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Discussion starter · #61 ·
Dear Dan,

many thanks for your comment.
The c/n 792 was chosen as I was still planing to build a 2-7x12 steam engine. While I'm building a totally freelanced Shay, any existing number won't match. So I decided to take one that's sounds good and matches the build time of my locomotive. But the c/n 792 matches the size of my Shay very well.
One week after I ordered the etched brass signs, I decided to build 2-7x7 because this steam engine would look much better on my Shay.

At last, as mentioned before in this thread, there are only a few guys who will ever notice that the number doesn't match the model ;-) So what matters.

The steam engine was hardly modified since the last posts about her in this thread. As described, I changed to a 2-7x7 and I used the plan from the yahoo-group for reference. I also changed many parts of the construction to capture the look of the steam engine.

Actually, I've enough steel at home to start with the crankshaft. I think this will be one of the most difficult parts on the steam engine. All other construction should be straight forward.

Bye, Gerd
 
Discussion starter · #62 ·
Hello all.

Well, looking on the lasat picture of the Shay in the garden, she looks "blind" without her head lights. So I start to made them from steel. 12 hours of work are spend and the same time will be needed to get them done. Here's an update photo from yesterday evening.

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Bye, Gerd
 
Discussion starter · #64 ·
Hello guys,


I made some progress on the details parts of my Shay locomotive the last weekend. The head lights are mostly finished and I'll add the supports for them during the next days.


I also made the dummy boiler feed pipes. The actual water feed heads will be installed inside the cab.
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Bye, Gerd
 
Discussion starter · #65 ·
Hi Folks,

the head lights are in place now. Actually I start work on some valve handles, details stuff and wood work to decorate the loco. I ordered a new parting tool for my lathe and will finally start with the steam engine soon.

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Bye, Gerd
 
#66 ·
Gerd: The Shay looks great. Your work is first class. But -- you are to have to start on the engine unit soon. Can't wait anymore.

Thanks for sharing this. Bob
 
Discussion starter · #67 ·
Hi Bob,

you mean somewhat like this ? *hehe*

I just started with the first cuts to make the crank shaft. I cut an 8 cm piece from a 60mm diameter steel rod to fabricate the cranks. Not so much to see yet, but the first cut was done to build the steam engine.

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Saddy, I killed the index bit on my parting tool so there was no further progress possible today. But I'll continue next week as soon as I get new parting bits.

Bye, Gerd
 
#69 ·
Hi Gerd. I thought you had an "Armstrong" power saw. You know, 2 stong arms pushing a hacksaw.

I've been dreaming for years of building that Shay in 2.5" scale. Need to get it going.

Bob
 
Discussion starter · #70 ·
Well... I just had 15 minutes yesterday to do some progress on the cranks... I turned the outer diameter down to 56mm. That works great with fresh and sharp tools.
Meanwhile, I repaired my milling machine in fact of a teeth less spur gear. Now my workshop is in fully operational condition.

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Cheers, Gerd
 
Discussion starter · #71 ·
Hello,


did some more progress and cut off two 24mm discs and drilled the holes for the crank pins and main axles.


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I' ll bring them to final shape on sunday and will split them up to get 4 cranks at least.


Cheers, Gerd
 
#72 ·
Hi Gerd,
Nice start on the crank. I will be watching the steam engine build with a lot of interest.

Is your plan to scale up Kozo's Stephenson valve gear solution? If so I think that that will work fine as it is very similar to a real Shay design and the Aster WM #6 is a scaled down version of Kozo's solution.

Cheers Dan
 
Discussion starter · #73 ·
Dear Dan,

yes, I'll go for the Kozo-Design valve gear.
I finally spend some more hours to redraw my steam engine design, regarding on the 7x7 engine posted on the Y-group. I had to make some technical compromisses but I think the engine will come along very nice.
It's my plan to have the loco running on air until the end of 2010.

Cheers, Gerd
 
Discussion starter · #75 ·
Hi Bob,

yes, I'll use press seats and pins to assemble the crank shaft. Some may silver solder this, but I don't like to apply so much head to the crank shaft in fact of ...

Well, I did some good progress yesterday, bringing the cranks to their final shape.

I used the parting tool to cut the raw cranks 2/3 in the center. So I was able to mill the outline in pairs.


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Once the shape was completed, I finally split them off and faced them on the lathe to final thickness.

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Next I'll file the edges and corners and drill some holes for pins and the clamp belt bolts. More details and pictures of the last progress steps are shown on my website as usual.


Cheers, Gerd
 
Discussion starter · #77 ·
"Those little men are great engineers"


Oh yes, they are... Some days ago, I stored three of them on a side board (for what reason ever.. I don't know) and searched for them a long time. I didn't find them... The funny thing is - most parts I build in this time without the little helpers, I made a lot of mistakes, wrong cuts and had no luck with the parts I was making for the Shay. Finally I spotted them on the board and since this day, I had much less problems... Isn't it strange?

Stay tuned for the next steps. Maybe I'll do some progess this evening...

Bye, Gerd
 
Discussion starter · #78 ·
Hello again,

meanwhile, the crank shaft has been assembled except for the valve gear excenters.

I drilled and milled some more holes and slotes to finally shape the cranks and sanded/filed them to finish. Then I cut 2 crank pins and pressed them into the cranks. I used a second shaft to allign the cranks during this step. Once both crank pairs are ready, I alligned them on the main shaft and glued them in place with loctite. I added 3mm pins through each joint to secure there position.


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In the next step, I cut out the main shaft between the cranks and I added the clmap bands around the lower section of the cranks, made from brass.


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After adding the excenters, the crank shaft is ready and I'll order stock material for the rest of the steam engine.


Cheers, Gerd
 
#79 ·
Gerd, Very nice work.
I have a very similar crank only a bit smaller on my desk. If you check any clear photo of a 7x7 Shay engine you will see that you have reversed the webs. I made this same mistake on my first crank and no matter how hard I tried I could not make it match the photo. I was not all that happy with the first try so I made a new one. Hopefully this message gets to you in time.

Cheers Dan
 
Discussion starter · #80 ·
Hello,

here's a short update on my Shay project. I installed the steam brake valve and added the pipes to the brake cylinder. The steam brake still doesn't work very well. Maybe I've to chance the piston seals.

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Last weekend, I started with the steam engine. The photo shows the cylinders and covers. Yesterday I finished both piston bores. Bore and strock are 30mm.

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Cheers, Gerd
 
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