Rear Tube Sheet Installation

Jim Connor reports on the installation of the rear tube sheet:

“Most of the job was done by Bob Ristow and welder Jeff Lund. The basic job was to reassemble the plywood template and see if it would fit through the front of the boiler, slide down the barrel and tip in between the throat sheet and fire box sheets. This worked and gave us the close assurance that the real sheet would do the same. It did. Sounds simple. The actual job of getting the sheet into place was NOT simple but went better than we expected. Next a hanger was welded inside the steam dome. A comealong was attached and used to lower the sheet into its final resting place. After some fitting the sheet was tack welded. More fitting is needed and sections of the firebox side sheets that have been cut out replaced. Next will be beveling the sheets and butt welding the tube sheet to the side sheets and crown sheet. The bottom will be riveted to the mud ring.”

Jim Connor photos.

Hole Boring Continues in Preparation of Riveting

Mike Wahl reports:

“For the third weekend in a row work has been happening in the shop. With the stress relieving completed back in January, we are able to move forward to complete the barrel seams. This is the number one priority on the boiler for us. The goal is to rivet all of the barrel seams during Spring Fling weekend. This ‘seams’ like a big goal, but there are only 175 holes to bore, bolt up tight, ream, and rivet.

“We made great progress on the rivet seams. The seam between the throat sheet and third course was completed. We were also able to complete approximately 50% of the seam between the second course and third course. This means we are approximately 50% completed with hole boring and bolt up.

“Next weekend we need to make a new throat sheet backer. This is number two priority. I would like to have this riveted in during Spring Fling or before so that the stud hole can be completed in it and this area ready for rear tube sheet installation. We have the code material at the shop and the old one for a pattern.

“Plans have been progressing in preparation for Spring Fling weekend. A new rivet forge has been purchased. Jim Connor picked it up and delivered it to the museum. We have a local source located for LP so we can rivet like mad and not run out of fuel. The required rivets for this task have been ordered and will be shipped in time for Spring Fling. We are compiling a list of other requirements and are working on procuring these items so we are prepared for riveting.

“The rear tube sheet template was shipped to the sub-contractor and a P.O. issued to make the rear tube sheet. The hope is to have this back by Spring Fling so tube holes can be bored in and it shipped out for heat treatment.

“Once the riveting is completed, the throat sheet backer is installed and stud hole drilled in the throat sheet backer we can start to fit the rear tube sheet.

“While this work progressed I spent some time looking over the tender tank. Discussion and ideas for repair were discussed so a plan of attack can be put fourth.

“All for now, hope to see you next weekend. There are many things to do.”

Jim Connor photos.

January 14-15, 2016 Work Session Update

Al Joyce reports:

“Just a work update on this past weekend. In short we made progress in the positive direction.

“Jim Connor and Ron Kokemuller drilled out the front tube sheet with the pilot holes (170). They did not do anything about cutting the larger holes because the core drill was only 2 inches instead of 2 1/16. One of the holes has a broken drill bit in it. That hole was marked for future work.

“Ed Dench worked on the smoke box by grinding the heads of the flush rivets. They look good. One may need some work as it did not fully fill the hole.

“With the combined help of Bryon Schumacher and Jim Connor, we got many more studs sized and installed in the boiler. They are in only hand tight so they can be removed. The boiler is starting to look like a porcupine with all the studs sticking out. Jim took some pictures so we hope to get them on the web site soon. With the help of Jim and Bryon we have doubled the stud crew membership. All the Stud Guys are qualified to work unsupervised at a pace that is comfortable to them.”

Jim Connor photos.

Ultrasounding Boiler Patches

Kelly Bauman reports: “It was a pretty productive weekend. Sorry, no pictures. But here is the rundown for Sunday. I don’t know if anything happened Saturday, but I think everyone was either in training, or on crew.

“Ed Ripp and I started out ultra-sounding the boiler patches. After determining we were unsure of how the boiler was originally done, we did our own coordinate set. (For the record it was 1-23 from the front to the back, and A-L starting on the engineer’s side. This needs to be written on the sheets yet.) After Ed and I were about half way through, Jim Connor and Bruce (I think, I’m terrible with names) finished the other half. We then moved out to the tender and set up a grid all the way around the outside two feet high. Jim and I also removed some of the crud off the sides of the coal bin, but after looking at it decided not to draw the grid. It’s in pretty bad shape just looking at it…. [Meanwhile], Ed Ripp and Jason Sobcyznski continued to remove accessories from the 1385. However thunderstorms and the picnic cut short any further work.

March 5-6, 2005 Work Weekend

This last weekend was most productive, also as we had a very nice crew hammering down staybolts and cleaning out holes in the throatsheet preparing them for welding. Betsy Zonnerville, Bob & Kevin Reihl, Mike Wahl, John Sorrel, Doug Crary, Dave & Bryon Schumacher, Al Hill, Chris Thompson and Kelly Bauman were there to lend a hand. Many staybolts were hammered down and the telltale holes were drilled clear to finish part of the firebox repairs. The staybolts are what hold the flat steel sheets of the firebox together against the pressure of the steam and water in the boiler. The throatsheet is the very front of the firebox that helps make the transition from the rectangular shape to the cylindrical shape of the barrel. The staybolt holes there are being filled with weld and will be drilled out to be threaded when the new rear tubesheet is fitted to the inside of the firebox/boiler. Once again, saying thanks doesn’t seem adequate but WE ARE DOING THIS!

Paul Swanson photos.