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On the loading ramp, ready to go to a meet in Maine.
1-1/2" Scale Shay under construction.
This Shay is based on the design by Kozo Hiraoka that appeared in Live Steam
magazine. It has been built to twice the size of the original plans. This Shay
has a 3 cylinder engine with Stephenson valve gear. The universal joints (one on
the left side of the crankshaft, 5 more sitting on the cab floor above) are
based on the design of Ken Schroeder's Shay.
The crankshaft was machined from a solid block of steel.
So far, I have not used any castings in the construction of this engine, parts
have been either machined from the solid or built up by silver soldering smaller
pieces together. The cylinder frames are a good example of the built-up
construction. Similar to the original design, I changed to a two piece
brass/steel assembly rather than cutting the part from one piece of brass pipe.
The tilting table was built so that I could machine all four main bearing faces
at once to be sure they are in the same plane.
Here the cylinders and engine frame have been placed on the lathe cross slide
for reaming. I didn't have a long enough reamer to go through all four
bearings so I did the first 3 bearings, removed the front cylinder, and reamed
the last bearing.
Here's a closer look at the engine. Cylinders are cast iron, cylinder frames are
made up of steel tube and brass bearing blocks. Connecting rods are steel, with
square bronze bearings. Crossheads are bronze. Most of the valve linkage is
stainless steel. The eccentric straps are bronze. All the valve linkage is
bronze bushed.
Another view of the engine showing the exhaust manifold leading forward. The
three piston blanks are stacked in front of the engine on the running board. The
piston rings will be made from 25% carbon filled Teflon (PTFE).The intake
manifold is visible above the top of the cylinder heads, the brass block at the
top of the manifold is the 3 way steam branch. Steam oil will be injected just
above this branch for cylinder/valve lubrication.
This view from the rear shows the valve linkage and a valve (bronze) located in
the valve chest.
This view shows the exhaust/intake manifold. Pardon the oversize bolts, they're
temporary until appropriate scale bolts are made.
Shown here are the remaining gears, all modified and ready for mounting. The
eccentric on the left hand side is for the lubricator pump. The pistons are on
the far left. On the right is one of the spaces to go between the large gears
and the wheels. This engine is designed to be converted from 7-1/4" to 7-1/2"
gauge.
One of the trucks with gears and lineshaft fitted. This unit is just about ready
for painting and final assembly. I decided to make this Shay into a 3 truck
locomotive so I will have to build another truck. The 3rd truck will carry the
engineer as well as a horizontal 20 lb propane cylinder.
Front truck with brakes, only journal covers need to be installed.
Brakes adapted from Ken Schroeder's Shay drawings.
That's all as of April 2, 2002. The engine should be running on air in a couple of weeks.
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UPDATE! ENGINE RUNS ON AIR!
Well, it took more than two weeks! But as of July 5, 2002 the engine does indeed
run well on air! In this picture the completed engine is shown. Yet to be made
are the links to operate the cylinder drain cocks. The drain cocks work fine. I
made them as small as I could and reasonably near prototype appearance.
Another shot of the completed 3 cylinder engine.
The reverse stand slots being machined. The MLA (Metal Lathe Accessories)
machining block came in handy here.
Drilling
the smokebox for rivets and smokestack.
Brake cylinder parts, per Ken Schroeder design. Kozo's plans did not
include brakes.
Brake cylinder mounted on frame, waiting for steam plumbing.
Cutting the slot in a brake clevis. I make two on one length of material
and then cut them apart, they are easier to hold that way.
Rounding the ends of a brake clevis.
Eight completed brake clevises.
Backhead. Shows water gauge and steam manifold valves.
Steamdome, showing safety valves, ball valve steam throttle and steam plumbing
to cylinders.
Handpump, mounted in PVC water tank. This internal tank will later be
hidden within the aluminum tender shell.
Exhaust piping between exhaust manifold and smokebox.
Pictures showng cylinder cocks closed on left, open on right. Fasteners to
be replaced with scale fasteners.
BOILER PHOTOS:
The boiler is made from 3/8" thick steel. It has two TIG weld passes and a
covering pass stick welded. It has been hydro tested to 300 psi.
This boiler is based on the Kozo design but with threads changed to 1/8" npt in
most places. Two additional fittings have been added since these photos
were taken. One fitting is for a direct connection to the top of the water
glass, rather than connecting the water glass to the turret. And the other
fitting is a 2nd water inlet connection for the left side of the boiler.
The steam exhaust pipe interfered with the boiler check valve I wanted to use on
the right hand side, so I moved it to the left hand side.
HOMEMADE BOILER FLUE ROLLER:
Thanks to Rich Dean for a drawing and information on how to operate a flue
roller. The boiler hydro tested to 300 psi with the rolled flues.
One flue weeped. It was re-rolled and the boiler was again hydro tested to
300 psi. No leaks.
Propane burner:
These
are LocoParts (http://www.locoparts.net)
burners under test on a breezy day. The burners burn blue on only a
couple of psi when there is no breeze blowing.
Ready for steam:
I
have constructed a PVC tender tank which will be housed within the tender shell.
Notice the pressure gauge and shafts just in front of the PVC tank, these will
be the main operating controls. Since this will be a three truck
Shay with the engineer sitting on the third truck I thought it would be wise to
move the controls back toward the engineer to shorten the reach. The
throttle lever will have a linkage added so that it can be operated from the top
of the tender tank. The shafts go down to valves below the floor.
These valves are for the injector water, injector steam, engine steam brake,
train vacuum brake and propane control. The gauges will show propane
pressure and vacuum level.
STEAMING:
The
engine was steamed up and tested on our private track. There are a
few items that need attention but no serious problems. Now I can
operate the engine while I complete it.
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