|2479 Update - March 28, 2015|
Machining of second piston is underway. If no issues are encountered, work could be complete next Saturday. It#39;s nice to have access to a huge vertical lathe. It may be taking up a large amount of floor space in the trolly barn, but it has been a valuable asset that has allowed us to complete a number or repairs.
Repairs to 75% of the boxcar roof is now complete. The unfortunately nice weather is allowing this project to move rapidly ahead.
Warm weather plus December rains have stimulated grass and weed growth at the locomotive restoration and 1215 display site. Both areas have been mowed over the past week.
Arrangements have been made with Andy Anderson at Oakland Machine Works to pickup the new valve cage Monday morning.
Small crew but we divided up into three groups and made some things happen.
Work on the second piston continues. Once all the grooves have been trued each piston will be set back onto the King to make each slot a standard width. This will help in forming in rings.
The boxcar roof is also coming along. Repairs to the roof should be complete by the end of February, sooner if this dry weather continues.
SP1215#39;s rods received some attention. Rust was beginning to form on the rods. Rust was brushed away and a coat of paint applied.
Rain kept most everyone away from the locomotive site, but most of the work was being performed at the trolley barn.
Today#39;s news is not all good. A close inspection of the engineer#39;s side piston revealed a number of cracks in the material that forms the sides of the piston grooves. In some cases these cracks radiate through to the opposite side.
We are pretty certain that these pistons are cast steel, thus welding is a possible solution. Cracks will be ground out and then filled with weld. The piston will then have to return to the King for machining. Repairs to the piston will most likely begin after next Saturday#39;s session.
Machining of the ring groove shoulders in the fireman#39;s piston is complete but not to a standard dimension. That dimension can not be determined until after the engineer#39;s side piston is repaired.
Progress is being made on the box car#39;s roof. Another 40 inch section was completed this past week. Only 120 inches of roof line remains to be repaired. That work could be completed this coming week.
Both pistons have been moved back to the fairgrounds site. One piston requires numerous weld repairs to the piston ring groove walls.
With rain and warm weather, weed growth is in high gear. Weed elevation was reset.
Repairs to the box car roof are complete. The roof still needs painting but the crew will shift over to the MoPac caboose. Its roof is in need of a good cleaning and paint.
In addition to maintaining site appearance, two major tasks were started.
The process of grinding out the cracks in the ring groove walls of engineer#39;s side piston was started. This is going to take some time as there are a lot of them. Its interesting that these cracks are all located in approximately the same half of the circumference of the piston.
The locomotive#39;s main and side rods are beginning to show early signs of corrosion. Its been decided to pull all of the rods, clean and apply a coat of paint. Paint will provide a better seal. This paint will have to be removed prior to operation which means the rods will have to be removed again.
Pad welding on another this area of the firebox outer sheet was completed. This section is ready for grinding and measurements.
Today the crew rolled locomotive and tender to keep journals and bearings lubricated.
The right main rod was removed for cleaning and a coat of paint.
More grinding on cracks in the walls of the piston ring grooves. Presently we are working on the wall with the deepest cracks.
News is not all good. The starter on the Clark lift is in need of a new Bendix unit. The gear in the unit has been destroyed.
The right main and side rods have been removed, cleaned and a coat of protective paint applied. This Saturday the rods will be set back into place on the locomotive.
Prior to installation, rod bores and driver pins will need to be cleaned and new coat of grease applied. Once rods are installed, locomotive will have to be repositioned to allow removal of the rods on the left side. If time allows removal of these rods can begin.
All of today's work was very heavy!
The right side and main rods were installed on the locomotive. These three rods received a thorough cleaning and two coats of white paint. Paint is to serve as a corrosion preventative. Installation of rods was real smooth with work completed by 10:30.
Left rod set requires the same attention. In order to remove these rods, the locomotive had to be rolled to different position. This allows for removal of the main rod from the cross head and removal of the pin that connects the rear side rod to the front side rod.
Things didn#39;t go as well as we would have liked, but all rods were eventually removed. Rods are now in a location that will allow cleaning.
Equipment failure kind of put a cap on the day.
During the week the left rod set was cleaned and painted. Today those rods were mounted on their drivers. As we were attempting to position the locomotive to mount the main rod, a hydraulic hose failed on the forklift. There was a nice display of fluid spray from the hose. (The hose will be replaced early next week.) ; Fortunately my jeep with a winch was able to finish positioning the locomotive to connect the crosshead to the main rod.
It has been decided that the new valve bushing will be pressed into place. There was a lot of concern regarding soaking the bushing in liquid nitrogen. At near -300 degrees F, the bushing could be very brittle thus easily damaged. We are also worried about safely handing a 70 pound part at -300 degrees F. Frost bite would not be much fun. Pressing (actually pulling) the bushing in place will be more work but in the end it will be easier.
Good size crew and a bunch of stuff completed. Thanks to all that participated.
As usual with this time of year, grass has to be cut at least every other week. Today was the day. Site looks nice.
This past week, the damaged forklift starter was rebuilt. Today the unit was installed. Also a damaged hydraulic hose was replaced.
Most of today#39;s work involved preparing to install the new left front valve bushing. The front and rear valve covers were removed. To remove the rear cover, the steam distribution valve crosshead and radius rod had to be disconnected from the cover. Fortunately the assembly could be suspended clear of the work area with ropes. If this could not be done, a lot of disassembly would have been required.
A plate is now being drilled to mount on the back end of the cylinder. This plate will be used to hold four pieces of all thread. The all thread will pass through another plate that will be set in front of the valve bushing. Nuts on the front end will be used to push the bushing into place. This is the reverse process that was used to extract the damaged bushing and it was removed without further damage.
The process of setting the bushing should take place next Saturday. Hopefully by noon time the task will be complete.