Summary of the March 17-18, 2007 Work Session
great weekend. Several different projects
were worked on, and we picked up one new volunteer (a young one at
that, which is important if the rail preservation field is to survive
beyond us gray-heads) that says he will return and bring his older
brother. Maybe he enjoyed himself, or possibly it was the food. The
bill-of-fare for Saturday evening: fried chicken with milk gravy,
mashed potatoes, peas, and Cole slaw. Dessert was not needed.
team built up
two complete sets of horns Saturday. The team
effort made rather simple work of the job. The welder burned a rod,
stepped out of the way while the helper cleaned the flux form the
just-applied bead of weld. While the helper was doing his task, the
installed another electrode into the holder, and was ready to weld the
instant the helper stepped out of the way.
horns were worn so oval, a few beads of weld were applied along the
of the horns to return them more closely to the round shape. This
the amount of concentration required for the welder to end up with a
that would "clean up" the first time it was machined upon in the lathe.
These beads were done with the casting laying flat on the bench. All
welding was done with the horns held vertically in a home-made
Welding started at the outer bottom of the horn, and spiraled around,
around, and around...until the top was reached.
the welded horns was done in the old 20 inch Lodge and Shipley
lathe, due to its large swing capability. A very crude drive arm was
to the chuck wheel to power the work piece, which was held between
The horns finish at 2.250 inch diameter. Due to the out-of-balance
of the part, all machining was done very slowly, about 15-20 RPM.
See Andy Fitzgibbon's posting on the
site for photos
of this process.
The scrap box welding fixture.
from old bearings, a
junk lathe chuck,
and scrap steel. It
can be mounted horizontally or vertically, as the case
requires. Note the
cable clamped on to rotating shaft. A lazy
welder simply stands in one spot and rotates the work as welding
progresses. No more
the welding rod". (Photo by Grady Smith).
A very ugly horn partially
built up with
weld. The purpose of the
vertical beads were to transform a very oval horn into an
approximate circle before building up the entire circumference of the
item to assure that the piece would really have
adequate material applied in the right places to machine
completely. This machinist/welder only likes to build up
parts once! (Photo by Grady
A completely built-up horn.
machined diameter will be 2.5 inches. This may or may not be
the same horn as the one
above. (Photo by Grady Smith).
All lathe work on the shorter of the
new square shafts was completed. The
portion that is to go into the socket of the horn casting was machined
0.006 to 0.007 inch interference, shrink fit. At assembly, the horn
will be heated several hundred degrees to expand the socket to the
that it can be simply slipped over the shaft without pressing or
After cooling, it will stay wherever it is until something breaks.
shrink fit situation go sour part way on is not a pleasant happening.
Lathe work on the second, longer shaft was started. After the rough
was blocked up on the tailstock end, an air motor was used to drill the
center hole. As can be seen in the photo, the drilling of this hole, on
this lathe anyway, would have been difficult if the forging had been
the piece had been much longer, we would have been in
Note the tailstock of the lathe hanging out past the end of the lathe
bed. (Photo by Grady Smith).
welding was done, and the
end is in sight for this part. The two top
reinforcement gussets were welded into place, and the welds ground to
fillets of a casting. After all the welding is completed, and the sharp
corners removed from the entire fabrication, all visible portions of
unit will be heavily needle scaled, giving it a peined look, to texture
surface to give it the "sand cast" look. Though the drawbar pocket is
not yet completed, the urge to slide it onto
the drawbar was too great to resist. See photos for the results.
(See the before and after photos at the bottom of this page).
of the Storage Locker
great portion of the weekend improving space in one of
the storage lockers to better accommodate and organize our growing tool
inventory. This is a pretty big job, and if there are any carpenters
there, extra help sure would be nice.
Main Frame Repair
eroded flanges on the top of the frame members have been removed.
was a dirty, gritty grinding job, but fun compared to the next part of
task: doing the same thing to the bottom side of the frame. A hint: the
thing is too heavy to turn over.