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.

Your Help is Needed to Complete Our New Display Building

Mid-Continent Railway Museum has one of the largest restored wooden car fleets in North America and is continuing to obtain and restore additional wooden cars. Nowhere else is there anything like it, and its potential is tremendous. At the present time the restoration department is actively restoring two wooden passenger cars and has many more cars waiting to be restored. Of those cars waiting restoration, many are stored outside and subject to further deterioration by the elements. The Car Shop, where the restorations take place, has room for approximately 8 cars and is currently full. If you would see, or have seen, the wooden cars that have been restored by the member volunteers, you would agree that the restored cars are works of art.

Currently once a wooden car is restored, there is no place to display or store the car. Mid-Continent has only one building on the property that is currently used for the display of restored cars, the Coach Shed, and that building is filled to capacity (13 cars). Three of the cars currently stored in the Car Shop are fully restored and take up room where other wooden cars could be stored pending restoration.  It would be totally impractical to place a restored car outside, subject to the elements, especially a Wisconsin Winter, as the car would have to be restored again in just a few years. The only reasonable solution is to build an additional coach shed for displays.

Tarped train car

A shortage of indoor storage and display space leaves tarps and temporary coverings as the only means of providing a modicum of protection to many of Mid-Continent’s treasured collection items – obscuring them from public view in the process.

In 2016, Mid-Continent received the final payment from a bequest from the estate of Laurence H. Dorcy totaling $968,046. The funds received from the Dorcy estate were restricted, but could be used to build “a structure for the restoration and storage of railroad cars.” The Board of Directors of Mid-Continent has approved the building of a new Coach Shed #2. At the present time, work has begun on the site development and grading phase of the building project. The next phase of the project is the construction of the Coach Shed and the building of track to the new Coach Shed. The total estimated cost of the project is $1,144,000.

Proposed site plan for new display building.

Proposed site plan for new display building.

Construction progress can be viewed in real time on our webcam.
Netcam

The mission of Mid-Continent is dedicated to preserving and interpreting the railroad legacy for the educational benefit of the general public. Its primary focus is on railroading of the Upper Midwest during the Golden Age of Railroading, 1884-1915.

This is why we are turning to you now. We need $176,000 to complete the project. Would you help preserve wooden railroad cars of a bygone era?  Please consider making a contribution to Mid-Continent so that this worthwhile project can be completed.

A Message from the Restoration Department

Our very large collection of wooden passenger cars dates from the Golden Age of Railroading (1884 to 1915). Several of the restored cars have received prestigious awards for their historically accurate and high quality restorations. These cars are gems, with the restored cars being diamonds and the cars awaiting restoration being diamonds in the rough.

The wooden passenger car collection consists of (24) cars, built by (9) different car builder companies dating from 1864 to 1912. Nine of the wooden cars have been painstakingly restored, two are in the process of being restored and the balance of the cars are awaiting resources to restore the cars to their former beauty. Restoring a 100+ year old wooden car is no small undertaking as it can take some 10,000 man hours and anywhere from $150,000 to $1,200,000 depending on the level of volunteer labor.  In the Car Shop the volunteers strip the wooden cars to their frame, replace any rotten or defective wood, and then rebuild the cars to their original glory, meticulously following the details that the original builders made when the car was originally built.

The collection contains a full array of passenger cars including luxurious first class cars, business cars, coaches, combination car, a sleeping car, baggage and mail cars. In addition the collection includes the only original “fish” car that has been preserved and restored. This unique car was built for the Wisconsin Fish Commission in 1912 to stock fish (fingerlings) in streams and rivers throughout the state of Wisconsin. The collection also includes complete sets of passenger equipment from specific railroads such as the Soo Line, Lake Superior & Ishpeming, Copper Range and the Duluth South Shore & Atlantic. These sets of equipment add to the importance and significance of Mid-Continent’s wooden car collection.

Presently only 50% of Mid-Continent’s wooden car collection is under cover with only 25% of them accessible for the public to view. This priceless collection is at significant risk due lack of appropriate enclosed exhibit space. The challenge now is to find the necessary resources to protect these gems from the harsh environmental conditions of Central Wisconsin. A new exhibit building is urgently needed to house Mid-Continent’s wooden passenger car collection, provide public access, provide additional exhibition space, and assure that these gems are preserved for future generations. We thank you for your consideration.


UPDATE: October 20, 2017

Site grading for the structure is complete and concrete subwalls are poured. Construction of the structure is now underway. The creation of the fire access road paralleling the building is underway as is installation of the subgrade for the interior railroad tracks. Over 1,100 new railroad ties for the project have been ordered and are expected to arrive in late October. The final phase – construction of the nearly 1/3-mile of new railroad tracks to access the building – is anticipated to occur in spring 2018, assuming adequate funding is available to complete the task. Your support toward completion of this final stage is appreciated!

Wall posts going up on the morning of October 20, 2017.

 


UPDATE: November 16, 2017

On Wednesday, Nov. 15, 2017, Cleary Builders wrapped up installation of the walls and roof and windows. The building looks fantastic, although there is still a lot of work before the building can be put to use. The walk doors, three overhead doors in the rear of the building, lighting and electrical are yet to be installed. There is also no floor in the building as of yet. The building will have concrete walkways running the length of the building (an improvement over the brick walkways found in Coach Shed #1). With colder temperatures setting in, the pouring of concrete has been pushed back to the spring.

Outside the structure itself there is still much work to be done. Many truckloads of rock need to be hauled in to form the roadbed of the new tracks and the ballest. Trackwork will be completed next spring by Knapp Rail Builders, a railroad construction firm used by Mid-Continent numerous times in the past few years for larger-scale track projects. Ditches need to be further shaped and seeded and culverts installed. Walkways must also be placed between the entrance of Coach Shed 1 and the new building.


Make your donation via mail using our New Display Building Donation Form or donate online using the form on our Donation page. Be sure to write in “New Display Building” in the online donation form. Credit/debit card donations can also be accepted by phone at 608-522-4261 or 800-930-1385 during museum office hours. Donation acknowledgement letters for tax deduction purposes are promptly mailed after each gift.

Mid-Continent Railway Historical Society, Inc., a not-for-profit Wisconsin Corporation, is an outdoor living history museum and operating railroad, and is accredited by the Internal Revenue Service as a 501(c)(3) organization. All contributions to Mid-Continent are tax deductible.

Fundraising total last updated: Nov. 16, 2017

News Article: Big (and Expensive) Period for Steam Locomotive Begins

Wisconsin State Journal reporter Barry Adams dropped in for a visit to SPEC Machine late last week to see what was new on the Chicago & North Western No. 1385’s restoration since his last visit to see Mid-Continent’s flagship steam locomotive one year ago. You can read the full Wisconsin State Journal article and view the numerous photos at Madison.com.

A few highlights from the article:

  • Steel for the new boiler will be cut this week (February 20, 2017) at Continental Fabricators in St. Louis.
  • Additional steel will be cut and shipped to Tennessee Valley Railway Museum where the new firebox is to be crafted.
  • The firebox will be delivered to Continental Fabricators in St. Louis, Missouri, attached to the boiler, then shipped to SPEC Machine in Middleton, Wisconsin where it will join the running gear and cab for final assembly.
  • Arrival of the finished boiler is now expected for June 2017.
  • This is the most costly phase of the locomotive’s restoration. The new boiler and firebox will cost roughly $700,000. (Please consider visiting our donation page!)
  • SPEC Machine is building a 1,500 square foot expansion to their shop to facilitate final assembly of the 1385 on-site.
  • Other upcoming projects at SPEC Machine include refurbishing brakes, installing pistons, rehabbing the superheater header, refurbishing the sand dome, and the many other parts that are yet to be installed.
  • Mid-Continent’s goal is to have No. 1385 fully assembled and returned to the rails in 2018.

 

C&NW 1385’s Boiler Design Review Meeting Held

A design review meeting was held at Continental Fabricators in St Louis, Missouri on Tuesday January 24, 2017  Members of Mid Continent’s 1385 Task Force were in attendance as were Gary Bensman of Diversified Rail Services, Steve Roudebush from SPEC Machine, and Brett Morley of Performance Engineering. The meeting covered all of the details necessary to build the new boiler as well as provided a platform for everyone involved in the design process to review the fabrication plan with the team at Continental.  It was a very productive meeting with everyone having input into the planning of the new boiler and Continental coming away with some clear direction enabling them to proceed with the task at hand.

Action items to come out of this meeting include the development of Continental’s final production schedule. Fred Steinkuehler, Vice President of Plant Production at Continental is currently developing their schedule. He is basing the plan on Mid Continent’s detail drawings and expects to be finishing up within a few days. While the production department work out their timeline, the engineering department will continue the preparation of internal shop drawings. We expect Continental to be wrapping up their engineering phase over the course of the next few weeks.

With the boiler process well underway with Continental Fabricators, and the major parts of the running gear and cab near completion, the Task Force identified the many remaining accomplishments still needed. Completion times were assigned to each and a general schedule was outlined. It has been determined that, excluding any major unforeseen concerns, the 1385 can be returned to Mid-Continent next year (2018).  Timing can be determined more accurately as these projects move along.

 

CNW 1385 Boiler Drawing 3D View

CNW 1385 Boiler Drawing 3D View

At this juncture of the 1385 restoration, it was decided to forgo hosting an Open House this year. The many hours otherwise required by Mid-Continent volunteers and staff to organize and host the event will instead be spent toward expediting the completion of 1385. In place of the Open House, there will be additional volunteer work day opportunities during the year.

The Task Force is very enthused and motivated, and thanks everyone for their support.