LIVE STEAM CASTINGS Tech Bulletin - 06 LocoGear

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LIVE STEAM CASTINGSLocoGearTech Bulletin - 06John D.L. Johnson3879 Woods Walk Blvd.Lake Worth, FL hnical Bulletin - 06November 16, 2003Copyright 2003 by LocoGearFabricating Instructions for:Tender Frame End Casting - 853-B-5005Safety Link Bar - 372-A-5082Engine and Tender Clevis Pins - 372-A-5083The following instructions are a step by stepdescription of the process for fabricating theTender Frame End Casting (Lima DrawingCard Number 853-B-5005), the Safety Link Bar(Lima Drawing Card Number 372-A-5082) andthe Engine and Tender Clevis Pins (LimaDrawing Card Number 372-A-5083). Only oneof each part is used on the Western MarylandRailway #6. Note that all of these parts werealso used on Lima’s Pacific Coast Shays. Youmay also want to use as a reference the WM#6’s Tender Frame drawing (Lima Card Number 858-A-5000). The Tender Frame drawingshows the Tender Frame End Casting in greatdetail.The Tender Frame End Casting is part ofthe Tender Frame and is the primary connectionbetween the engine and tender. The tongue ofthe Tender Frame End Casting fits inside theupper pocket of the Engine Frame End Casting(Lima Drawing Card Number 483-A-5071)which are held together with the Engine ClevisPin. The Safety Link Bar extends into thelower pocket of the Engine Frame End Castingand is connected with the same clevis pin. TheSafety Link Bar also extends into the lowerpocket of the Tender Frame End Casting and isconnected with the Tender Clevis Pin. (See theprototype photos of these parts on the WesternMaryland Railway #6 on page three.)Lima originally made the Tender FrameLocoGear Technical Bulletin - 06End Casting as a single steel casting from LimaPattern Number 85-110, but for the live steammodel, this part can be fabricated from six steelpieces. The three large pieces, the Top, Centerand Bottom Plates are cut from 1/2" cold rolledsteel bar stock which are bolted and brazed together. The other three smaller pieces are madefrom 1/8" steel plate. We will begin by makingthe Top, Center and Bottom Plates, assemblethem, and then finally rivet and weld these intoplace in the Tender Frame along with thesmaller pieces.It should be noted that beginning with step13, the Tender Frame should be nearly finished.The instructions to build the Tender Frame arenot included in this LocoGear TechnicalBulletin. The installation of the Tender FrameEnd Casting is the last component needed tocomplete the Tender Frame. A drawing of theTop, Center and Bottom Plates is on pages 6and 7. A drawing of the smaller pieces is onpage 10. A drawing of the Safety Link Bar ison page 12.1. To begin making the Tender Frame EndCasting, take a piece of 1/2" x 3" cold rolledsteel bar stock and layout each of the threeplates as dimensioned on the drawing onpages 6 and 7. The Top and Center Platesare then band saw cut to rough shape leaving as little material as possible to file,1

21grind and/or mill to the finished dimensions(see photos 1 & 2).2. The Bottom Plate is rough band saw cut toabout 2 1/2" x 2 1/4". The Bottom Plate is nextcentered in a four-jaw lathe chuck. A 1/2" holeis drilled through the center using a drill chuckin the lathe tail stock (see photo 3). Next a boring bar is setup in the lathe tool post and portion of the center hole is enlarged to 1.875" diameter and 0.312" deep (see photo 4). Thiswill become the inside of the lower pocket ofthe Tender End Frame Casting used to connectwith the Safety Link Bar.433. The Bottom Plate is then band saw cut acrossthe front edge curve of the lower pocket leavingas little material as possible to then file or grindsmooth to the finished dimension. This leaves2the two front corners which will be milled totheir final shape in step 5, but first we need tomake a clamping fixture in step 4.4. In order to hold the Bottom Plate while machining the two inside front corners of the lowerLocoGear Technical Bulletin - 06

Tender Frame End PlateTender Frame End CastingEngine Frame End CastingSafety Link BarLeft Central TenderFrame Channel(Above) This prototype photo shows the Engine Frame End Casting, the Tender Frame End Casting andthe Safety Link Bar on the Western Maryland Railway #6. This view is from the left side of the tender.Note the rivets through the left central tender frame channel connecting to the Tender Frame End Castingbehind it. Also note the rivets which extend out the tender front plate through the side wing of the TenderFrame End Casting. (Below) This prototype view is from right side of the tender. Note that the TenderClevis Pin uses a washer above the cotter pin. Both Photos by Jim Salmons.Tender Frame End CastingTender Clevis PinWith Washer andCotter PinSafety Link BarEngine Frame End CastingLocoGear Technical Bulletin - 06Engine Clevis Pin3

pocket, two 1/4" holes are drilled at the rearcorners of the Bottom Plate in an area that willlater be trimmed away. A piece of bar stockwill be used as a fixture to clamp the BottomPlate during the milling process in the step 5.This fixture is made from a piece of 1/2" x 5/8"cold rolled steel bar stock about 6" long whichis drilled with two 7/32" holes matching thetwo holes at the back of the Bottom Plate andthen taped 1/4"-28 tpi. Two 1-inch long 1/4"28 socket head cap screws are used to hold theBottom Plate to the clamping bar fixture. Youmay find it useful to drill the clamping fixturewith additional holes to match the Center andTop Plates so that they can be clamped as wellfor milling.55. With the Bottom Plate bolted to the clampingfixture, clamp this assembly in the milling viseset at a 10-degree angle to mill out the insidefront corners from the front edge to the tangentpoint of the inside back curve (see photos 5 &6). Mill both inside front corners this way.6. To finish the Bottom Plate, remove the clamping fixture and band saw around the outsiderear edge leaving as little material as possible.Then file or grind to the finished dimension.7. Mill all rough surfaces of the Center Plate tothe finished dimensions (see photo 7). Notethat the two side wings have a 1/8" radius to467ward the front which can be left by using a 1/4"diameter end mill, and are square toward theback. The front edge of the Center Plate is filedor ground to the finished radius of the curve aswell as a radius along the bottom front edge.8. Mill all rough surfaces of the Top Plate to thefinished dimensions (see photo 8). The sidewings are milled .375" deep from the top with a1/4" end mill leaving the angled brace. Notethat the two side wings also have a 1/8" radiustoward the front which is left by the 1/4" diameter end mill, and are also square toward theback. The front edge of the Top Plate is filedor ground to the finished radius of the curve aswell as a small radius along the top and bottomfront edge.LocoGear Technical Bulletin - 06

8Pin from above before welding the TenderFrame End Casting into place, because you willnever get the pin completely out! Since there isnot very much room for full size hands to maneuver the cotter pin into the Tender Clevis Pinhole when it is inserted in the “upside down”orientation, it is recommended that a “snap”cotter pin be used instead of the standard “bent”cotter pin (see photo 12). Once the TenderFrame End Casting is installed, the “snap” cotter pin can be easily removed from the “upsidedown” oriented Tender Clevis Pin with a longneedle nose pliers, thus allowing the TenderClevis Pin to be completely removed for maintenance or replacement.99. The Top and Center Plates each have threeholes drilled in them. The 1/2" diameter hole inthe Center Plate is aligned with the 1/2" diameter center hole in the Bottom Plate. This is forthe 1/2" x 1-1/4" Tender Clevis Pin that is usedto connect the Safety Link Bar. NOTE that onthe model, we recommend the Tender ClevisPin be oriented “upside down” with the flangebelow the Bottom Plate and the cotter pin holeabove the Center Plate. There is NOT enoughroom for the Tender Clevis Pin to be inserteddown into the hole from above once the TenderFrame End Casting is installed in what otherwise might be considered the “normal” orientation for a clevis pin. This is because the Forward Tender Frame Deck Plate covers the holemaking this area nearly inaccessible. If theTender Clevis Pin is positioned with the flangeabove the Center Plate, there is also NOTenough room to raise it high enough to insertthe Safety Link Bar into the lower pocket and ifthe Tender Clevis Pin should need replacing, itwill be very difficult to remove. The sameproblem was present on the prototype whichLima resolved by making cotter pin holes onboth ends of the Tender Clevis Pin (see prototype photos on page 3). This method could alsobe used on the model, but with no advantage.If you follow our recommendation, DO NOTmake the mistake of inserting the Tender ClevisLocoGear Technical Bulletin - 0610. The 17/32" diameter hole in the Top Plate isaligned with the center hole in the EngineFrame Center, and is used for the 1/2" x 2-1/2"Engine Clevis Pin to connect the Tender FrameEnd Casting and the Safety Link Bar with theEngine Frame End Casting (see photo 9). Thishole is made 1/32" larger to provide some playbetween the engine and tender. The tender mayrock due to track conditions and some play willbe necessary to avoid binding and possiblebreakage of any of these parts. A standard“bent” cotter pin was used on the prototype forthe Engine Clevis Pin. Note that clevis pins ofthe two sizes required are commercially available, however, the drawing on page 8 showstheir dimensions should you want to make yourown.11. The other two holes in each of the Top and5

LocoGearJohn D.L. Johnson9 River Oaks DriveChico, CA 95973-1089www.LocoGear.comCopyright 2001 by LocoGear0.563"2.500TAP 625"1.500DRILL 1COUNTBORE 30.125" R.0.625"1.500"0.532"DIA.2.750"1.125"0.125"CENTER PL0.750"3.625"TOP PLATE0.125" R.1.687"1.687"0.125" DIA. HOLES0.500"NOTE:SIDE PLATO P/N 8TENDER858-A-50FOR DIMHOLE PLBRACE PAND TOMBRAZE JOINTFRONT VIEW ALL PLATESLocoGear Technical Bulletin - 06

WESTERN MARYLAND RAILWAY SHAY No. 6TENDER FRAME END CASTINGTOP, CENTER & BOTTOM PLATESLIMA CARD NUMBER 853-B-50050.563"0"0.500"DIA.0"/4"ER3/8"LATEDRAWN BY JOHN D. L. JOHNSON - 11/14/20011.125"0.500"DIA.0.938"1.875"2.500" 0.500"0.750"0.750"2.500"BOTTOM PLATEGRIND TO SHAPEATES TO BE WELDED853-B-5005 AS PERR FRAME DRAWING00. SEE FOR DETAILSMENTIONS AND RIVITLACEMENT, ALSOPIECES TO BE FITTEDLDED INTO PLACE ASED.2.500"BRAZE JOINTTOP PLATER PLATEM PLATEBRAZE JOINTSIDE VIEW ALL PLATESLocoGear Technical Bulletin - 067

10Center Plates are used to hold the plates together for brazing with two 1/4"-28 tpi sockethead cap screws that are each 1-inch in overalllength. The two 1/4" bolt holes in the CenterPlate are counter bored from the bottom so thescrews do not extend beyond the surface of thetop of the Top Plate or the bottom of the CenterPlate. The two bolt holes in the Top Plate aredrilled 7/32" and tapped 1/4"-28 tpi. Thealignment of the smaller holes is critical so thatthe center to center distance between the twolarger holes used by the clevis pins is exactly2.500". Once the Top and Center Plates arebrazed together, the two screws are no longerneeded, however, they can be left in place andjust covered with filler before final painting.12. Once the machining of the Top, Center andBottom Plates is completed, they should becleaned for brazing. On the mating surfaces,prick punch several points so that once clampedtogether, there is a small space between thepieces to allow the braze to flow between them(see photo 10). Use the Tender Clevis Pin tohold the Bottom Plate in alignment with theCenter plate while brazing (see photo 11 and12). Clamp and braze the three plates together(see photos 13, 14 and 15).13. The side wings of the Tender Frame EndCasting are riveted to the Tender Frame withfour rivets. These rivet holes should now belocated and drilled for 1/8" rivets. At this pointthe Tender Frame should also be nearlycompleted and made ready for installation ofthe Tender Frane End Casting including thefollowing steps 14 and 15.14. Take a piece of 1/8" steel plate and layout each81112LocoGear Technical Bulletin - 06

131415of the two Side Plates and Rear Plate as dimensioned in the drawing on page 6. They are thenband saw cut to rough shape leaving as littlematerial as possible to file, grind and/or mill tothe finished dimensions.15. The two Side Plates are drilled for 1/8" rivitsand each riveted to the inside surfaces of thetwo central Tender Frame Channels before theTender Frame is built. The Side Plates thencreate a pocket in the Tender Frame for theother pieces to fit into for final welding.16. To attach the assembled Top, Center andBottom Plates in the pocket formed in theTender Frame, first rivet the four rivets thathold the side wings to the Tender Frame FrontPlate. Then with the Tender Frame upside16LocoGear Technical Bulletin - 069

10LocoGear Technical Bulletin - 06.438"REAR PLATE(1 Required).500".125"SIDE PLATES(2 0" Radius.500"1.500".500"Drawn by John D.L. Johnson 11/13/20012 RequiredMade From 1/8" Plate Steel.125"1.500"Tender Frame End Casting Side & Rear PlatesLima Card Number 853-A-5005Western Maryland Railway Shay #6Drill for 1/8" Rivets Typ.John D.L. Johnson9 River Oaks DriveChico, CA 95973-1089www.LocoGear.comCopyright 2001 by LocoGearLocoGear.375".875"

1817down, clamp everything together except theRear Plate and weld along the two seams wherethe Center Plate lays along the bottom insideedge of the two central Tender Frame Channels(see photo 16). Next insert the Rear Plate andcontinue welding along these seams as well asthe bottom of the seam between the Rear Plateand the Center Plate. You may need to bevelthe edges of the Rear Plate along the weld seamto create a “V” grove for proper welding (seephoto 17). Finally, turn the Tender Frame rightside up and weld along the top of these seamsto complete the welding.17. Grind smooth all welds, clean and prime theTender Frame for final painting (see photos 17,18 and 19).This completes the fabrication of the Tender FrameEnd Casting.19LocoGear Technical Bulletin - 0611

.188"LocoGear Technical Bulletin - 06.125".750" R.532" Dia.1/8" DrillSAFETY LINK BARMake from 1/4" C.R. Steel1.250"2.500"Drawn by John D.L. Johnson11/14/20011 Each RequiredMade From Cold Rolled Steel1/8" Drill.490" Dia.625" Dia.188"2.500".125"ENGINE CLEVIS PIN.750" R.532" Dia.Safety Link Bar & PinsLima Card Number 372-A-5082/5083Western Maryland Railway Shay #6TENDER CLEVIS PIN.625" Dia.490" Dia.John D.L. Johnson9 River Oaks DriveChico, CA 95973-1089www.LocoGear.comCopyright 2001 by LocoGearLocoGear1.250"12

also used on Lima’s Pacific Coast Shays. You may also want to use as a reference the WM #6’s Tender Frame drawing (Lima Card Num-ber 858-A-5000). The Tender Frame drawing shows the Tender Frame End Casting in great detail. The Tender Frame End Casting is part of the Tender Frame and is the primary connection between the engine and tender.

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