undertaken by first removing the four bolts in the area affected.  Wood dowels were wrapped in plastic and inserted in the bolt holes as shown in this photo.

Epoxy was poured into the softened wood, first a thin mixture to penetrate, then a thicker mixture to fill in the cracks and holes.

This photo shows the repair after curing.  Some grinding was needed to flatten the surface.

In this photo Bill K. has removed the plugs and is re-drilling the holes before replacing the bolts.

In this photo the bolts have been replaced and Craig is levelling the surface of the sill prior to installing the subfloor plywood.

Also it was noted that several of the cross braces were projecting above the sills.  These would have to be levelled before installing the plywood.

In this photo Craig is using a chisel to remove the protruding part of the brace.

This is after levelling.

Meanwhile Don and Bill are starting to cut plywood.  It is 11/16 thick and installed with the surface grain across the car.

The two sections of the sheet meet on one of the inner sills, alternating sills with each adjacent sheet.  The bolt head locations were marked with chalk powder for drilling.

In this photo Bill K. is putting in deck screws to fasten the plywood to the framing.

This photo shows the completed subfloor.  The plywood at each end was left loose so as to have access to the pivot area of the trucks.
















These two  photos show the pivot plates that were fabricated by John Weiss and will be placed between car body and the trucks allowing the trucks to rotate.  These were delivered recently.

Bolts of the proper length to attach the steps to the end sills were obtained and installed by Craig and Bill K.

We also received the castings for the seats as shown here by Craig.  He has his hand on one of the armrests and the raised part in the center supports the backs for the two seats.  These will be powder coated prior to installation.  The legs are angled toward the outside of the car to allow more room for feet as people move in the aisle.

This photo shows a prototype seat that Craig built.

The seat back drops down and the seat slides out to meet the adjacent seat, making a "bed" for the travellers.  A platform above drops down to make an upper bunk so there is room for 4 people to recline (cozily).  Bedding was not supplied so travellers brought their own.

Craig has also been busy in his shop starting the process of making the seats.  This photo shows some of the lumber (red oak) that was delivered.

Here he has cut grooves in a stack of boards for the seat frames.

This shows tenons cut in the material for the seats and backs.

We are also planning for finishing the roof of the car.  Here Randy is measuring for the metal roofing material that will be installed.