July 10-11, 2004 WC&C #1 Work Session

The turnout was light for the July session. Rick Peters got at least one more binder fit up on the frame to facilitate alignment and also removed the engineer’s side piston from the rod so the piston can be built up and machined to proper size. Steve Seibel and Kelly Bauman helped get the steel frame under the smokebox and we made another step in getting the 2nd course patch fit in. It may seem slow but positive steps are being made all the time.

Progress on Fitting Second Boiler Course

June’s work weekend resulted in progress on the fitting of the second course of the Montreal. We had a very nice turnout of workers including Mike Wahl, Kelly Bauman, Bob Jackson, Steve Seibel, Doug Klitzke, Darryl Gasser, and Bruce Case. The second course is the tapered course which is especially difficult to fit. Finished to a point where Becker Boiler needs to fabricate an attachment to allow finish fitting of the patch.

Holes were cleaned up for many of the new studs by tapping the sheets with special boiler taps (tappered). It is necessary to ‘clean’ the holes so that a completely sealed ‘joint’ will be made between the stud and sheet. Obviously, leaks will not be tolerated.

Driving box binder fitting was initiated on the frame. This is necessary to determine the repairs and alterations required to renew the shoes and wedges.

Ultra sounding of more of the boiler sheets was also accomplished. Becker Boiler has started welding up the ‘old’ stay bolt holes so that they can be redrilled, reamed and tapped to return the stay bolts to the original 7/8″ diameter size. When a stay bolt breaks, it can be renewed by replacing it with a new bolt a little larger in size (usually 1/16″ larger in diameter). As time goes on, the bolts can wind up much larger than the original size which can result in more frequent breakage. Returning the bolts to the orginal design size will allow future repairs without jeopardizing the original design specifications.

It may seem as though the progress is slow at this time….fitting of the boiler patches are extremely delicate and MUST be done correctly the first time! Various inspections are also requirred through out the boiler patching process which can result in longer lead times.

Plans are being made to manufacture new tube sheets to complete the boiler repairs.

Magnaflux Testing of Driving Wheels

The driving wheel centers for the WC&C #1 were tested for cracks using the Magnaflux process. Heavy cable was coiled around the section of the wheel to be tested. It was then connected to a very large machine similar to a welder. The area to be checked is then sprayed with an indicator which contains fluorescent iron particles. The machine then passes a very large electrical current through the wire to set up a magnetic field in the coil as well as the iron it is coiled around. If there are any cracks in the material, a flux leakage occurs which creates a disturbance in the magnetic field similar to two separate magnets being very close together. The iron particles are attracted to the flux leakage just like the end of a magnet. A very high power ultraviolet light is then shone on the area. If any cracks are present, the concentration of the fluorescent iron particles at the crack are extremely easy to see. The results? A few cracks were detected and final analysis will be determined by the General Foreman of Running Gear.

Ultrasound Testing Nearly Complete, Testing of Drivers Scheduled

Progress was made during the last work weekend. The ultra sounding is basically completed, the rear flue sheet template done, and the second course patch started for fitting. The testing of the wheel centers is scheduled and should be completed shortly, this will tell us the condition of the spokes and centers of the drivers. If you remember, the 1385 drivers had only two spokes that didn’t have cracks and some of the spokes had several cracks. We do have ‘new’ tires that can be machined and shrunk onto the centers.

Successful Spring Fling Work Weekend

Spring Fling was compact but successful. We had the help of Doug Klitzke, Kelly Bauman, Jim Connor, Phil Blinderman, John Sorrel, Jeff Bloohm, Bob Jackson, Doug Crary & Mike Wahl. Both diesels were inspected and readied for the season although serious problems were found with the “A” prome mover of the 4. The work of fitting the second course patch is about half done. More ultrasounding was completed and a cardboard template of the rear tubesheet has been made. Our next work session is the 8th & 9th. Opening Day! More of the same, ultrasounding, drilling of staybolts and also drilling rivet holes in the 1st course patch. More fun to be had by all!