Disney American

[jbodenmann]

Last one for now. Brass & solder, now off to the foundry.
Jack

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[jbodenmann]

Hello My Friends
Here are some photos of the brake shoe master for the American. This is a model of a Christy
brake shoe. This brake shoe although first used in the 1860's and designed for a wood brake beam looks quite modern.

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[jbodenmann]

After a bit of band sawing.

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[jbodenmann]

Here the pocket for the wood brake beam has been milled.

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[jbodenmann]

Broaching the square hole that will receive a square head bolt that will hold the brake shoe holder to the wood brake beam.

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[jbodenmann]

Here is our little brake shoe holder so far. Pocket for the wood brake beam, square hole for mounting bolt and little recess for brake hanger.

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[jbodenmann]

Here the actual brake shoe is being started using the mill and rotary table.

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[jbodenmann]

Brake shoe blank set against the shoe holder.

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[jbodenmann]

Brake shoe with the pieces that will be silver soldered on to form the ends and keys that will locate it on the holder.

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[jbodenmann]

Brake shoe and holder so far.

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[jbodenmann]

Last one for now. This is how they fit together. There are still some little bits to be stuck on that the curved key will slide into, and some shaping. Hope to finish it up tomorrow.
No shortage of things to do!
Jack

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[jbodenmann]

Here are a couple photos of the brake shoe, holder, and key. The little pieces that the curved key fits through were soft soldered to the shoe and holder so as not to melt the silver solder. Then everything was given a good blast in the sandblast cabinet to give things a sand cast texture that these parts would have had.

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[jbodenmann]

And here is how the whole mess fits together. The key holds everything in place. Pull the key out and the shoe is easily removed and replaced.

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[jbodenmann]

Here are a few more brake rigging bits and pieces. The upper piece bolts to the tender frame under the deck and supports the lower end of the shaft that holds the brake wheel. A chain winds around this shaft and goes to one of the the brake levers. The lower part is the upper brake shaft support and bolts to the tender deck. It also has the latch gear and brake pawl. Still more brake rigging masters to make, the brake levers, hangers, hanger brackets, safety hangers for the brake beam safety chains, brake lever fulcrums, and last the brake wheel. This last part is a fun bit, as there was a great variety of brake wheels deciding which one to make will be the hard part. Too much fun!
Jack

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[jbodenmann]

Here are a few of the tender tank. This is the one piece flanged tender tank bottom.

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[jbodenmann]

Here is a drilling fixture being used to drill the side sheets. The holes were located in the drilling fixture using the milling machine and digital read out.

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[jbodenmann]

Fitting the side sheets to the bottom.

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[jbodenmann]

Here is the setup for bending the side sheets. A vee block and round stock in the hydraulic press. No annealing needed with this method.
See ya' later alligator.
Jack

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[alanstepney]

Jack, as I've said before, superb work.

Keep it coming as I am sure many will find your posts helpful.

[Shawki Shlemon]

I agree with Alan , I watch it regularly with interest . Good stuff . Well done .