Running Gear, Shop Prepares to Receive Boiler

Specs and drawings are finished for the boiler and all current drawings have been released to Continental Fabricators in St. Louis, the manufacturer of Chicago & North Western #1385’s new boiler. Continental spent late November and December working on the firebox. The stay bolt layout is in full swing with cutting and fitting the sheets taking place in December.

Stay bolt sleeves and washout components are currently in process at SPEC Machine. Stay bolt lengths have been compiled so that work can begin on machining these components in preparation of the firebox assembly.

There will be an amount of trial and error with the sizing and tolerancing of some of the components. The welding process that each will endure during fitting to the boiler has the potential to distort the parts significantly. SPEC Machine is building some sample parts to try to simulate the installation process. These samples will better estimate how much distortion to expect so the appropriate adjustments can be made. This will require some extra work but will minimize the potential for these parts to cause issue on on the actual boiler.

The latest engineering work has been centered on the the steam dome. Designs are currently being reviewed by Continental Fabricators with an emphasis on compliance with American Society of Mechanical Engineers (ASME) code.

Continental Fabricators is currently set to begin production of the bulk of the boiler in early-to-mid January. Once production ramps up, things should move quickly with the new boiler anticipated to be completed in late March or April 2018.

Upon completion of the boiler, it will be shipped to SPEC Machine in Middleton, Wis. where it will be set onto the running gear. In the intervening three to four months, the 1385 Task Force and SPEC Machine personnel are doing their best to have the balance of the locomotive ready. The goal is to for the most part complete the repair phase on the rest of the locomotive so by the time the boiler arrives, efforts can be entirely focused on reassembly. The plan calls for having as many parts as possible finished being machined or cast so workers can simply grab an item from the shelf, attach it to the locomotive and move on to the next item. Areas that are going to be seeing attention in the coming weeks include items like grates, grate bearers, brackets, water glasses, throttle linkages, lubricators, journal pads, oil celler liners, and many other small but crucial parts.

Part of preparing the locomotive for the boiler’s arrival involved moving it into SPEC Machine’s new shop bay. The preexisting shop did not have adequate clearance for the 1385 in a fully assembled state so an expansion of the shop was required with a larger door and higher ceiling clearance. That construction project was completed in late fall 2017.

With the new shop bay ready, the next step was to move the 1385’s running gear to its new berth. What sounds like a relatively small task was anything but. Even without the tender, boiler, or cab to worry about, the locomotive’s running gear alone still weighs approximately 90,000 lbs. The first task was to construct temporary panel track into the new shop bay. Volunteers gathered at SPEC Machine on November 11th to construct 60 feet of new track.

MCRM volunteers Ed Ripp and Dick Gruber, both of whom’s careers are in the Wisconsin & Southern Railroad’s maintenance-of-way department, led the effort. The other volunteers, all of whom were new to track work, were ready and eager to be imparted with knowledge. Lessons included using the proper tools for the job and how to work smarter, not harder. Each person got a chance to try all the various tasks. Nancy Kaney, one of the first-time gandy dancers commented, “It was a great learning experience. Dick and Ed were really good teachers.”

With the panel track prepared, the next step was to move the partially reconstructed locomotive into the new shop bay, a distance of only about 30 feet. This took place December 18th. Volunteers began arriving around 5 a.m. to lubricate and tow the locomotive out the shop door. A crew from Ideal Crane Rental arrived at 7 a.m. and began setting up the crane and adding the necessary 100,000 lbs. of counterweights.

MCRM volunteer Ed Ripp looks on as the crew from Ideal Cranes readies for the lift.

By 9 a.m. a small crowd of 20 or so volunteers, family, friends, and well-wishers had gathered to watch the process. The first lift attempt occurred shortly after 9:30 a.m. but was was halted so that a few small brake components could be removed to avoid taking damage from the lifting cables. A few minutes later they were ready to try again but had to stop when the the fireman side of the locomotive was raising slightly faster than the engineer’s side. After a few minutes of adjusting the cable lengths, the crane operator tried once more, this time gracefully hoisting the roughly 90,000 lbs. and four years worth of hard work off the ground.

While the locomotive was suspended in the air, ground crews slowly spun the the locomotive’s running gear 180 degrees. Completing this maneuver now will simplify steam-up tests later this year by making it so the locomotive will only need to be pulled forward by 20 feet or less to have the smokestack clear of the building.

Mike Wahl, 1385 Project Manager (Left), and Steve Roudebush, owner of SPEC Machine (right) check the locomotive’s alignment before it begins its decent down to the rails.

With seeming ease, the crane operator lined the locomotive directly over the track and gently lowered it onto its own wheels once again – the whole operation taking only a couple minutes once the wheels were off the ground.

With the locomotive back on the rails, volunteers and crane crew went about removing the cables and attaching a custom made drawbar to allow a tractor to tow the locomotive inside its new berth. With the job complete, the crew disassembled the temporary panel track and headed into the shop for a chili lunch and to make plans for the next work session.

Putting on the Brakes (In a Good Way)

The Steam Readiness team is gearing up for the return of the C&NW 1385 next year. In late July an order was placed for a new water pump which is to be installed at the end of the line at Quartzite Lake. For the foreseeable future, it will serve as the museum’s primary locomotive water supply source. The water tower at North Freedom is not presently able to hold water due to deterioration of the wooden tank, plus it used to be fed by the Baraboo River, but the river’s poor water quality makes it unsuitable for future use. The museum’s well is only low capacity and is just adequate to keep up with restroom usage.

The new pump at Quartzite Lake is rated at 300 gallons per minute (the 1385’s rebuilt tender has a capacity of 7,500 gallons). A 2-1/2 inch fire hose will be utilized to get the water from the pump to a bottom-feed port built into the tender tank. This will eliminate the need for crew members to climb on top of the tender tank to take on water using the old water column—an important safety consideration given that many Mid-Continent volunteers are retirees and may not be as agile as the typical steam crews of yesteryear.

The 1385’s boiler progress continues to move forward at a steady pace. Initial assembly of some of the fundamental components identified several minor discrepancies. It was noticed that a few pieces of the raw material did not conform to the design tolerances. While the discrepancies did nothing to jeopardize the boilers construction, they did warrant an extensive review of the computations and detail drawings that support the firebox. This review was completed and addressed all of the issues adequately.

Continental Fabricators has spent the following weeks updating their engineering data to accommodate these revisions. This has caused some delay in the assembly of the boiler but fortunately no alterations are necessary. The task force members, working in conjunction with Continental’s Engineering team are nearing completion of this task. As soon as the data streams are re-aligned, work on assembling the boiler will resume. A new fabrication timeline will be developed as soon as work is ready to be resumed.

Meanwhile, Steve Roudebush and company at SPEC Machine have stayed busy working on other components of the locomotive. The photos and captions that follow highlight the recent work taking place at SPEC Machine’s shop in Middleton, Wisconsin.

Report by Jeffrey Lentz with contributions from Brett Morley and Steve Roudebush.

C&NW 1385 Update – June 2017

Brett Morley, the 1385’s boiler engineering expert from Performance Engineering provided a brief update on the 1385’s boiler production as of mid-June for the museum’s  member newsletter, the STEAMER. That article is reproduced here:

The flanged sheets worked on by Gary Bensman of Diversified Rail Services were completed and sent back to Continental Fabricators at the end of April. This was a little longer than we had hoped but the finished results were well worth the wait. I had instructed Continental not to proceed with any of the additional fabrication until the finished flanged sheets arrived and could be verified dimensionally. This proved to be a worthwhile wait as the sheets had to be altered a little in order to fit through one of Gary’s flanging dies. In order to fit his standard tooling he was forced to reduce the inside radius of the door sheet and rear flue sheet from 2” to 1.5”.

The deviation from the print does nothing to effect the boiler’s performance, nor would it be noticeable with the naked eye. It did however change the dimensions for the mud ring. We were able to adjust the boiler’s 3D model and produce a mud ring that fit the flanged sheets. Continental then proceeded to fabricate the mud ring to the new dimensions and ship it to SPEC Machine. It was test fitted for dimensional accuracy and all of the dimensions aligned as expected. While at SPEC we took the opportunity to drill and tap the underside of the mud ring to alleviate the need to do this after assembly. This negates the need to perform this task upside down ( a real pain). The completed mud ring was shipped back to Continental Fabricators at the end of May along with all of the new 5” flues that were previously housed at the museum.

Since the mud ring completion I have been updating the stay bolt layout for the throat sheet and backhead. The radius change required a slight change to the outer edge of the stay layout. We had known for some time that the original backhead layout needed some adjustment so this turned out to be the ideal time to perform this task. I completed the new layouts over in early June and began transferring them to Continental Fabricators on June 12th.

Bending Steel

During the second week of March, SPEC Machine’s Steve Roudebush and Tyler Roudebush along with Brett Morley of Performance Engineering traveled to Tennessee Valley Railway Museum to meet with and assist Gary Bensman of Diversified Rail Services. Diversified Rail Services was contracted by Continental Fabricators to flange the four firebox sheets needed in building 1385’s new boiler.

Catalog page

The McCabe Flanger in a 1921 American Society of Mechanical Engineers Catalogue and Directory.

Flanging is a process to make a smooth bend in steel forms while the steel is cold. Flanging can also be done while the steel is hot but it adds more time, work and requires more people. The choice of whether to use hot or cold flanging is made largely on the shape being bent and where on the sheet of steel the bend needs to be made.

The machine seen in use here is a McCabe Flanger, a steam-era machine which uses pneumatic pressure for power. The bends are made a little at a time to prevent creating a wrinkle in the sheet.

The accompanying photos show the the aforementioned persons along with formation of the 1385’s rear tube sheet. The tube sheet forms the front of the firebox, meaning one side will be exposed to intense fire and combustion gases while the other side will hold back a wall of water. Before being installed, the rear tube sheet will have holes drilled for and support nearly 200 2-inch fire tubes and 24 superheater flues. The tubes and flues go through the water space of the boiler to conduct the combustion gases from the firebox to the smokebox at the front of the locomotive and allow the water and steam time to absorb more heat from those gases. The tubes and flues also serve to help support the tube sheet. Since the sheet is a large, flat surface, steam pressure is constantly pushing on it, trying to bow the sheet, but the tubes and flues mechanically tie together the front and rear tube sheets, providing strength and holding the sheets flat.

curved tube sheet

C&NW 1385’s new rear tube sheet takes shape. This is a view of a blend from a straight side to 12.5″ radius corner to 72″ radius crown sheet. Photo courtesy Gary Bensman. Mr. Bensman of Diversified Rail Services was contracted by Continental Fabricators to form the sheets for #1385’s firebox and tube sheets.

 

Above video courtesy SPEC Machine.

“Drawing” Conclusions on C&NW 1385

On the afternoon of Friday, February 24, 2017, the C&NW 1385 Task Force received the latest packet of shop drawings for the new boiler from Continental Fabricators for Mid-Continent to markup and approve. The painstaking process was started the following day at SPEC Machine and great progress was made.

Boiler review meeting

A C&NW 1385 boiler review meeting is held on, Feb. 25, 2017. The locomotive’s running gear and cab are just visible in the far left background. Photo courtesy Pete Deets.

Previously, Brett Morley of Performance Engineering had completed a SolidWorks™ 3-D model derived from countless hours measurements of the original boiler by him and others on the 1385 team as well as a study of the Chicago & North Western’s drawings for the locomotive, obtained from Lake States Railway Historical Association. The model provides a 3-D representation to check, among other things, whether and how well all the parts will fit together. Files derived from the model were provided to Continental Fabricators who then created their own preliminary construction drawings that are now being sent back to us to proof, mark up and return. The packet received on February 24th is the latest iteration.

boiler drawings

CNW 1385 boiler drawings undergoing review. Feb. 25, 2017. Photo courtesy Pete Deets.

The 1385 team must examine every minutia of the shop drawings to prevent any mistakes. It is a very painstaking and tedious process but the manufacturer will build precisely what is on the paper and it is Mid-Continent’s responsibility to make sure what is there is what we want and need.  

A few of the many details being reviewed include:

  • Diameters and shapes of each course
  • Overall length of the boiler
  • Mud ring size, shape, placement, and material
  • Shapes and placements of clearance holes
  • Size & placement of washout plugs
  • Placements of the throttle/superheater header/branch pipes
  • Size and placement of the safety valve outlet and appliance manifold outlet
  • Placement and size of cutouts in the smokebox

Every dimension on every drawing is going to be checked. Every description of every weld called out will be cross checked. The material listed for each part will be checked. These things will each be cross referenced against the C&NW drawings, actual measurements of the old boiler, and the SolidWorks™ model.

CNW 1385 drawings on table

The CNW 1385 boiler review meeting team sets up shop at SPEC Machine. Feb. 25, 2017. Photo courtesy Pete Deets.

With a project this scope, any mistakes are forbiddingly expensive so the team is proceeding as swiftly as they can without rushing the job. As the first round of checking concluded on Saturday, a fair sized chunk of the job has been completed. So far the Task Force have been quite pleased with what has been supplied from Continental and when finished, all the corrections will be sent back to them. Once those corrections are applied, Continental will send another packet and the process will repeat until there are no more corrections. Despite the intense workload on the Mid-Continent volunteers and partner contractors, the project is staying quite close to the manufacturing timeline and we are getting ever closer to the actual build.