↓
 

Mid-Continent Railway Museum

North Freedom, Wis.

Text: Mid-Continent Railway Museum. A historical and educational experience. Images of railway cars, people, and Mid-Continent logo.
  • Home
    • Home Page
    • News
    • Join Our Email List
    • Media
  • Plan Your Visit
    • Buy Tickets
    • Train Ride/Museum Info
    • Special Events
      • Autumn Color™ Weekend
      • Pizza Limited
      • Harvest Flyer
      • Pumpkin Special™
      • Root Beer Float Flyer
      • Santa Express™/Holiday Flyer
      • Stars and Stripes Special
      • Vintage Rail Car Tours
    • Cancellation Policy
  • Gift Shop
  • Restorations
    • Major Projects
    • Steam Status
      • Overview
      • C&NW #1385 Status Updates
      • Western Coal & Coke #1 Status Updates
      • Dardanelle & Russellville #9 Status Updates
    • Car Shop
      • General Updates
      • DSS&A Sleeper DULUTH
      • EJ&S #2
      • Badger #2
      • Copper Range #25
      • MLS&W #63
      • Copper Range #60
  • Equipment Roster
    • Equipment Roster Home
    • Steam Locomotives
    • Diesel/Other Locomotives
    • Wooden Passenger Cars
    • Steel Passenger Cars
    • Wooden Freight Cars
    • Steel Freight Cars
    • Cabooses
    • Service Equipment
    • Former Collection Items
  • Resources
    • Online Archives Home
    • Wooden Car Builders
    • MCRM Newsletters
    • Gazette Archive
    • Audio Archive
    • Video Archive
    • Wallpaper
    • Kids Page
      • Kids Page
      • What Makes A Diesel Locomotive Work?
      • What Makes A Steam Locomotive Work?
  • About Us
    • Contact Us
    • About Mid-Continent
    • Board of Directors
    • Department Leaders
    • Our Staff
    • Become a Member
    • Volunteer
    • Employment
    • Tour of Grounds
    • Local History
    • Mid-Continent Timeline
    • Privacy Policy
  • Donate

Tag Archives: tube sheet

Post navigation

← Older posts

Front Flue Sheet Installation

Mid-Continent Railway Museum Posted on March 30, 2018 by Jeffrey LentzMarch 30, 2018

New photos are now available from the Continental Fabricators factory floor in St. Louis showing Chicago & North Western 1385’s new boiler under construction. The new images mostly show the installation of the front flue sheet at the front of the boiler.

The front flue sheet (along with the rear flue sheet) support the flues which carry the smoke and hot gasses from the firebox – located at the rear of the locomotive – to the smokebox – located in the front of the locomotive – where they can then escape through the smokestack.

The front flue sheet also has multiple larger diameter holes for supporting the superheater flues. In a superheater-equipped locomotive such as the 1385, the superheater re-heats the steam generated by the boiler, increasing its thermal energy and decreasing the likelihood that it will condense inside the engine. Superheating the steam increases the thermal efficiency of the steam engine.

Lastly, the single largest hole in the front flue sheet supports the dry pipe. The dry pipe carries the saturated steam (i.e. non-superheated steam) from the steam dome to the superheater header before being directed to the superheater flues. Inside the superheater flues the saturated steam becomes superheated and is then directed to the cylinders, which in turn provide power to the driving wheels.

flue sheet before installation

C&NW 1385 new front flue sheet. March 21, 2018. Photo courtesy Gary Bensman.

1385 boiler interior with worker
A Continental Fabricators welder installs C&NW 1385’s front flue sheet. Photo courtesy Gary Bensman.

front flue sheet welding
C&NW 1385’s new front flue sheet is welded in place. Photo courtesy Gary Bensman.

The following two images show 1385’s old boiler to help give perspective of where the front flue sheet resides within the locomotive.  You may notice the pattern of the smaller holes for the tubes is different between the new and old sheets.

One advantage of building a new boiler is that we can correct some compromises made when the Chicago & North Western modified the engine to add the superheaters.  We can also incorporate an updated design for arch tubes in the firebox which will allow us to put tubes back into the area formerly blanked off in the old boiler.  The old boiler has a patch in the belly of the barrel to repair cracking believed to be caused by uneven heating.  Those thermal stresses were thought to be the end result of that bottom area of tubes being removed.  Another advantage of populating that area with flues again is a gain in heating area so the new boiler should steam a slight bit better.

1385 old boiler
This image of 1385’s old boiler shows the location of the front flue sheet at the front end of the boiler where it connects to the smokebox. Note the steam dome visible on top of the boiler toward the rear. MCRM photo.
1385 old boiler
Detail of 1385’s old boiler showing the front flue sheet and smokebox.

The last image from St. Louis shows the hole cut into the top of 1385’s new boiler where the steam dome will be installed.

boiler steam dome hole

The large hole is where the 1385’s steam dome will sit. Photo courtesy Gary Bensman.

Tagged boiler, flue sheet, steam dome, tube sheet

1385’s Boiler Assembly Underway

Mid-Continent Railway Museum Posted on January 22, 2018 by Jeffrey LentzJanuary 22, 2018

The assembly of C&NW 1385’s boiler began in earnest late last week at Continental Fabricators in St. Louis. Here are the latest photos from the shop floor, courtesy of Gary Bensman.

front flue sheet
C&NW 1385’s front flue sheet. Jan. 21, 2018. Gary Bensman photo.
backhead sheet
C&NW 1385’s backhead sheet. Jan. 21, 2018. Gary Bensman photo.

firebox wrapper sheets
C&NW 1385’s firebox wrapper sheets. Jan. 21, 2018. Gary Bensman photo.
boiler course seam
The 1385 new boiler’s 2nd course longitudinal seam ready for x-ray. Jan. 21, 2018. Gary Bensman photo.

boiler course weld
C&NW 1385 boiler’s 2nd course longitudinal welds . Jan. 21, 2018. Gary Bensman photo.
boiler course weld
C&NW 1385 boiler’s 2nd course longitudinal welds . Jan. 21, 2018. Gary Bensman photo.

boiler course weld
C&NW 1385 boiler’s 2nd course longitudinal welds . Jan. 21, 2018. Gary Bensman photo.

 

Tagged boiler, C&NW 1385, firebox, tube sheet

Bending Steel

Mid-Continent Railway Museum Posted on March 22, 2017 by Jeffrey LentzMarch 23, 2017

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.

sheet metal
The metal sheet which will form the 1385’s rear tube sheet is carefully measured before any cutting or bending begins. Photo courtesy SPEC Machine.
sheet metal cutting
Excess material is removed from the rear tube sheet using a torch track. The self-propelled cutting torch gives a better cut over a long distance than can be achieved by hand. Photo courtesy SPEC Machine.

measuring sheet metal
Gary Bensman carefully marks the locations and degree of the bends to be made. Photo courtesy SPEC Machine.
McCabe flanger
The McCabe Flanger machine at Tennessee Valley Railway Museum’s shop. Photo courtesy SPEC Machine.

sheet metal with markings
The rear tube sheet is marked up and ready for the flanger. Photo courtesy SPEC Machine.
Crew members move the sheet into position. Photo courtesy SPEC Machine.

flanging
Steam veterans Gary Bensman, operating the McCabe Flanger, and Al “Uncle Al” Phillips (left), are assisted by 1385 Team representatives Steve Roudebush and Brett Morley as the 1385’s rear tube sheet is positioned for flanging. Photo courtesy SPEC Machine.
bent tubesheet
A slight bend in the tube sheet is visible here after a turn through the McCabe Flanger. Photo courtesy SPEC Machine.

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.

Tagged boiler, firebox, tube sheet

Drilling Mudring Holes and Needle Scaling Cylinder Casting

Mid-Continent Railway Museum Posted on January 9, 2007 by Jeffrey LentzApril 15, 2015

Today, Dave drilled the mudring holes in the rear tube sheet, side sheet patches and the rear corner patch. The 3/4” tack bolts were installed. The next step is to pull the sheets tight and check the sheets for gaps between the sheet and the mudring. If any unacceptable gaps existed, the sheets will need to be flattered into position. Jeff will be next week to start the welding on the rear tube sheet.

Bob worked on needle scaling the frame and cylinder casting. He still has a ways to go to complete this. The next step will be start checking the frames for cracks.



Tagged boiler, cylinders, tube sheet, Western Coal & Coke 1

New Pilot Completed

Mid-Continent Railway Museum Posted on December 21, 2006 by Jeffrey LentzApril 15, 2015

The new pilot has been completed and delivered. The pilot was built by Roger Hugg in his shop at his home in Elroy.

Also, the boiler patches and rear tube sheet are fitted and tacked to the boiler. We now wait for the fit-up inspection.

The front coupler, pilot beam and deck plate have been removed. The new timber for the pilot beam has been purchased and Roger Hugg has delivered it.

The fireman’s side piston and cylinder head have been removed so inspection of the piston, cylinder and rod can begin.

Thanks to Roger Hugg, Jeff Lund, Bob Ristow, Dave Lee, Kelly Bauman and Jim Connor.




Tagged cylinders, pilot, tube sheet

Post navigation

← Older posts
QUICK LINKS
PLAN YOUR VISIT
BUY TICKETS
GIFT SHOP
DONATE
JOIN OUR EMAIL LIST
VIEW WEBCAMS
Live view of North Freedom depot

Contact Us

Mid-Continent Railway Museum
P.O. Box 358
E8948 Museum Road
North Freedom, WI 53951
Office phone: 608-522-4261
or 800-930-1385
E-mail: inquiries@midcontinent.org

Recent News

  • “Last Spike” Ceremony
  • Engine House Track #2 Update
  • 1385 Steam and Air Line Installation/Donation Update
  • #1385 Cab, Smoke Stack, and Hand Rail Installation/Donation Update
  • Your Help is Needed to Bring the C&NW #1385 Home Again!
©2025 - Mid-Continent Railway Museum - Weaver Xtreme Theme Privacy Policy
↑