Tuesday, December 24, 2013

Coupler end brackets

Today I added the detail plates that go above and below the couplers.  They were epoxied in.  I also filled in the gap at the corners of the coupler pocket with epoxy.  I need a file without side teeth to clean up the epoxy after it hardens.

Weld in trays
Hook up the electronics
Decide if brake & throttle will be active
Find a headlight
Buy speedometer
Install speedometer
Find a horn or bell system
Get and wire up auxiliary power
Buy a keyed switch
Velcro down batteries
Install circuit breaker
Install speed limiter
Install charge port
Install Jeffreys
Install brake wheel
Install throttle lever
Install coupler plates
Install safety chain mounts
Sandblast entire thing
Paint
Attach wood
Stain wood
Make 5 trailing cars

Monday, December 23, 2013

Epoxy The Jeffrey

Today I made a jig.

To place the JEFFREY letters in the right spot.
This completes a very important / decorative step.  Well I may drill and pin the letters in place as an added level of security to the epoxy.
I also made the choice to drop the electronics tray to the underside of the pedestal spacer bars.  This drops it below the frame by an inch and and eighth, giving some weight to the middle visually.  I looked at the prototype pictures and can not figure out if the real one had a lower center.  I can see that at least the drivers end had a belly.

Saturday, December 21, 2013

Center Tray

Today I started by making the risers for the spring so there is some compression.  The coupler center height is now a little above 4.5"  it is supposed to be 4-7/16" +0 -3/16",  I guess that is about right because the wood top, end steps, and electronics are not onboard.  Not sure what it will do when I sit on it.

I also made the center tray for the electronics, this went much easier than I was expecting.  It is a simple tray, I folded over the top edge to limit the sharp edges.  I did have to file down the frame on one side so it would slip (with persuasion from a hammer) in.

Nancy said I should make a list of things left to do like:
Weld in trays
Hook up the electronics
Decide if brake & throttle will be active
Find a headlight
Buy speedometer
Install speedometer
Find a horn or bell system
Get and wire up auxiliary power
Buy a keyed switch
Velcro down batteries
Install circuit breaker
Install speed limiter
Install charge port
Install Jeffreys
Install brake wheel
Install throttle lever
Install coupler plates
Install safety chain mounts
Sandblast entire thing
Paint
Attach wood
Stain wood
Make 5 trailing cars

Wednesday, December 18, 2013

New Seat & Battery Tray

Today I decided not to fix the brakes on the truck, there is a leak about 3 feet infront of the drivers rear tire.  I decided to purchase Nancy a Christmas present.  I made a new seat for the Jeffrey.  This one does not have a through hole.  I started by taking the center drill out of the 2-3/4" hole saw, clamping a 1/2" thick board onto the drill press table and made a round blank.  I cleaned it up first on the bandsaw, then on the grinder by putting a nail in a blind hole i drilled in the bottom and holding it on with a piece of plastic. After it was ground round I sanded the faces and the edge by hand.  The new seat is now as large as the bottom of the mannequin.

Afterwards I worked on the battery trays.  I made the two small pieces for the tray with the back jog.  I found it worked best to hold the blank in the arbor press and bend it over with a hammer.  It definitely is much easier to not have that jog.

Overall it was not a lot of work accomplished today, lots of hesitation and pondering but I have now accomplished two steps that I was dreading.

Sunday, December 15, 2013

Significant Step

Today I got the four motor 4 bars installed.  This allowed me to put the frame on the wheels and test the springs.



I think I will need to install stronger springs on the back end as my weight was disproportionately at that end.  It would also work to make the truck to have a 3 point suspension rather than 4.  I have been reading old Live Steam magazines and the experiences on the backyard railroads facebook group.

I used the old pedestal caps that I replaced.  Drilled them out to 1/4" long and rounded the ends.  Does this mean I have 4 less pieces of scrap?  I also trimmed the excess off the plum cove motor supply.  Used a dremel to do most of the work, but it is dieing, had to do some by hand.  Glad it was aluminum so the shavings were not attracted to the motor magnets.


Wednesday, December 11, 2013

drillin and tappin

Today I drilled the pedestal caps that were loctited to the ends of the pedestal with the #27 drill.  To keep things in line I had C clamped the cap to the brass slides.  Of the 4 sets, 1 cap came loose while drilling, 2 more were loose when I removed the clamps and one was still tight together.  I followed up by hand tapping and drilling out the tap with clearance holes.

The issue is the bolts are left at Jeff's house.  As it is not worth going down to get them I either wait until we come back home on the 31st or order some that are 1/2" long.  McMaster has them 10 for $5.  As the bolts Jeff has are 1" long and would need to be cut down I am not sure which I will do.


Monday, December 09, 2013

redo

I remade the pedestal caps tonight.  Cut them a half inch longer than before, then drilled the #27 drill one of them and used that as a template to face spot the other three.  Then after I cleaned up the ends of the pedestals I loctited the two together.  Now I will be spending some time painting the barn quilt we will be placing on our garage.

Saturday, December 07, 2013

Spring holes

Today, despite still recovering from my cold I worked on the journals and pedestals.  First I finished drilling the clearance holes for the bolts that hold the 3 parts together.  Then I cleaned up the flashing & burrs on the parts so that the journals slide on their respective pedestals.  Next came drilling the holes for the spring mounting buttons.  Last was drilling the holes in the journal retainers.  Not much work for the day, but to be able to see the journals in position is a wonderful sight.



Wednesday, December 04, 2013

One end

Today I am back at it.  Did not want to since I have a head cold / sinus thing going on but Jeff asked me if the parts he made fit.  And Nancy suggested going down for a half hour.  

In the two hours I was down here I fixed Anna's solar flower, found a drill bit to drill clearance holes for the journals from Jeff, cleaned off the oil from two of the journals from Jeff, and put them onto and axle, mounted them on pedestals.  Journal 1 was loose Journal 2 was tight, I sanded it bigger with the Dremel and a sanding drum.

I still have some work to do loosening things up so everything slides easy.  Then to install the springs and journal keepers.