[Gerd]

RE: Are you interested in 2" scale shay building log?

Well, here's another preview of the actual progress. I'm working on the pedestals and on Sunday, I milled the uprights to form the right side pedestals that will fit around the crown gear.

I'll tell you some more details this evening. BTW, I bought the gears as also the wheelsets, but both has to be machined on the lathe to match. The gauge will be 5" (127mm).

When you're intersted in more informations and pictures, check out my website www.shay.de.ki and read more about this project.

Cheers, Gerd

@Dan : nice to see you here too ;-)

 

[Gerd]

Hello,

it's time for a progress update.

The pedestals are neraly complete since I've assmbled the last one yesterday. Only the journal and gear cover are missing. I ordered the journal covers as laser part so I'm still waiting for them. Here are detail photos of both style pedestals.

While I was waiting for new thread taps, I spend time on the axle driven water pump. The excenter ring was made from brass as also the whole pump. Two stainless steel balls are used for the valves. After the pump was finished, it was tested in the kitchen and works fine. You can see it at Youtube => http://www.youtube.com/watch?v=4Is5XUhN-hk

Finaly, I start work on the lower bolsters by cutting the raw material to length and machining the first parts.
Normaly, those early type Shays had wooden bolster instead of steel. I know that the bolster is "very heavy duty" for my little Shay, but it brings approx 4 more pounds of weight to each truck so this helps me to reach the final minimum weight of 100 pounds. The story could be, that the roundhouse crew has replaced the wooden bolster after a train wreck in reason of a brocken bolster.

Detail photos of the bolster during construction will be added with the next report. For today, I'll close with two mokeup photos, showing how all will come together.
Oh, the wheelsize is 22" and the wheelbase will represent 36". I guess this will match with a small 10 to 11 tons Shay.

Will be continued.

Bye, Gerd

 

[Gerd]

RE: Are you interested in 2" scale shay building log?

The scale ratio is 1:6 and the gauge will be 127mm (5").

Gerd.

 

[Gerd]

RE: Are you interested in 2" scale shay building log?

Hi Dan,

yes you're right. After some thoughts, I think this will be the best solution. I'll also add an injector and a hand pump.

Cheers Gerd

 

[Gerd]

RE: Are you interested in 2" scale shay building log?

Hi Tony,

my first steamer in this size has also a axle pump and I'm very happy with this design. I had always trouble in operating an injector while driving, so a simple and easy feed system will be worth a lot. But that's my opinion and also my experience that I made.

It's also a question in boiler size. As smaller a boiler is, as more importend is a good feed system. While a larger boiler will run one lap on a layout, a small one will only do a half lap before the water level will reach the lower level. The next problem is, that the steam source on a small boiler is also limited and most steam will be needed to keep the engine running, so there's no in many cases there's no steam free to operate feed systems while driving the engine.

I take a look on google for the Torquay Manor and the boiler will be near twice the size of my Shay boiler.

Bye, Gerd

 

[Gerd]

Hello and good morning ;-)

@Bob : they are doing a great job. But meanwhile, they need fork lifts and cranes to handle the growing truck. But step by step....

My girlfriend was working this weekend (she's working as nurse), so I had a lot of time for my second girly Abby *hihi*

First I build the bolster stands (I don't know if this name will be correct) from chanel, flatbar and threaded rod. On the rear, I mounted some 10mm square bar as guide for the spring plank.

Next I screwed the lower bolster together and milled it to final shape. The bolster for the rear truck got also a special grove to hold the axle pump. After milling the spring pockets, the bolster ist neraly complete. I also added the pivot points for the break rigging. Remember, that the Shay will get a working steam break.

Finally, I cut the spring planks from heavy flat bar and installed them on top of the springs. When the Shay will be finished one day, I've to adjust all the spring work to the final weight of the locomotive.

But these was only the work from Saturday... On Sunday, I started with the next chapter, the archbars. I raw cut all bars and started to bend them by using a chisel and hammer on top of an old vice. This works very well even on 4mm thick steel flat bar.

I stared with the lower frame with only a few bends to test this method.

Then I've gone ahead with the upper arch bars. I printed a 1:1 side view of the trucks to control each bend .

To get a feeling of the growing trucks, I started assembling of the front truck by adding the lower frame and upper archbars. That looks pretty good for the moment.

Still missing are the middle archbars. While this bends are very sharp (approx. 70° ) I used 15x3mm flatbar for this. The first two have been bend in the same way as shown above.

Now stay tuned => the first truck rolls out yesterday in the very late evening !!! But no photos yet and the truck was hold together by clamps. But it rolls and that was a very great feeling. Unnecessarily to tell, but I sleeped very well last night.

Some more pictures of several other steps can be seen on my website.

That's all for now but will be conitnued...

Cheers, Gerd

 

[Gerd]

RE: Are you interested in 2" scale shay building log?

Hi, the guys are typical G-scale figures. The left for example is an engineer from an Bachmann 2-4-2 Lynn. Bye, Gerd

 

[Gerd]

RE: Are you interested in 2" scale shay building log?

Hello Dan,

at first thanks for your gratulation and also for the hint for the columns.

To size the springs, I guessed the total loco weight to approx. 55kg (120 lbs) and substraced the trucks weight with 9kg (19 lbs) each. The rest was divided by the number of springs (16) so each spring will carry 2,3kg (5 lbs). With this data and the needed minimum length, I used a tool from my spring dealer to find the right size. So the springs will be the final one.

What I'll have to do when the loco is finished, is to adjust all the springs by drilling the pockets deeper. So I can change the free length and pre-loading to bring the whole loco into balance in length- and crosswise.

When I'll be back at home, I'll post some pictures of the front truck with pedestals and wheelsets in place.

Cheers, Gerd

 

[Gerd]

RE: Are you interested in 2" scale shay building log?

Here are the pictures I mentioned above.

Enjoy the pics, Gerd

 

[Gerd]

RE: Are you interested in 2" scale shay building log?

Hello Dwight,

it's based very far on the Kozo books. I have them both and use them as reference for ideas and constructions designs.
But finally, I build my own design. At least while I'm building in 2" scale and this is much larger then Kozos engines. I use several plans from the Mich-Cal-Shay and a fine detailed drawing set from Al Armitage, publised in several isssus of FinescaleRR and NG&SL Gazette.

The final look of my Shay will be like the Bachmann On30 engine, but with a cab in stained wood optik like my Forney. I don't like "all in black" locies.

The gears are ordered from a German dealer for standard parts. The have 30 and 15 teeth and have the modul 2.0 .

@tony23

Take a look on the last pictures. The wheelsets and inner flangs of the pedestals have already been painted. I really hate it to assemble a model and disassemble it again for painting. So I prepaint the components and assemble them only once (in most cases). Another reason on this trucks is, that there's a lot of adjusting work needed to get the wheelsets running smooth and parallel. So I hope they will work in this design for many many years.

Cheers, Gerd

PS.: I changed the latest pictures with newer views of the truck.

 

[Gerd]

RE: Are you interested in 2" scale shay building log?

Hello again,

the second truck is also ready to run. I added the line shafts with the bevel pinions and will start the universal joints next.

I also posted a large number of several new progress photos on my website.

Now, I'm totally OOM (Out Of Material) and I'll order new stuff for the frame next week. And I'm still waiting for the laser cut journal covers and break rigging parts (break shoes and links) to complete the trucks. But the laser guy is ill so it will take some more time.

So don't worry, the project will be continued soon (because I can't wait to get the loco running )

Bye, Gerd

 

[Gerd]

RE: Are you interested in 2" scale shay building log?

Hello all,

I made only small progress the last days. I machined the universal joints and test run them. The work great.
But I'm still waiting for delivery of the ordered material and laser parts :-(

Details are shown on my website as always.

Cheers, Gerd

 

[Gerd]

Hello Livesteamers,

it's a while ago since my last post. So I'll show you an update on my Shay.

Meanwhile, the trucks are completed with brakes, covers and color. Also the frame is mostly done.

Many more descriptions and pictures are on my homepage.

Cheers, Gerd

 

[Gerd]

RE: Are you interested in 2" scale shay building log?

Hello Dan,

I faked the channel for the side beams by using a rectangular sttel bar with 10x25mm and added 2x16 flatbars on top and bottom. This flatbars are hold in place with the screws of the run board supports. This has several reasons : I couldn't find I-beams with th right size and this version brings more weight to the model. Actual, the Shay weights 30 kg.

This evening I started with the break levers for the frame underside. I also had a long phone call with a boiler maker. We discussed the price of a cooper T-boiler and now I've to collect the money for the boiler. Once the boiler is here, the most difficult parts are ready except the steam engine.

Cheers, Gerd

 

[Gerd]

Hello Bob,

you're right, the Shay will get a T-boiler. I'll finish the drawing set today and will send it to my boiler maker.

Meanwhile, the break rigging on the frame was also installed and works fine. I also added two braces on the engineers side running from the side beams to the each of the end beams. Actually, the frame was painted black and is now ready for the next steps. First I'll add the runboards and will continue with the break cylinder and hand break lever. I've also to build a working break steam valve as I'm building a working steam break.

As the small folks were on vacation over the easter weekend, I placed myself behind the Shay frame on this outdoor photo. The photo was taken on April 10th, just before painting.

Cheers, Gerd

 

[Gerd]

RE: Are you interested in 2" scale shay building log?

Good morning,

I spend a couple of hours on my Shay last weekend to build the brake cylinder. A test run on compressed air works very fine. Some work is still to do and the initial piping is also missing. I hope I can add this during the next days. The final piping and brake valve will be installed when the cab is on one day.

The brake cylinder was made from bras and stainless steel for the piston rods. Some more progress photos are hosted on my website.

There's a small video of the test run at YouTube => http://www.youtube.com/watch?v=urOGqKYZ5hI

Cheers, Gerd

 

[Gerd]

Hello,

it seams that I missed some progress posts here on this board... So I'll give you a small update...

Meanwhile, the run boards and cab floor has been mounted and stained into a dark brown (not shown in this photos). I also added steps for the cab and the universal slip joints, that are running great. http://www.youtube.com/watch?v=29zxJTffMhY

I also completed the boiler drawings and send them to my boiler maker.

Actually, I'm working on the tender tank of the Shay. This tank is built from brass sheet and brass angle. Over 600 small copper rivets will hold them together. After construction, I'll soft solder each joint to seal the whole tank. Capacitiy will be 6 liters.

More details and photos can be found on my website http://www.shay.de.ki

Cheers, Gerd

 

[Gerd]

Digging out an old thread *hehe*

Hello folks and Shay fans : After a break of 6 month, I'm back on my Shay project and did some progress last weekend.

At first, I added a hand brake to the loco. All parts are home made from stock material (steel & brass).
I need to rebuild some parts of the installed brake rigging of the steam brake.

The first tank design shown in a previous posting was very close to the prototype, but very bad in operation handling. Remember that I build a "ride on" scale Shay and have to handle all cab controls and at last the coal shovel. The now used tender design was successfull tested on my Forney locomotive so I decided to use the same desing on my Shay.

So I build a new tender from plywood and sheet metal (aluminum & brass). The rear section will hold a square watertank made from brass sheet while the front section is for coal. I also added first details to the tank. Once the water hatch has been installed on the cover, the tank will be painted and finally set in place.

Finally, I start with the rear sandbox, using the same way as done on the tank. A piece of plywood was covered with aluminum sheets.

 

[Gerd]

Hi folks,

I made some good progress the last days.

The rear sandbox was completed with details and has been installed after painting. The water tank got the hatch on and was also mounted after painting.

Click on thumbs for large pictures.

After some hours and many sketches, I came back to the first design for my Shay and build a wooden std. cab without side windows. The cab is colored to match the look of the Forney.

I used plywood for the basic superstructure and added boards to create the typical look of a Shay cab.

Next I made the bell. The bell itself was bought some years ago from a sail & boat supply shop. All other parts are made from steel.

Click on thumbs for large pictures.

So here's an actual view of the whole thing from yesterday :

That's all for now. I ordered material for the sand dome yesterday and will continue with the dome and the head light next. Once all boiler adds are done, it's time to start the steam engine... So I'll spend some hours on the CAD drawing board to create the steam engine. I think I'll build a mokeup from wood and styrene first. By building those parts correctly, I can use them to oder castings in bronze, brass and other material.

Bye, Gerd

 

[Gerd]

Hello Ray,

TJV in Spain doesn't produce live steam trains anymore.
I meet the former owner and manufacturer some years ago, but I don't have any contact infos of him. I'm sorry.

At last, many thanks for your comments. This evening, I spend some hours on the drawing board for the steam engine. It's quite tight to get the engine in there, but i think it will work...

More to come in a few more days.

Bye, Gerd