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Discussion Boards => HO => Topic started by: Thomas1911 on February 15, 2013, 02:29:15 PM

Title: Thomas1911's Shay Project
Post by: Thomas1911 on February 15, 2013, 02:29:15 PM
I mentioned in my layout thread a while back that I was starting on a Shay project.  Well, here it is....

While perusing the web one day, I came across a site detailing the different types of geared steam locomotives.  On the page covering the Willamettes, I found the following picture of a design that was apparently on Willamette's drawing boards when they went out of business.  A two-truck, 6-axle locomotive.

http://www.mrollins.com/willam.html

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/willamette6-axle_zps8287442e.gif)

Thinking what an interesting model this would make, I immediately started wondering what it would take to turn a Bachmann Shay into this never-built locomotive.  Some initial studying and measuring of the Bachmann model lead to the conclusion that it was feasible, but I decided that since this isn't really a prototypical locomotive, I would save some headache and not try to turn the Shay into a Willamette.  Building the proper cylinder bank and valve gear didn't seem very appealing.  

My original plan was to turn this into a "Pacific Coast" –style Shay with the all-weather cab, girder frame, and cast trucks.  After much thought, I decided I didn't want to tackle trying to scratch-build the cast truck side-frames.  This decision lead to the next decision that making the frame and cab modifications would be pointless without the cast truck frames.  I decided I would only worry about necessary changes to fit the 3-axle trucks, leaving the factory truss-rod frame, boiler, and cab.  Modifications needed would be the front and rear pilots and water tank / fuel bunker.  Maybe in the future I'll come up with a way to make the cast truck side-frames, and then make the other modifications.

The physical part of the project started with extra front and middle Shay trucks that I had in my workbench drawer.  I began disassembling them and taking measurements of all the components.  I then started drawing the components in AutoCAD to determine how certain components were going to fit together and what would need to be modified.  For simplicity sake and compactness, I decided to not model the truck equalizer bolster as seen in the Willamette design.  Instead, I would utilize two factory middle trucks and graft on an articulating 3rd axle and frame cut from the other trucks.  I worked out the pivot point and designed the needed parts for the articulating 3rd axle in CAD.  

With design work done, I began by modifying the extra trucks.  Only minor trimming needed to be done to the middle truck.  The front truck saw considerable cutting and splicing of the side-frames to form the single-axle unit.  Next, pivot parts were cut from styrene and a bushing from brass tubing, then the parts were glued (with CA) to the appropriate truck component.  Holes were drilled (and tapped) after the glue had dried.  Lineshafts were reassembled with NWSL gears and one of the original slip-joints cut down to the appropriate length to go between the 2nd and 3rd axles.  This makes up the front 3-axle truck.

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/TruckDesigning1_zpsd8488af0.jpg)

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/6-AxleTruckSideframes_zpsd276f2e6.jpg)

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/6-AxleTruckFit-up_zpsa05e8027.jpg)

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/6-AxleTruckPivotParts_zps7f9bbeb4.jpg)

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/6-AxleTruckAssembled_zps6768fa7c.jpg)

I didn't want to spend money on another Shay until I was surer this truck was going to work.  So, with the first truck done and appearing to function as expected, I was confident enough to make a purchase.  During the planning and design process, I had been keeping an eye out on eBay for a suitable Shay.  After a few months of watching, I was lucky enough to score the particular model I was looking for at an acceptable price, an undecorated steel cab model.  

Before any serious or irreversible damage was done to the new Shay, I wanted to test the first trucks operation under its own power before proceeding any further.  This meant disassembling most of the locomotive and removal of the front pilot for the new truck to fit.  Testing went well.  Only issue that arose was that the shortened slip-joint would come apart while negotiating left-hand curves.  The truck would want to articulate instead of rotating in relation to the frame.  I solved this by adding a travel limiter to the 3rd axle frame.  I also added some weight to the 3rd axle frame to help it track a bit better.

As seen in the pictures the front pilot will need to be extended forward about 7/8" to clear the 3rd axle.  I may look into the possibility of moving the front bolster rearward to reduce the amount needed to extend the pilot.  

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/6-AxleTruckampShay_zps91dba1b6.jpg)

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/3-AxleTruckTesting_zps15a3d027.jpg)

Currently, work is beginning on the rear truck.  Once it is complete, will move on to extending the front and rear pilots and figuring out what to do with the water tank & coal bunker.

More to follow.....
Title: Re: Thomas1911's Shay Project
Post by: Doneldon on February 15, 2013, 04:29:04 PM
Thomas-

This looks like an interesting project being done well. I congratulate you.

As to extending the front of the loco, I wouldn't worry about how that might look.
Articulated steam engines all have huge front porches and yours would be no
different. In fact, it just might be the feature which best attracts eyes to the
locomotive. People will realize right away that they are looking at something
unique.

                    -- D
Title: Re: Thomas1911's Shay Project
Post by: WoundedBear on February 15, 2013, 06:00:45 PM
Outstanding!

Sid
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on February 15, 2013, 07:48:30 PM
Thank you for the compliments.

D,
I wasn't to concerned with the looks of the "front porch".  In fact, I thnk it would look fine.  I expect it would have been an excellent place for the crews to transport frequenly used tools, rigging equipment, etc.

However, I have just realized that pushing the coupler too far out from the bolster may lead to some derailment issues in curved sections of track.  Going to have to do some checking on this.  Probably won't be a problem with normal rolling stock.  Cars where the couplers run relatively close to the centerline of the track, like disconnect trucks, may be a problem though.
Title: Re: Thomas1911's Shay Project
Post by: Doneldon on February 16, 2013, 03:42:01 AM
Quote from: Thomas1911 on February 15, 2013, 07:48:30 PM
Thank you for the compliments.
However, I have just realized that pushing the coupler too far out from the bolster may lead to some derailment issues in curved sections of track. 

Thomas-

You're welcome. You earned the praise.

You can let your whole draft gear pivot which should help a bit with the coupler misalignment problem on curves.

                                                                                                                                                                             -- D
Title: Re: Thomas1911's Shay Project
Post by: jward on February 16, 2013, 09:17:37 AM
what about mounting the pilot on the front truck similar to a mallet? that would solve the swivel problem. normally i don't recommend truck mounted couplers, but you should have enough weight on the front truck to minimize any problems.
Title: Re: Thomas1911's Shay Project
Post by: Geared Steam on February 16, 2013, 12:03:32 PM
Very interesting project, I will be watching this thread with much interest  8)
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on February 16, 2013, 01:02:21 PM
Thanks for the ideas on the coupler problem.  I'm going to make some temporary mounts for the front pilot and see just how much of a problem I really have.

Jeff, mounting the pilot to the truck is a possibility I hadn't considered.  Thanks.

Did make a little progress modifying the side-frames for the rear truck last night.
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on February 21, 2013, 12:00:19 PM
Finished modifications for the rear truck last night.  Went a lot faster second time around.

I don't have a decoder for this yet, so testing has been limited to a short, back and forth runs on a section of track with an old power pack.  It has run well with the amount of testing thus far.

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/3-AxleTrucksComplete_zps9d6d6cbd.jpg)

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/3-AxleRTruckTesting1_zps3faba7f9.jpg)

Now on to extending the frame.
Title: Re: Thomas1911's Shay Project
Post by: Doneldon on February 21, 2013, 02:39:21 PM
1911-

I've been thinking about your project a little. If you are still having problems with the drive shafts pulling out of their receivers on the front and rear mini-trucks, you can just make the sockets a little deeper. If that interferes with turning, cut out small amounts of the pockets on both sides of both pockets so the drive shafts have a little more clearance but not so much that they can pop out. Making the cut outs just a hair larger than the drive shafts but smaller than the head of the drive shaft should do the job.
                                                                                                                                                                                                 -- D
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on February 22, 2013, 01:34:07 AM
D,
Thanks for the suggestion, though I think the issue is pretty much taken care of with the travel stops I added.  I left the sockets as long as I could, but still collapse enough to make an 18"R curve.  With the slip-joints being so short, it doesn't leave much in the way of travel.  Then add in the loose fit....things have to be just right.

I'm sure some final fine-tuning will be needed, but I think its going to work out alright.

Now just to get some extended test runs in.
Title: Re: Thomas1911's Shay Project
Post by: ryeguyisme on February 23, 2013, 10:21:27 AM
it's killing me how really cool this is, I mean TRULY this is an amazing idea
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on February 23, 2013, 01:46:21 PM
Thanks Rye.  This design was different enough and by having the extra parts, just couldn't resist trying.

It's too bad Willamette didn't get a chance to build the design.  Or Lima could have incorporated it into their Shays, though I imagine patent restrictions were probably the reason they didn't.
Title: Re: Thomas1911's Shay Project
Post by: ryeguyisme on February 23, 2013, 01:58:49 PM
All you really have to do is maybe put a bigger/longer boiler on there and make a bigger fuel bunker, the third "tender" fuel bunker shell might be big enough for your needs

http://estore.bachmanntrains.com/index.php?main_page=product_info&cPath=66_68_92&products_id=1645
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on February 23, 2013, 05:10:32 PM
I wasn't going to do anything with the boiler, just extend the front pilot to clear the truck.  The original water tender frame will be spliced on to the rear of the main frame.  Then the water tender body and coal bunker will be spliced together in some form or another.  Haven't decided exactly how to go about this yet.
Title: Re: Thomas1911's Shay Project
Post by: WoundedBear on February 23, 2013, 06:52:06 PM
Quote from: ryeguyisme on February 23, 2013, 10:21:27 AM
it's killing me how really cool this is, I mean TRULY this is an amazing idea

Glad I'm not the only one who is impressed with this. I agree whole heartedly....this is an amazing project.

Thomas, did you put the NWSL steel pinion gears in the trucks? I've done the conversion on 3 of my Shays now....it's a major improvement and well worth the bucks spent.

Sid
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on February 23, 2013, 07:31:55 PM
Yes, I installed the steel gears on this one and also my other "regular" 3-truck Shay. Nearly all the gears on both locos were already split when I pulled them from the packaging.  Bachmann sent me two replacement trucks for my first Shay, but unfortunately the replacements had split gears also. 

Are the gearboxes on your shays noisy?  Both of mine sound like they have sand in them, a gritty sound.  I think both are from a production run from 2002.  I've been meaning to open them up to clean and relube them, but haven't got around to it yet.
Title: Re: Thomas1911's Shay Project
Post by: WoundedBear on February 23, 2013, 07:39:38 PM
I have one that sounds like a grinder buts runs fine. It's probably from that same time frame as yours, yet it's still got all it's original gears. The others are quieter......but the beauty is the one factory sound equipped Shay I have. Even muted, she is absolutely silent.

I found the gear problem to be spotty.....like I said....some had 5 of 6 cracked, that other one is still on it's originals....weird.

Sid

Sid
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on February 23, 2013, 08:28:26 PM
Definitely weird.  I'll have to tear into mine before long and see if I can figure out what's going on.
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on February 27, 2013, 03:37:06 PM
Did some measuring of the frame last night and have come up with a design for extending the front pilot.  Fairly straightforward I think.  Material required will be some 1/8" C-Channels and several thicknesses of sheet.  Planning to do this with styrene.
 
As I mentioned in the original post, I'm looking at extending out 7/8" (roughly 6' 4" scale measure) to clear the 3rd axle on the truck.  Still toying with the idea of relocating the front bolster rearward by some amount to reduce length of extension.  I expect less than 1/8" change could be had, so may not be worth the effort.

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/PilotExtensionDesign_zpse262ab88.jpg)
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on March 07, 2013, 12:21:15 PM
Making progress with extending the front pilot.  Have it fitted to the frame, but not attached.  I'll move on to the rear pilot modifications then attach both to the frame at the same time.

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/FrontPilotExtension1_zps84f0d66e.jpg)

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/FrontPilotExtension2_zps54c05fd4.jpg)

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/FrontPilotExtension4_zpsa22b0fe2.jpg)

That extra 7/8" doesn't look as long on the model as I thought it would.
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on March 20, 2013, 09:09:56 PM
Been a little tied up with other projects, but have made some progress on this.  The rear frame is now modifed by splicing the water tank frame to the rear of the main frame.  Still trying to decide exactly how I want to do the new tender body.  Planning to build on the existing water tank to add the coal bunker, just not sure how it should look and how I want to attach it to the frame.  Need to get a decoder ordered soon to get this thing running, also.

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/RearFrameExtension1_zpsdb652745.jpg)

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/RearFrameExtension2_zps55fc60ae.jpg)
Title: Re: Thomas1911's Shay Project
Post by: trainboy6936 on March 22, 2013, 12:40:42 PM
Dude that is got to be one of the coolest shays I've ever seen that is sweet.
Title: Re: Thomas1911's Shay Project
Post by: Doneldon on March 22, 2013, 03:28:15 PM
Thomas-

That looks great to me. Refresh my memory, though. Are you planning a third truck in the middle or just a long drive shaft? A third truck seems the most likely but I suppose one could have an extra long two truck Shay as a novelty. Maybe one truck was irreparably broken so the railroad just fashioned the long shaft to keep the loco in service. A fine model either way.

                                                                                                                           -- D
                         
Title: Re: Thomas1911's Shay Project
Post by: WoundedBear on March 22, 2013, 03:58:20 PM
Doneldon....

The 3 steam cylinders and crankshaft still need to go in there.....that's what looks odd to you. To me it looks like Thomas hasn't moved the position of the front truck, and the rear truck is located where the center truck of the stock model was. I don't think he should need to do any driveline mods.

Sid
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on March 22, 2013, 04:57:03 PM
Sid, you are correct. 

In the photo, I had the cylinder/ash pan assembly removed to avoid damaging i while cutting on the frame.  It will take up the space befween the trucks, no modifications.  The modified trucks are installed to the original front and center bolsters.
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on April 24, 2013, 10:30:29 AM
Finally able to find some time to work on this project, starting modifications to form the tender body.  Decided on a plan to join the original coal bunker and water tank.  Not much yet, but have the coal bunker cut down now.  Need to determine how much to cut off the front of the water tank, then join it to the coal bunker.  Once joined, will just need to add some trim-work and details.  Hope work on this some more over the next few days.

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/TenderBodyMods2_zpsc816a01f.jpg)
Title: Re: Thomas1911's Shay Project
Post by: WoundedBear on April 24, 2013, 11:36:00 AM
I've said it before and I'll say it again..........this is an impressive project! Hopefully you won't have too much rivet detail to redo. I've been using the rivet decals from Micro-Mark....have you tried them yet? I like them better than others I've used in the past.

Keep going Thomas....I'm enjoying this.

Sid
Title: Re: Thomas1911's Shay Project
Post by: jward on April 24, 2013, 11:38:56 AM
it reminds me of a steam version of the sd40-2
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on April 24, 2013, 12:37:19 PM
Quote from: WoundedBear on April 24, 2013, 11:36:00 AM
I've said it before and I'll say it again..........this is an impressive project! Hopefully you won't have too much rivet detail to redo. I've been using the rivet decals from Micro-Mark....have you tried them yet? I like them better than others I've used in the past.

Keep going Thomas....I'm enjoying this.

Sid

Thanks, Sid.  Haven't tried them yet, but I plan to order some soon.  There is a few other odds-n-ends I need to order from them as well.  I expect there will be some rivet details that I will need to add or replace.

Quote from: jward on April 24, 2013, 11:38:56 AM
it reminds me of a steam version of the sd40-2

I'd say that's probably a fair comparison, Jeff.  Maybe I'll start calling this locomotive "Shay-2".  ;D
Title: Re: Thomas1911's Shay Project
Post by: jonathan on April 24, 2013, 04:32:06 PM
Haven't chimed in on this one, yet.  I was going to wait until the end.  But it's getting exciting.

Can't wait to see the completed loco.  Nice!

How will the turning radius be?

Regards,

Jonathan
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on April 24, 2013, 05:51:14 PM
Thanks Jonathan.  I designed the trucks to run on an 18"R, which is the smallest I plan to use on my logging lines.
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on April 29, 2013, 12:40:05 PM
Getting closer, a little more work done fitting the water tank and coal bunker.  This is going to take a little more work than I initially thought.  The water tank is slightly narrower and slightly taller than the coal bunker.  The height issue is easy enough to solve with a shim, but not sure what to do about the width other than blend with some filler after joining.  Would mean redoing much, if not all, of the rivet details on the sides.  Also, the water tank walls are quite a bit thicker than the coal bunker, so will have to thin them down to reinforce the splice, at least with the way I see in my head.

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/TenderBodyMods3_zpsd8d6a4e7.jpg)

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/TenderBodyMods4_zpsfecdb761.jpg)
Title: Re: Thomas1911's Shay Project
Post by: WoundedBear on April 29, 2013, 12:45:30 PM
Looking good man. ;D

I would try to laminate some styrene to the sides to get the width corrected, then redo the rivets. Looks like that Micro-Mark order may come sooner than later, huh? I think this would look better than the putty route.....but you decide. So far your choices have led you in the right direction.

Sid
Title: Re: Thomas1911's Shay Project
Post by: BaltoOhioRRfan on April 29, 2013, 04:23:01 PM
Been keeping a close eye on this built. Looks good.'

You gonna put toolboxes on the front deck?
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on April 30, 2013, 01:45:33 AM
Quote from: WoundedBear on April 29, 2013, 12:45:30 PM
Looking good man. ;D

I would try to laminate some styrene to the sides to get the width corrected, then redo the rivets. Looks like that Micro-Mark order may come sooner than later, huh? I think this would look better than the putty route.....but you decide. So far your choices have led you in the right direction.

Sid

That's an idea, Sid.  The coal bunker is only .014" wider (.007" per side) than the water tank.  I think the thinnest styrene sheet I've seen available is .010", might be a little difficult to work that down evenly.  I was thinking after I joined the halves together, I would use some glazing putty or body filler to build up a gentle transition at the joint and sand it smooth.  Definitely going to need to place that Micro-mark order soon.

Quote from: BaltoOhioRRfan on April 29, 2013, 04:23:01 PM
Been keeping a close eye on this built. Looks good.'

You gonna put toolboxes on the front deck?

Yup.  Planning to do a toolbox or two and probably some loose tools (axes, saws, shovels, etc.) and some coils of chokers.  Have to wait and see exactly what there is room for.
Title: Re: Thomas1911's Shay Project
Post by: Doneldon on May 01, 2013, 02:52:00 AM
Quote from: Thomas1911 on April 30, 2013, 01:45:33 AM
Planning to do a toolbox or two and probably some loose tools (axes, saws, shovels, etc.) and some coils of chokers.  Have to wait and see exactly what there is room for.

T1911-

Just because there might be room for a bunch of tools doesn't mean you have to put a
bunch of tools there. Sometimes less is more. Thanks, Mies.
                                                                                            -- D
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on May 01, 2013, 01:46:31 PM
Good point, D.  It's all just ideas floating around in my head at this point still.
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on June 03, 2013, 09:45:08 PM
Sorry guys, not much to report as far as progress over the last month, tender body still in two pieces.  Been busy with the usual spring house/yard work and whatnot.  Though I was able to order a decoder last week and it came in the mail today.  Going to try and get it installed this week and send this thing on its maiden trip around the layout.  Will see if I can't get some video to show this thing in action soon.
Title: Re: Thomas1911's Shay Project
Post by: WoundedBear on June 03, 2013, 10:18:11 PM
It will be interesting to see how much this thing is able to pull. Got a fish scale?

Sid
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on June 03, 2013, 11:13:19 PM
No, I don't unfortunately.  Micro-mark has a digital scale that's been on my "To-Buy" list, hasn't been a priority though.

My estimate is that it will be less than that of the 3-truck being that the 3rd axles don't bear any weight.  Probably around 2/3 to 3/4, depending on how much weight I can cram in it.
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on June 13, 2013, 09:28:57 AM
Finished decoder installation last night.  Made a test run on the layout to check functions, ran and tracked well.  Need to adjust some CV's and clean track, then work on that video.  Stay tuned.

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/DecoderInstall_zps3bc5c962.jpg)

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/DecoderTest-Run_zps4b3978d1.jpg)
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on June 18, 2013, 01:16:20 AM
https://www.youtube.com/watch?v=VG8tmeIzurk&feature=youtube_gdata_player

Video as promised, let's see how this works.  First time doing any kind of video editing and first time uploading anything to youtube.  29 years old and just now losing my youtube v-card.

Recorded and edited the video on my phone, may try it again on the computer later on.

EDIT:

This video is a little less janky.  Same as the other minus the pass by at the end.

https://www.youtube.com/watch?v=-8UflW4x54A&feature=youtube_gdata_player
Title: Re: Thomas1911's Shay Project
Post by: jonathan on June 18, 2013, 07:14:21 AM
Great work.  Looks like it's running fine.  You have some great patience working with all that tiny gear work.

Nice solid benchwork and trackwork, too.

Now slap some scenery on that wood!   ;D

Regards,

Jonathan
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on June 18, 2013, 10:30:07 AM
Thanks Jonathan.

Scenery will come.  Been hesitant to start until I'm sure I don't want to change any more trackwork or anything.  Time and money better spent on other things at this point I feel.
Title: Re: Thomas1911's Shay Project
Post by: utdave on June 19, 2013, 11:43:05 PM
and you had to top it off with a john deere tractor    nothing runs like a john deere  and plus your locomotive was super with  great sounds.


Dave
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on August 12, 2013, 02:54:49 PM
No significant progress to report, but I am trying to start on it again.  Wanting to get this project wrapped up before I start on my layout reconstruction.  I did get the needed rivet decals ordered over the weekend, also ordered a replacement water tank hatch since the original cast-on hatch will be cut away.  Working to get the tender body halves joined over the next few days.

I do have a question, can anyone tell me what the bullet-shaped details are on top of the water tank? They can be seen in my photo in my reply #32 on page 3.  One is to the left of the original water hatch and the other is to the right of the back-up light.  Not sure if they're some weird looking lifting eyes, water level sight glasses, vents, gun mounts, ....?  Wondering if I should worry about replacing the one next to the hatch that I will be removing.
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on August 14, 2013, 10:52:05 AM
OK, some progress.

Last night I was able to get the "mill work" done on the water tank half of the tender body in order to join the coal bunker to the water tank.  Added a shim to the bottom of the coal bunker to correct the height difference with the water tank.  Once the glue has cured completely, I will smooth the sides and finish trim work and details.

With my rivet decals arriving in the next day or two, started giving some thought as to how they will be placed on the side of the tender body.  Came up with a tentative plan.

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/TenderBodyMods5_zps6e55a85b.jpg)

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/TenderBodyMods6_zpsc1807239.jpg)

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/RivetPlacementPlan_zps29ca2bb6.jpg)
Title: Re: Thomas1911's Shay Project
Post by: jonathan on August 14, 2013, 11:14:57 AM
So... we're down to rivet counting, eh?  ;D

I'm starting to see light at the end of the tunnel.  Good on ya.

Regards,

Jonathan
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on August 15, 2013, 09:57:45 AM
Getting close, Jonathan.

More progress last night.

Was able to file the sides of the tender body flat without too much trouble, correcting the width difference.  Had planned to use some filler to help hide the seam, but after starting to file off the cast-on rivets the sides were nearly flat.  Just kept filing until they were, which didn't take much.  The zinc material the parts are made of works pretty quickly.

Trimmed the factory coal load to clear the splice reinforcement material, fit the coal load in place, then installed the water fill pipe to locate the new water hatch.  Drilled a hole and installed the hatch.  Added a "rear wall" to divide the coal bunker and water tank.

Debating whether or not I want to fill the rounded corner on the front of the coal bunker to more or less blend the tender body into the rear wall of the cab, giving a more one- piece look.  The filler piece would have the filleted corner up towards the cab roof similar to the later Shays.

Other than deciding on filling the corner, pretty much ready for the rivet decals, paint and final assembly.

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/TenderBodyMods7_zps623e77e8.jpg)

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/TenderBodyMods9_zps1a4a7779.jpg)
Title: Re: Thomas1911's Shay Project
Post by: Doneldon on August 15, 2013, 08:14:49 PM
1911-

It looks to me like you're making great progress. It all looks good.

                                                                                         -- D
                               
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on August 16, 2013, 11:41:49 AM
Thanks Doneldon.

Checked the tracking on my rivet decals, shows they won't get delivered until Monday.  Looks like I won't be getting much done on this over the weekend.  I have to say I'm far from impressed with these "smart post" shipping methods companies are using.  Takes twice as long to receive a package that would normally take 3-4 days.  Not sure what the shipping companies are gaining by doing this.  Must be some cost savings, but I don't really see how.  Sorry for the rant.
Title: Re: Thomas1911's Shay Project
Post by: Doneldon on August 16, 2013, 07:01:12 PM
1911-

The parcel services sometimes have the USPS make the final delivery after the parcel company moves the package from its
origin to the distribution center nearest the recipient's home. That has to add a day or two. It seems inefficient to use two
organizations but I suppose it allows the delivery services to concentrate on the distance cartage without having to run local
delivery services everywhere.

                                                  -- D
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on August 17, 2013, 12:01:21 AM
I guess in some instances that makes sense from a logistical perspective.  Just kind of irritating when you pay standard shipping prices.  I would have expected it if I paid for economy shipping.

Maybe I'll get lucky and my package will be in the mailbox tomorrow.
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on August 19, 2013, 09:58:05 AM
Attempted to add the filler to blend to the rear cab wall as mentioned previously, but it wasn't working out; couldn't get it to look right.

After all my whining, ended up getting my rivet decals in the mail on Saturday and completed engineer's side last night.  Pretty happy with the decals, nice product.  Expect to complete fireman's side tonight or tomorrow.  Had to order another bottle of engine black paint, surely will be here by end of the week and can paint this coming weekend.

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/TenderRivetDecals1_zps5c78dbc3.jpg)
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on September 09, 2013, 04:11:24 PM
Well, for all intents and purposes, modifications for the Shay are done.  Only lack a few misc. details, weathering, a crew, and may add roadname decals later on.  Pretty happy with how the Micro-mark rivet decals turned out.  I do need to order a replacement footboard for the rear pilot.  It didn't want to come off easily during disassembly, ended up bending it with all the handling, and then it snapped off after more handling. I'm pleased with how this has turned out.  Usually my wild ideas end up in the parts bin or the trash.

Thanks to everyone for the comments, suggestions, and encouragement.  It's much appreciated.

I'll update and show more pictures as I add details and such, though not sure how soon that may be. 

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/CompletedModifications1_zps3db9d814.jpg)

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/CompletedModifications2_zps29cada9b.jpg)

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/CompletedModifications3_zps67f0b445.jpg)

(http://i989.photobucket.com/albums/af15/85MUSTANGGT_TJM/Train%20Pics/CompletedModifications4_zps2c649802.jpg)
Title: Re: Thomas1911's Shay Project
Post by: jonathan on September 10, 2013, 06:14:51 AM
Great locomotive!  Sure will be a treat to have your unique project running around the layout. 

Congrats!

Regards,

Jonathan
Title: Re: Thomas1911's Shay Project
Post by: Thomas1911 on September 11, 2013, 12:12:05 AM
Thank you, Jonathan.  It will indeed.