Category Archives: Car Shop

Follow the restorations in Mid-Continent’s award-winning Car Shop.

DULUTH Sleeping Car Receives $15,000 Grant

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We are very pleased to announce that Mid-Continent Railway Museum has received a $15,000 grant from the John H. Emery Rail Heritage Trust (ERHT) for use on Mid-Continent’s Duluth South Shore & Atlantic sleeping car “DULUTH”.

The DULUTH was built in 1902 by the Barney & Smith Car Company. The 10-section sleeping car operated daily on the DSS&A’s passenger train between Sault Ste. Marie, MI and Duluth, MN until 1934. After the car was taken out of service it was sold to a private resident of Laurium, MI and it spent the next 81 years as a summer cabin on the shore of Lake Superior. In 2015 the car was donated to MCRM and in 2016 the DULUTH was moved to the MCRM, where restoration work began to return the car to its original configuration and operating condition. For additional historical information, see the DULUTH’s Roster Page.

Much work has been done to date to restore the car. To date, volunteers and employees have dedicated a combined 3,200+ hours working on the DULUTH. This 2022 grant from the ERHT will enable MCRM to focus on the sleeping compartment, making new stained glass windows and performing some exterior work. Once this phase is completed, restoration of the car’s other interior sections, seat upholstery, carpeting and the exterior restoration will take place as separate phases of the whole project.

This is the second grant the John H. Emery Rail Heritage Trust has awarded to the DULUTH project. The Trust previously awarded $9,000 for the DULUTH in 2018 and has supported other museum projects as well, including the C&NW #1385 steam locomotive and the museum’s DL&W #595 coach car. Mid-Continent Railway Museum sincerely thanks the John H. Emery Rail Heritage Trust for their most generous grant.

About the John H. Emery Rail Heritage Trust:

The John H. Emery Rail Heritage Trust was created by John Emery, a native of Chicago, and a lover of the classic passenger trains of America. The Trust was founded as a way to support Mr. Emery’s interests in the passenger trains of the 1920s through the 1950s. The Trust operates as a tax-exempt 501(c)(3) foundation

Volunteer Kathy removes decorated trim pieces from the DULUTH sleeping car’s arched windows. William Buhrmaster photo.
Volunteer Nancy removes trim pieces from the DULUTH sleeping car’s windows. William Buhrmaster photo.
Stu pulles wires for the berth lamps in the DULUTH’s sleeping compartment. February 20, 2022. William Buhrmaster photo.
March 17, 2022 progress photo showing stripping the interior finish off the DULUTH sleeping car’s walls. Stripping of the entire interior is 90% complete. William Buhrmaster photo.
Progress photo taken March 17, 2022 showing stripping of the DULUTH sleeping car’s interior woodwork. William Buhrmaster photo.

EJ&S #2 2021 Year-End Restoration Update

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Update by Peter Becker

We had a productive year working on the East Jordan & Southern No. 2 in 2021.

Exterior Work

The year started out with Owen making a new lettering stencil for the car so he will be ready to letter the car when the time is right.

East Jordan & Southern #2 stencil.

A lot of time was spent cleaning up the trucks and truss rods.  They were then primed and painted.  We ran out of warm weather so there is some painting left to be done.  Also under the car, the north end draft gear was put back together with new spring followers, the plates that transfer force from the draw bar to the car body.

EJ&S #2 truck and truss rod.
Un-rusted new spring followers mounted in draft gear.

All four platform steps are now functional.  This required everything from a complete rebuilt for the southeast step to straightening the metal side of the northeast step to simply replacing the treads of the southwest step.

Straightened and repainted northeast steps.

The platform deck boards were replaced also.  The work required the removal of the door thresholds and some repair around them.  On the south end this also required repair of the rotten platform sill.

New platform deck boards.

Repair work on the sound deafening ceiling, the boards attached to the underside of the car body frame, was started.  The deafening ceiling was partially removed in the past to facilitate repair work so it is now piece work to fit replacement boards in.

Under-car deafening ceiling.

Other exterior work included fastening the lower roof drip rail in place, repairing the south end canopy, straightening the north platform hand rail and installing a hand brake shaft and wheel on the south end platform.  An additional post for the south end hand rail was also found and installed.  The following two photos show the south platform with the roof drip rail, the new wood on the canopy corners and the installed brake wheel and hand rail post.

EJ&S #2 southeast corner.
EJ&S #2 south end.

Interior Work

The project last winter was to clean the clerestory windows and mount them in new sash that was built some time ago.  There are 30 windows and 28 are now done.  Two stained glass panes are missing which is delaying completion of the final 2 windows.  There are 2 patterns of glass which are shown here in new sash.

One of two clerestory window patterns.
One of two clerestory window patterns.

Most of the interior work this year was stripping paint and removal of the headliner sheet metal. The next two pictures show the current state of the interior.  The plan is to repaint the baggage section in the reddish color and the passenger section will be stained and varnished.

Wood revealed after stripping paint.
In this picture, you can see the truss plank cap and the lower wainscot board were installed.

Finally, the original examination of the car interior found evidence that the partition between the baggage section and the passenger section was 6 windows from the north end of the car.  In the process of stripping paint we realized the partition was originally next to the baggage door.  Since we plan to use the original partition location, additional coach seats are needed.  We ordered 5 mores sets of cast iron seat parts and they finally arrived just after Christmas.

Peter Becker holds up new cast iron seat parts which arrived at the end of 2021.

All this work was accomplished by Dave M., Owen H., Jeff H., Jim B., Bill B., Dave W., Tom B., Richard P. and I am sure a few others that I am sorry to miss. Thanks for the help.

2022 Restoration Department Work Session Dates Announced

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Mid-Continent’s Restoration Department has released its 2022 work session schedule. These work sessions are a great way to get involved at Mid-Continent Railway Museum.

Our doors are open to anyone willing to give us a hand and help us with the restoration work. Give us a hand for a day or several days throughout the summer. Every bit of help makes a difference and is appreciated. We have a wide range of needs (i.e. painting, cleaning, stripping, wood work, roofing, refinishing, upholstery, metal work, and more) and everyone can be a help.

If you’re interested in volunteering please reach out! To be placed in contact with Bill Buhrmaster, MCRM Restoration Manager, send us a message using the below form or call the museum office at 608-522-4261.

Session Number2022 Work Session Dates
1February 19-20
2March 11-12-13 Rescheduled to March 17-18-19 due to weather
3March 25-26-27
4April 8-9-10-11
5April 22-23-24
6May 14-15-16
7June 3-4-5
8June 24-25-26
9July 8-9-10
10July 23-24-25
11August 5-6-7
12August 20-21-22
13September 9-10-11
14September 24-25
15September 30-October 1-2
16October 14-15-16
17October 28-29-30
18November 11-12-13
19December 2-3-4

Duluth, South Shore & Atlantic DULUTH Sleeping Car Restoration 2021 Progress Report

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Very good progress was made on the DULUTH project in 2021 thanks to a great crew of volunteers, contractors and hired help. The primary focus was to work on restoring the 10-section sleeping compartment but a lot of other areas and parts of the car were also worked on during the year. The most noticeable progress on the car has to be the interior woodwork that has been stripped of its 120 year old varnish and shellac. What has reappeared is beautiful mahogany and marquetry throughout the car. Another significant milestone for 2021 was the upper sleeping berths and lower berth seat ends, as they were completed and delivered to the museum. This included six replicated upper berths and four restored (original) upper berths. The berths are absolutely beautiful and we look forward to the day when they are reinstalled in the car. Underneath the car significant progress was made the air and hand brakes. As of the end of the year we now have functioning air brakes and the hand brake system is 95% complete.

Photos and additional information on the progress made on the DULUTH Project during 2021 follows.

Berths

View of the sleeping compartment showing the woodwork that has been stripped during 2021
  • Completed the construction and finishing (staining/varnishing) of the (6) new upper berths
  • Completed the construction and finishing (staining/varnishing) (6) new lower berth seat ends
  • Applied final finish (stain/varnish) to the (4) original upper berths
  • Delivered all of the completed berths, seat ends, seat cushion frames to the museum
  • One of the original upper berths after being restored and following fresh coats of stain and varnish.
  • Another of the original upper berths after being restored and following fresh coats of stain and varnish.
  • A crate containing (5) of the upper completed berths being loaded in Michigan.
  • A crate containing (5) of the upper completed berths being unloaded at Mid-Continent.
  • (3) of the (6) new lower berth seat ends getting ready to be loaded and shipped to MCRM

Interior

  • All of the old finish (shellac) has been removed from the existing woodwork in the sleeping compartment, men’s smoking room and the women’s toilet room. This work was performed by hired help due to the extensive scope of this work and the large number of work hours required.
  • All of the clerestory windows were removed from the car. New windows are being made as the railroad revised the design of these windows and eliminated the original stained glass.
  • Sent out 100+ pieces of interior trim and wood parts to be chemically stripped
  • (12) sets of new seat cushion frames were made. Each set includes a head rest, seat back and seat bottom
  • (12) sets of seat cushion support frames and seat back top rails were made
  • (12) pairs of seat cushion support blocks were made and finished
  • Test fit the revised berth partition overlay piece (prototype)
  • Material was purchased for reproducing the headliners in the car
  • Interior woodwork in the process of being stripped inside the DULUTH.
  • Interior woodwork in the process of being stripped inside the DULUTH.
A portion of the end door after being stripped.
  • Mirror frame in the process of being replicated. Original frame (top) and replicated marquetry for a new frame (bottom).
  • New bottom seat cushion supports.
  • Test fitting the berth partition trim piece in the sleeping compartment with the aid of a laser frames and the seat cushion frames.
  • Taking delivery of the replicated oval window.

Men’s Smoking Room

  • Volunteers have further developed the drawings for the missing Smoking Room and Men’s Toilet walls
  • Removed the deteriorated headlining panel along the east wall.
  • Ordered a replacement wall panel (for above the three windows) that had significant water damage
  • The east wall of the smoking room showing the headliner and upper wall panel removed.
  • The west wall of the car across from the smoking room showing the stripping in process.

Exterior

  • Continued to remove the roof material (rolled asphalt and tar) off of the car. The roof is presently approximately 75% stripped and the majority of the wood on the roof deck appears to be in very good condition
  • (9) new oval window frames (mahogany) were made
  • (25) new outer window frames (mahogany) were made
  • 160 feet of new poplar window sills have been made for the car at an area technical college
  • We have started to remove some of the deteriorated wood siding and trim from the car
  • New replica oval window frames.
  • New lower sash window frames.
  • The cross-section of the original window sill.
  • Making the new window sills at an area Technical College.
  • View of the lower roofing being removed.
  • The upper roof deck after the roofing material has been removed.

Air and Hand Brakes

  • Completed the fabrication and installation of all of the air brake cylinder levers and rods
  • Tested the functionality of the air brakes
  • Finalized the hand brake system design
  • Completed the installation of all of the hand brake levers, rods , supports and guides under the car
  • Remaining work on the hand brakes involves installing the hand brake levers (handles), stems and support bracket in each vestibule
  • Two of the new brake cylinder levers that were made. The steel levers are 1 inch thick and 36 inches long.
  • The bottom side of the Duluth showing the air cylinder with the new levers, rods and hangers installed.
  • Volunteers installing some of the hand brake brackets.
  • View of the air brakes being tested on the DULUTH.

Parts and Hardware

  • Cleaned, restored and delivered over 400 pieces of berth and sleeping compartment hardware
  • Presently 95% of the berth and sleeping compartment hardware has been obtained, reconditioned and restored
  • Cleaned and restored the hardware and rollers for the (25) window shades
  • Secured a Baker heater for the car. The original one had been previously removed from the car
  • Restored Berth Pulley mechanism.
  • Restored and polished window shade hardware.
  • Boxes containing over (400) pieces of restored berth hardware.
  • Baker Car Heater acquired for use in the DULUTH. Awaiting restoration.

Planning

  • Updated the list of the sleeping compartment work tasks and sequence of activities
  • Obtained a proposal for reproducing additional wood parts for the car
  • Updated the three year restoration plan
  • Developing 2022+ grant requests

Fundraising

  • A total of $35,185.12 was donated (plus $1,000 pledge) to the DULUTH Project during Nov. 1, 2020-Oct. 31, 2021 fiscal year.
  • The DULUTH Sleeping Car “Matching Your Funds Drive” campaign kicked off in 2Q 2021 and met its goal in the 4Q of 2021 by raising a total of $30,000
  • The “Giving Tuesday Fundraising Challenge” held on November 30, 2021 raised a total of $2,200 

Financial

  • A total of $41,851.79 was expended on the project during the Nov. 1, 2020-Oct. 31, 2021 fiscal year. This is a combination of labor, contractor and material costs.
  • In 2021 Volunteers logged (418) man hours of time on the DULUTH project.

Report by
William Buhrmaster
MCRM Restoration Department
January 8, 2022

This report is also available as a PDF.

2021-DULUTH-Progress-ReportDownload

DULUTH Fundraising Status

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Created using the Donation Thermometer plugin https://wordpress.org/plugins/donation-thermometer/.‘Thanks$75,000‘Thanks100% Other Donors ($46,750) SLHTS ($1,250) Dailey Foundation ($3,000)Emery Trust ($24,000)

A $75,000 fundraising effort is presently underway to allow major material acquisition and some labor cost for the DULUTH to allow its restoration to move forward. This post will be updated regularly to show progress toward reaching that goal.

To help Mid-Continent restore the DULUTH to its former glory, please consider making a donation to the DSS&A Sleeper DULUTH Fund. Donating is tax-deductible and easy to do. You can make your donation via mail or donate online using the Donate button.

DONATE

Be sure to write in “DSS&A Sleeper DULUTH Fund” on the printable donation form or check memo line if sending a donation by mail. Credit/debit card donations can also be accepted via phone at 608-522-4261 or 800-930-1385 by speaking to our staff during administrative office hours Monday-Friday.

The fundraising total shown is as of March 10, 2022. The fundraiser began in May 2019. Total excludes monies raised through the Buy-A-Berth campaign and Matching Your Funds matching fund drive.