Mt Pleasant Independence Day Celebration

Instead of having pictures of the parade, afternoon passenger train, or the nighttime fireworks, this blog entry has the usual "behind the scenes" activities of the MCRR staff. (After all, it is the "shop blog.")

Despite the fact it had been decided to use the diesel powered switch engine (14), a few of us hapless souls chose to ready the three truck Shay (9) for service. After all, the MCRR is a steam railway.













Ha! The 9 had other ideas!

Since the 9's boiler had been "washed and dried" last December, our railroad requires the boiler to be pressure tested before being put under steam pressure. The process consists of replacing the boiler washout plugs, injector check valves, cleaning the sight glasses, and cleaning the tender drains.

The set of boiler plugs is shown here. They had been wire-brushed and Teflon taped and were ready for installation.













We have a laminated "road map" for the plugs to insure the plugs always go into the same hole which they were removed.













With the plugs replaced and the other chores complete, we topped the boiler, started a fire to warm the water, and after reaching the proper temperature, extinguished the fire and attached the high pressure pump.

In keeping with years' past, several of the superheater pipe leaked at their connection with the boiler's superheater manifold. Actually, this indicates a possible second problem: a leaking throttle, as the steam (and water) should not be reaching the superheaters until the throttle is opened.

Fixing the superheaters requires someone to crawl into the locomotive's smoke box to unfasten the pipes. Griffin W. squeezes inside the smoke box which keeps this author from having to do so. (Thank you, Griffin.)













This is what a set of "well used" superheaters look like. These three are located in flue pipes on top of one another, hence their varying vertical size. A close look at the ends shows the erosion which we have to fix every year.













While a few volunteers were dealing with the 9, a few others took advantage of the wonderful weather to apply herbicide on the healthy set of unwanted plants (sometimes referred to as "weeds") which were populating the tracks and switch mechanisms.

Volunteers Brian B. and Paul K. mix the ingredients in the tank of our special UP (Unwanted Plants) "flat car."


























Brian applies the herbicide around a switch stanchion.













By this time, we gave up on having the 9 pull the afternoon train. Although the superheater leaks were eventually plugged, we needed to determine why there was water in the pipes in the first place. This required removing the steam dome cover and lid to inspect the spool valve and throttle valve standpipe's connection to the dry pipe.

Removing the steam dome lid was far more difficult than in any time in recent past. The studs had splayed outwards, making removal of the lid extremely difficult. Usually, removing the 24 nuts shouldn't be a big problem but this time two nuts refused to budge, apparently having seized to their respective studs. A bit of torch to heat the nuts and a 3/4 inch impact wrench helped spin the nuts off but two nuts had seized so tightly, the nuts took the studs' threads with it. The only solution was to cut the nuts off and replace the studs. The studs had other ideas.

Sometimes, we can grip the studs with pipe wrenches but not this time. Paul K. and Griffin W. prepare to weld large nuts onto the studs for removal. The heat from the weld often loosens the studs in their seats. Not this time. The last I heard, remnants of the studs were still in the boiler, having resisted drilling and torching.

And the mystery of where the superheaters' water was coming from still exists.


























A closeup of the broken studs.


























I am not sure what Paul K. and Griffin W. were doing here but it looked interesting.

-steam.airman
some photos courtesy Anita N.

June 2010 Work Weekend

The return of the boiler has revitalized many of the shop volunteers' enthusiasm. With the goal of seeing the Six move under its own power by Labor Day, 2010, a concerted effort is being made to make it happen.

This work weekend saw activity primarily in or around the Six. There were two primary tasks: a) prepare and paint the boiler jacket and b) anything else.













For the "paint" task, the first challenge was to select the jacket color. Nothing will be disclosed about the color selection; it will be a surprise for everyone not wandering in or around the shop.

After 25-odd years, numerous coats of wax had been applied to the jacket and numerous layers of grease and dirt were located everywhere else. The next few pictures show John G. using a special elixir from the auto part store's paint department. Reading the ingredients on the "wax remover" was like reading the ingredient list on a package of "Twinkies" or "Pringles." John G. did a tremendous job of removing the wax and grease.









































Besides removing the wax and grease, the upgraded boiler presented some other opportunities.

With the flexible stays' sockets making the overall boiler diameter a bit more than before, we used slightly thicker insulation between the boiler's shell and the jacket. The end result was that the tight fitting jacket was now fitting like someone who ate too many treats during the winter holidays.

Letting out the jacket at its seams in turn caused holes for various boiler fitments to be slightly off from their current position. Moving a hole in sheet metal presents some typical auto body shop activities. Cut the new hole; weld a panel into the old hole, apply body filler to smooth the finished product.

The next few pictures show Elliot H. forming a metal patch before welding and the other John sanding the filler smooth.



























With the jacket let out at the seams, the running boards along each side were rubbing against the metal, plus the boards (well, "metals") were simply in the way for preparation and painting.

Once removed, the running boards needed about 1/2 inch of material removed for extra clearance. Due to a bit of less than perfect torch cutting, a bit of grinding was necessary. Paul K. grinds the slag away from the cuts in the next few pictures.



























The other project ("anything else") was rebuilding the brake cylinders and mounting them on the boiler.

Dustin B. and Griffin W. disassemble the cylinders and clean the walls.













Brian B. helps with the insertion of the pistons back into the cylinders.













Bradon B. helps his dad lubricate the cylinder walls before installing the other piston.













Tightening the rubber "piston ring" on the piston.













Once the cylinders were reassembled, they were mounted onto the boiler and frame. These beasts weigh around 150 pounds so it took our resident power lifters to get it in place. Fortunately, the cylinders hung off of studs making their remounting much easier.













Dallas K, Bradon B., and Griffin W. discuss the next move while balancing on a large two wheeler cart.













Paul K. and Brian B. install the brake shoes onto the cylinders. Like the cylinders, the shoes were quite heavy and resisted being put in place.













On Sunday, with the heavy mechanical work complete and the jacket ready for paint, Jennifer B. and Dustin B. begin the covering of locomotive parts that didn't need to be painted.













MCRR president Matt C. adjusts the paint gun.













Elliot H. suits up for the mission. Any sort of spray paint demands that the operator do what they can to keep overspray from their skin and lungs.



























Spray enough paint and one can cause a fog to form near the target.













In the meantime, Paul K. had a few items that needed sandblasting.

-steam.airman
pictures by SteamA and John G.

May 2010 Post Work Weekend Special - III

During the Memorial Holiday Weekend, volunteers Fred H. and John W. refinished the floors inside the Bellevue and Cascade caboose and the "Quinn" coach. See this blog entry for views of other bits of maintenance being performed on the "Quinn" coach. (Summary: during the official May work weekend, members removed the seats and thoroughly cleaned the coach's insides.)

This weekend, the old finish was removed from the floors of both cars and a new commercial grade finish applied.

Besides doing a large portion of the work, volunteer Fred H. also donated the materials to complete the job.

Fred H. roughing up the old finish in the caboose's baggage area.














John W. doing some hand sanding. He doesn't look too happy; he found out that his pay had been cut -- again! (Actually, he was sanding the floor by hand, not sanding his hands.)































Applying the new finish to the floor.














Several views of the caboose's refinished floor.




























Inside view of the "Quinn" coach after the floor was refinished.













The pictures don't do justice to the look of the floors. Fred H and John W worked extra hard to make these the best they've ever looked. We are contemplating asking riders to place protective covers over their shoes before entering!

The "Quinn" coach's seats had been removed from the coach and stored in the South Station's conference room (the "M&E Room"). Before reinstalling them, the upholstery was cleaned and other bits of mechanical maintenance was performed.

-steam.airman
-pictures courtesy JohnW.

May 2010 Post Work Weekend Special - II

Several shop volunteers were busy in the past few weeks!

As can be seen in these pictures, not only has the boiler been placed on the chassis, but a good amount of work has been completed.

It almost looks like a steam locomotive again!

-steam.airman
-pictures courtesy BrianB.

May 2010 Post Work Weekend Special - I

After the first coat of primer was applied to the boiler, a second coat was added. Pictures are available, but it is nearly impossible to tell anything changed.

A few after the second coat was applied, Griffin W and Dallas K, along with several other volunteers (unknown as of this writing) placed the boiler on the chassis officially marking the reassembly of the 6.




























Dallas inspects the smoke box end of the boiler as it rests on the steam saddle. Some sort of elixir was applied to the saddle to seal any possible steam or smoke leaks.














Griffin mixes the elixir.

-steam.airman;
-pictures courtesy BrianB.