The end of the year saw completion of the installation of the new outer sill on the south side of the car and transition to working on replacing the north outer sill. The roof jacks were removed from the south side and installed on the north side of the car. Splits in both intermediate sills were repaired.
Tie rods were cut to free up the old sill.
A view of the west end of the north sill. The roof jacks have been moved to the north side of the car. A couple of the wall framing members that were deteriorated have been cut off although there will be less need for replacement on the north side compared to the south.
A closeup of the north end of the west bolster showing deterioration of the outer sill around the end of the bolster.
A view of the north end of the east bolster showing considerable deterioration of the outer sill in this area also. The roof has been jacked up slightly with the wall framing elevated about an inch off the sill.
Work continued in the meantime on the new north outer sill in the roundhouse. Craig and crew were routing mortises for the wall framing. The old sill was used as a pattern.
Repairs were begun on the split in the east end of the south intermediate sill. The area was cleaned up with air prior to gluing.
Larry is applying epoxy glue to the split.
It is glued and clamped.
This is one of the angled tie rod anchors that has been mortised into the new sill. Nice job!
Joe has made new grab bars.
A view of the northwest corner of the car after removal of the outer sill.
This is a closer view (with Larry gingerly entering the car) showing a door post for the side door on the floor next to the jacks that Craig has made. The door posts have a tenon on each end and will be installed in the new sill when the jacks are removed.
The northeast corner at the same time as above.
This is a view of the under side of the west end of the north intermediate sill showing deterioration.
Meanwhile in the roundhouse work is continuing on the new north outer sill using the old sill as a pattern for the mortises.
Craig has made a guide for the router...
...which cuts the new mortise. Dean follows with a hand chisel to clean it up.
A photo of the west end of the north intermediate sill (left center of the image) showing a split near the middle.
Glenn is placing a jack under the northwest corner to take load off the intermediate sill prior to repairs.
Repairs are underway, The deteriorated underside has been replaced with new wood.
In the roundhouse the new sill is being drilled for tie rods. A drill guide is fastened in place to keep the holes plumb.
Works better than an eyeball!
The new sill going into place.
Old bolts were removed from the bolster.
This is the third split in an intermediate sill, located in the north intermediate sill extending from the east bolster toward the center of the car. The bolster can be seen at the extreme left of the photo.
Here a steel plate is being installed in the repaired split in the west end of the north intermediate sill. Holes were first drilled in the plate then into the sill.
This is the same area after drilling before placing the bolts through the plate and wood.
HAPPY NEW YEAR ALL!
