Summer Workweek Report 2012

Although lightly patronized, a good amount of work was accomplished during our summer work session last month in Portola, July 19^th – 21^st, 2012.

Roger Stabler and I arrived on Wednesday, and again to our delight, the Pullman car was in fine “move-in” shape and required very little cleanup. Thanks to the Museum staff for keeping everything much cleaner than it has been in the past.  Roger had brought up a new ice machine for the gift shop that he donated, (thanks to Roger for that!) he spent the majority of the evening replacing the old water filter with a larger more “industrial” version. We now have copious amounts of ice at our disposal.

After the long journey up from Lakewood I was ready for some steaks, also provided by Roger, as well as plenty of sides; a great start to the week!

Thursday morning Charlie and I set up some shade out by the engine, and Roger, with helper Hank Stiles began tacking in the patch on the wrapper sheet. This area was wasted away and needed replaced, being in the corner of the cab where moisture was trapped for a very long period of time. Charlie had to run into Sparks for some welding gasses, which delayed things a bit, but he came through as he always does. Dick Coudin, who came in very early that morning, was given the task of cleaning up the drivers and applying a coat of primer.  Assisting him were locals Dave Anderson and Steve Parry. To my delight, Kirk Baer has been cleaning up the locomotive frame since our last visit, getting some primer on, and making the engine look like someone cares! Thanks Kirk!

Patch is tacked in place, ready for the root pass.

Roger and Hank continued the welding project on Friday, lots of welding and even more grinding between passes. Hank chased the threads on more of the flexible stays, still plenty of those left to do, but every one counts. 

Norm Holmes stopped by to pick up a train order signal casting that Paul Boschan had brazed together for him. Evidently when the SN cut the mast down back in the day, it fell like a mighty redwood, and broke the head casting in three pieces. The casting is back together again, and Norm hopes to erect it at his new place in Carson City. Norm brought with him a truck load of steam paperwork, parts and a few surprises, like the numberboard glasses from quite a few WP locomotive headlights, including the 165’s! Those will make a great display someday. Norm also donated a folio with drawings of valve measurements and settings for every WP engine. That will come in quite handy, Thanks Norm!

Roger grinds the passes down smooth before adding more metal.

 

Thursday night, around 11PM, I panicked when I heard a locomotive fire up right next to us in the Pullman car. It didn’t last long idling. Come to find out it was an eager Seth Adams firing up our latest acquisition, the WP 1503. Good to hear her finally alive again, although a little warning next time would be nice! (Just kidding Seth).

Later Friday evening, Roger and I cut out early at 4PM to drive up to bucolic Greenville, to meet a fellow by the name of Ross who claimed to have a turbo generator we could use on the 165. The generator that came with the engine was missing the half that contained the windings, presumably purloined by copper thieves. Ross is a great fellow, who lives on a few acres in a WP wood caboose, surrounded by the spoils of his time working for Dobbas Trucking. His company made a living picking up derailments; to say quite a few treasures made it to his property would be an understatement. I thought I was in an episode of “American Pickers”. Ross also donated a three chime whistle off now scrapped WP derrick 27, which now resides in our collection. Thanks to him for his hospitality and generosity. Also thanks to our bookkeeper Susan for hanging around her office long enough for us to pick up the check.

Upon inspection of the generator by Roger, it was determined to be in good enough shape to go ahead and purchase. Saturday Roger cleaned out the wasps nests and other detritus in the turbo blades, oiled it, put some air to it, and it spun right up, it even made 32 volts! Thanks again to Norm for arranging to meet Ross, one of the more interesting people I have run across during this project.
 

Another video here.

Saturday it was back to work, welding and grinding for Roger, who was getting quite gritty at this point, and more cleaning for the shop crew, joined this day by Eddie Chase, as well as more primer. In the end Dick’s crew got paint on half of the drivers, an excellent start. We will continue in the Fall and hopefully complete the process before the wheels go back under the frame.

Dick Coudin applies primer to one of the locomotive driver castings.

 

All this time, Bob Sims has been tirelessly working on the interior framing of our steam shop car, D&RGW 62962. He has to date gotten the man doors in the side installed, as well as an air conditioner. Bob designed it so when you close the big old sliding door on the side of the car, these newly installed doors are not apparent. After I left on Sunday morning he continued apace and got a couple of the stud walls tacked into place. Before long this will serve as a workshop area and a clean place for the steam crew to “retreat” during our work sessions and eventually operation days. We can’t thank Bob enough for his extraordinary efforts!

Utter exhaustion set in Saturday night by the time we needed to start picking things up. Luckily the weather cooperated until Saturday, by which point we were quite warm, especially Roger in his welding coat. After getting everything put away and a brief respite in the Pullman, Roger, Dick and I went off to the Beckwith Tavern for dinner. Prime rib is a great way to wind up a weekend of good progress.

Another reminder that our Superheater Fundraiser is ongoing. Thanks again to Bob Sims and James Mason for kicking it off. Click the graphic in the right pane to donate online. Every $350.00 donation nets another flue, as well as your name on a donors plaque in the cab of the 165, for perpetuity. Now is the time to keep the momentum up, and bring steam back to Portola!

Have a great rest of your summer season, and we will see you September 27^th through the 29^th  2012 for our Fall work session. - JCA

Roger loves grinding!

Superheater Flue Fundraising Drive

Hello everyone!

I hope you are having a wonderful Spring and are ready for another Summer season. The Steam Team in Portola is happy to announce that we are finally ready for superheater flues to be replaced in the 165's boiler. We are asking our ardent and generous supporters to please consider donating the funds to purchase one or more of the 24 flues that will be needed to make our locomotive steam again.

The purchase and fabrication cost for each flue is estimated at $350.00, which is of course a tax-deductible contribution. You can watch the progress above on this nifty graphic (Thanks Eugene!) as each flue hole is filled in as the contributions arrive. As an added incentive, each donor who gives $350.00 or more will have his or her name inscribed on the donors plaque, to be mounted in the cab area in perpetuity.

We are lucky that Norm Holmes was able to work an excellent deal for the 2" diameter tubes which we now have in storage on site. The 5 1/2" diameter superheater flues represent the last major components necessary to make the boiler steamable again.

Thanks again for all of your past and future support for the WP 165 restoration and all of the volunteer efforts at the Western Pacific Railroad Museum!

Checks in the amount of $350.00, multiples thereof, or any amount, may be made payable to:  FRRS
Please note "165 Flues" on the memo line of your check.

Mail to:

Western Pacific Railroad Museum - 165 Fund
PO Box 608
Portola, CA 96122-0608


Click here to make a donation online.

Thanks again! Have a safe and productive summer season. - JCA

Update 7/17/12: Four more flues donated by James Mason! A big thanks to you James!


Update: Our first flue has been donated by Bob Sims! Thanks for your support Bob! 

Cutaway showing superheater elements and flues.

Spring 2012 Workweek Report

 

Dick Coudin and I arrived Wednesday evening in anticipation of performing our usual two or three hours of cleanup in the Pullman car. To our delight, Rick Gruninger had the place looking much better than I have ever seen it. All that was required was some light touch up, setting up the berths, and running some heat into the car. Thanks to Rick for his efforts to make us feel welcome!

Another winter was behind us, except that no one told Mother Nature. Our first workday, Thursday, April 26^th in Portola was confined to mostly indoor activities.

Driving box cleanup day.

Steve, Charlie, Kirk and others formed a “scraping circle” and began the task of cleaning out the oil cellars in the tops of the driving boxes, as well as drilling out the oil ports that had been plugged up for likely most of the 20^th century. Handling these heavy and cumbersome iron castings was made easier thanks to Hank Stiles and Dick Coudin, who came up with a handy lifting rig so the boxes may now be moved around using the forklift. Hank and Dick also started the cleanup on the grease cellars for each box, which were equally caked with multiple layers of journal lubricant.

Hank and Dick show off their driving box lifting rig.

Bob Sims has been busy converting our D&RGW wood-bodied boxcar into a tool car for us. He and Charlie spent some time in Reno procuring plywood and security doors for the interior stud walls. When complete the car will look like just another boxcar from the exterior, but inside will be a usable and clean space for the steam crew’s use. Thanks again to Bob for taking on this sizable task!

Our electrician, Duane, with some help from Charlie managed to get the 16” Lodge & Shipley lathe back up and running. Thanks guys for having it working in time for the steam session. Thanks again to the Union Pacific shops in Roseville for donating it to the cause. Severn Edmonds is repairing some of the previously broken handles, as well as making up tooling for mounting an Aloris tool block, which will make things much quicker and easier. Severn should be back in July, hopefully to start turning staybolts.

Thursday night saw the arrival of our friends from the Golden Gate Railroad Museum. During the course of the weekend we were joined by Jeff Boone, Ken Asmus, Nancy Harden,  Deanna Knowles, Bob Bradley, Jim Prettyleaf, Dave Varley, Dave Hensarling, and of course the ever affable Dave Roth.

Dave Roth happily chasing threads.

Friday the 27^th, after our morning safety meeting and carbo-load at Sharon’s Diner in historic downtown Portola, we emerged into a gloriously sunny albeit frigid morning. The task of the day was to attempt removal of the throttle dry pipe in the interior of the boiler shell. Prior to doing anything major with a cutting torch, Dave Varley ran the thickness readings which were taken by Dave Roth and Dick Coudin last Fall. Dave determined that given the thicknesses remaining, we were well within our factor of safety for the pressures we would be running at. The drypipe project was abandoned and we moved on.

More clean-up continued on the driving boxes while the patch on the wrapper sheet side was removed for drilling. First the holes for the cab bracket studs were located, which involved holding a heavy chunk of metal up on the side of the boiler while someone else marks hole locations; nothing light when it comes to working on a steam locomotive. The GGRM crew made quick work of clean-up on the pedestal binders as well.

Hank Stiles made up a handy round die holder so he could chase the threads on the flexible staybolts sleeves, followed by an application of thread lubricant to prevent deterioration. He and Dave Roth took turns over the weekend chasing threads and managed to get a large number of them chased.

Dave Varley carefully taking down measurements for the FRA Form 4.

Friday I met with Steve Lee (Union Pacific’s now retired steam program manager) and Dave Varley (GGRM Chief Mechanical Officer) to go over progress made toward generating our FRA Form 4. This document is in essence a huge number of stress calculations which ultimately allow us to determine the maximum allowed working pressure of the boiler. James Cowdery and Nathan “Maverick” Osborn have all but finished taking the thickness readings on every surface of the boiler shell and firebox; thanks to you two for sticking with it. Steve and Dave will perform the calculations based on this data, and quite a bit more information that Dave and his crew took Friday and Saturday.

Longitudinal braces and their pins were measured, inspected, and all of the rivets were hammer tested. None failed. Hammer testing of the stays will come later. Tapping on each rivet should give a resounding “ring” sound. If one is hammered with a “thud” it is most likely broken and would need to be re-set. The stayed surfaces on the backhead were measured as well. Roger Stabler began tapping out staybolt holes in the wrapper sheet in preparation for welding in the patches later this season.

Nancy Harden hammer tests rivets while
Dave Roth and Jeff Boone continue thread clean-up.

Roger Stabler has a job briefing regarding the wrapper patch work. Jim and Jeff listen closely.

Work continued on Saturday until the afternoon began to wind down. A few stories were told, some exaggerated for dramatic effect, some not. Hank and our newest steam team member, Kirk Baer of Portola, assisted me in putting a few more parts away in the second storage car, and after a clean sweep of the shop, we called it a day. Thanks to everyone for coming out, especially our friends from GGRM, who have been incredibly helpful and supportive through their loan of time and tooling. No small thanks also to our major financial donors, including Bob Sims, James Mason, and Roger Stabler, who will be footing the bill for the leaf spring repair! Thanks go to Norman Holmes for providing us with spare parts donated from his personal collection, such as the whistle off the WP 166. And of course another big thanks to Charlie and Steve Habeck for getting things ready for our arrival in the shop.

I look forward to our next session, Thursday, July 19th - Saturday July 21st. With some luck and persistence, we should have the boiler and frame back on its drivers in the Fall. Until we meet again, have a wonderful Spring and Summer season, and be safe. -JCA

2012 Fundraising Calendar now available.

The 2012 WPRM Steam Department Calendar is now available through CafePress:

http://www.cafepress.com/wprrsteam.597983315

A portion of the proceeds from each sale goes toward funding the restoration of locomotive 165. Thanks again to Eugene Vicknair for his assistance with several unique images this year.

Have a wonderful Christmas season and a happy, safe and productive 2012! - JCA

WPRM Steam Work Dates for 2012

Dates for steam work sessions at Portola in 2012:

Thursday, April 25th - Saturday April 28th.
Thursday, July 19th - Saturday July 21st.
Thursday, September 27th - Saturday September 29th.

Additional dates will be added as necessary. As always please contact the Museum Manager ahead of time if you wish to arrange accommodations in the Pullman.

Have a happy and safe 2012!

-Chris Allan

Fall 2011 Work Week Report

The 2011 Season for the Steam Department has ended, and we can be proud of our accomplishments over the past year. The lion’s share of the work was toward our 1472 day FRA inspection, with all but a very few of our ultrasonic thickness readings on the boiler shell completed by Nathan Osborn and James Cowdery. Nathan has also been meticulously transcribing the thickness readings into a format that is more “user friendly”.

We welcome new steam team member Dick Coudin, who I met onboard Roger Stabler’s private car “Two Rivers” on the Railroad Days Special to Portola in August. Dick met me in Woodland on Tuesday the 27th of September, and together we motored back over the hill to Portola in time to get moved into the Pullman before dinner.

Steve inspects the drivers with the D&RGW tool boxcar in the background.


Nathan takes a turn at scraping grease and paint.

A clean journal surface, ready to be polished out.

Wednesday we were joined by Steve Lee, in from Cheyenne to lend a hand and help us get through our initial FRA boiler internal inspection. The inspection was to take place on Thursday, but was cancelled Wednesday evening by the inspector for reasons beyond his control. We will reschedule in the spring of 2012, and continue on with boiler work in the meantime. Roger Stabler arrived about this time, and got to work on the base of the cab, welding up what Erin Swain had tacked in place during the summer work session. Dick drilled out for the rivets along the bottom of the sides. These will be driven into place, hopefully, in the spring. Thanks to Roger and Dick for finishing up around the base. All that remains is to patch the drip rail areas on the roof. Charlie Spikes has the cab mounting brackets pilot drilled. Those will be finished off with the magnetic base drill after the cab is in place. He has also been systematically cleaning up the driving boxes over the summer. The grease is quite stubborn, and progress is slow, but he is sticking with it. With any luck we will have them ready to lower the frame and boiler back down on the drivers by this time next year. Wednesday evening ended up with some delicious rib eye steaks grilled to perfection by Roger, a nice way to end the day.

Dick drills holes for the rivets at the base of the cab.

Thursday a twenty-thousand pound capacity forklift, sourced out by Charlie, was delivered to unload our 16” lathe from where it has been residing over the summer, in the back of the dump truck. This machine was too heavy for our beleaguered white forklift, so more power was in order. After the lathe was set in place, the next logical move was to relocate the locomotive drivers indoors where they could be cleaned and inspected for cracks, a chore the giant rented forklift handled readily, and we sent it back on its way. Our good friends from the Golden Gate Railroad Museum, Dave Roth and Severn Edmonds arrived to find us at work in the shop. Dave pitched in with Nathan and Steve on needle scaling and scraping the driver sets, and Severn set about cleaning the years of built-up scrunge on the lathe, which as he discovered, is in nice shape. Duane started the wiring, and he hopes to have it operational soon. Our thanks to the Union Pacific railroad for their donation of this machine. Steve Lee inspected each driver spoke closely, and found no cracking, which was a huge relief. Repairs to spokes can be a costly and dramatic undertaking.

Our "new" 16" lathe indoors at last!

Steve scraping grease around the hubliners.

Roger began prepping the patched area on the right side of the wrapper sheet that had been removed last season. The sheet was corroded to the point of needing replacement, so new pieces of code steel were obtained. Roger and Dick ground the new plate to fit, beveled the edges for welding, and tacked in place so we could transfer the staybolt locations for pilot drilling. The two larger patches up on the roof area of the wrapper still need to be fitted; more work for the Spring. Thursday night was dinner at the Roadhouse across the river. Thursday was a good night for dining there- no Karaoke.

Friday cleaning continued on the locomotive frame outside. This less than pleasant task was undertaken by Ed Chase, Steve Cope, and Jim Greco, who was experiencing his first day in steam restoration (and hopefully not his last!). The guys found a formerly undisclosed crack in one of the frame spreaders. This can be ground out and welded in situ due to its easily accessible location. Thanks to them for sticking with it, a good deal of the frame may now be inspected for cracking. Dick and Charlie primer painted the pilot beam and deck, as well as one of the cylinders. The 165 is starting to look like someone cares!

Roger preps a patch area for weld.

Severn cleaning up the lathe.

Roger and Dick forming a piece of boilerplate using heat.

The patch tacked in place and marked for drilling.

New section of steel around the base of the cab.

Friday continued with more of the same. Grease, paint removal, on and on it went. Roger’s company thought they might need him at some point, so he headed back to Woodland that evening. Thanks to him for bringing up his welding machines, and getting a good deal of work accomplished. Steve Lee was presented with the Ultrasonic thickness readings taken to date. He will be begin to generate our FRA Form 4, which is essentially a big book of stress calculations, over the winter back in Cheyenne. Given the average winter temps in Cheyenne, he should be encouraged to stay out of the wind and get a lot done. Thanks again Steve for coming out to Portola and your continued support!

Dave and Dick took preliminary UT readings on the drypipe inside the boiler, the pipe that delivers the steam from the throttle valve on one end, to the cylinder admission pipes on the other. This is simply a length of seven inch diameter pipe with fittings on each end. Readings revealed thin areas in several places. I opted for replacement, Steve concurred. Now is the time to replace this component, since the boiler is devoid of tubes, and front tube sheet is partially removed, giving easy access. If we waited until after the engine was in operation, and this pipe failed, even if nothing bad happened due to the uncontrolled acceleration, we would have to go through seven levels of Hell to get it out. Another dandy project for the spring.

All week long Bob Sims was hard at work measuring our ex-D&RGW tool car for interior build outs to outfit it as a machine shop and work area for the Steam Department. Thank you to Bob for taking this necessary project on. As I write this about half of the materials necessary are onsite. Bob will with any luck and good weather get a lot done later this year.

Saturday we winterized, tarped, and generally put things away. Another season is behind us. Sunday morning Dick and I headed down the hill and stopped into Colfax, where our Museum’s train was on display, staffed by our friendly volunteers, for the Railroad Days celebration in that town. The equipment looked shiny and spiffy, a rolling ambassador to the WPRM.

Thanks again to all of you for your continued support. Thanks also to the team behind the scenes that makes sure we keep moving forward, including Rod & Gail McClure, yardmaster Steve Habeck, treasurer James Mason who keeps us grounded, our webmaster Tom Carter, Eugene Vicknair, our graphics department and cheerleader for us from time to time, Norman Holmes who continues to donate more bits and pieces for the engine he comes across, and of course to Steve Lee, whose mentorship during this project has been invaluable. Special thanks go to Charlie Spikes who spends days getting ready for our arrival making sure everything is in place when we arrive.

Interestingly, after a gorgeous week in Portola, the weather turned just days after we left, and snow was flying again by the middle of the week. Everyone have a nice holiday season, and we will pick up where we left off next year! We will convene again at the end of April, after things thaw out a bit. - JCA