DL&W 565 2011 progress report

[afboone]

Another year of work has started!

Feb 3 workday:
We started building up the worn area on the Radius Bar Cross Tie. The area over the years has been worn it was decided to have us build it back up with weld. We are half way done with the build up and should be able to finish that next time up. Once the welding is complete we will mill it smooth. ... Also there were cracks in the corners of the bracket that we v-grooved. Once we re-install it to the engine we will weld that v-groove up.

The lower bracket for the Radius Bar Cross Tie has been made for stock. We used 1" steel for the plate and then cut 3"X4" stock to make the spacers to have room to attach the radius arm to the bracket. We still have to bore the large 3" hole thru the center once the main bracket is finished. We drilled the attaching holes for the bolts. We will do a final reaming of the holes once can put the upper and lower brackets together to get a good alignment for the new bolts.

Front driver springs we made from old ones on the scrap dock are ready to be shipped out to the vendors for final assembly. They have been sandblasted. The plan right now is to ship them out and have the straps made and the slots cut on the ends.
We have cut the stock for new pins for the equalizer bar, radius arm, and bolts for radius bar cross tie. The radius bar cross tie bolts are tapered and will be make from new stock. Plan is to make all of these in the few months on the lathe.

Check out our Facebook for pics.
http://www.facebook.com/album.php?aid=2 ... 3629534133

[afboone]

March 17 workday---The build up is complete on the cross tie! Next time up we will mill that baby! We sandblasted the Petticoat pipe and it's now ready to installed in the smokebox.
The smokebox cover was installed and we installed the bottom and top bolts. We have several more to put in but we have to ream the holes in the smokebox ring to make everything fit.
Work continues on the parts for pilot truck.

[afboone]

We had our first weekend workday on May 15! Len and his gang were there and we had 5 folks there. We completely finished installation of the smokebox cover. All the bolts are installed and we attached the flag brackets. The marker light brackets need to be drilled to fit. The grab rail is done also.

--We installed the exhaust nozzle to the cylinder. We installed Heli-coils due to the heavy corrosion. The exhaust nozzle bolt holes are damaged so we are going to document it in the records and call it good for now.
--The exhaust muffler is sitting in the smokebox and just needs to be bolted on.
--The smokebox lift pipe needs a strap made for it to connect it to the smoke stack.
--The steam pipes are completely connected to the cylinders. Yeah nice big bolts! 7/8" in diameter bolts
--Scaffolding has been installed behind the cab so we can start removing the wood from the cab. Pictures have been done of the current condition for the report. We are going to send out a sample to make sure we use the right wood. Plus I want to have our plan approved for cab restoration for the NPS. I have to get approval before we start replacing any metal or wood. We are trying to get ahead on this while we are waiting on parts to made for the pilot.
--We have a plan in place to make the center pin for the pilot. Should be done in the next few months.

[afboone]

Saturday June 11, 2011 Len and the gang were up this weekend.

--The Marker lamp holders back on the smoke box. Holes were reamed to fit.

--Sandblasting continues on more parts.

--Started to strip the cab of wood. We came across a lot of coal soot up in there. We removed all the top wooden strips up the vent in the roof and 7 strips on the Engineer side of the roof.

[afboone]

Well this year we saw plenty of work and parts made for the 565.

We installed the smokebox cover and some of the internal parts for the smokebox.
Bolted up the steam pipes
Removed the wood from the cab. Cab report is under way.

The pilot truck installation was a goal for us but we fell short due to some unexpected parts needing to be made/repaired. We are close.
--Modified both journal boxes to fit.
--Welding is under way for the cracked radius arm.
--Crosstie on the frame for the connection of the radius arm has been refinished and bottom plate is made and just needs final sizing and welding.
--Dan Barrett's High School completed all the parts needed for the pilot truck swivel point to be attached.
--Spring set for #1 driver are ready to be banded.

Still need:
Center pin to be made
Bushing for where the center pin goes thru the frame
Grease wells made for modified journal boxes
Made brass for the axle to ride on

[Cactus Jack]

And what is the end goal ?

Accurate cosmetic restoration or return to service ?

What time period will the finished project represent ?

[afboone]

The end goal is for a cosmetic restoration.
The time period really is going to be when she was done at Dansville and Mt Morris RR. The difference will be the high vis tender will be returned to it's look during the DL&W time. It's the best we can do with what we have.