Author Topic: Shay Locomotive  (Read 63281 times)

Offline Steamer5

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Re: Shay Locomotive
« Reply #90 on: March 02, 2015, 01:22:24 AM »
Hi Dan,
 This thread just gets better & better ! Just need better eyes to see those
tiny bolts!!
Keep up your amazing work, & forwarding the updates from Japan

Cheers Kerrin
Get excited and make something!

Offline Roger B

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Re: Shay Locomotive
« Reply #91 on: March 05, 2015, 08:13:03 PM »
Shin’ichiro Ukitsu's work is amazing  :praise2:  :praise2: Thank you for posting it  :ThumbsUp:  :ThumbsUp:
Best regards

Roger

Online Dan Rowe

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Re: Shay Locomotive
« Reply #92 on: November 02, 2015, 06:20:26 PM »
Several months back I heard that there was a plan to dedicate a Centenary plaque to the Mapleton Tramway in a park in Mapleton. I was asked if my drawing could be used for a 6' stainless steel laser engraved sign. I of course was excited and said yes to the project.

The celebration took place over the weekend and I received some photos of the plaque. The big cut out version is on the back of a stone bench which faces the smaller version with a bit of history.





The words:

"For 30 Years from 1915, two almost identical Shay locomotives called Dulong
and Mapleton ran on a two foot tramway track between Nambour and Mapleton.
The tramway ran down the Lilyponds Park entrance and across to
Obi Obi Road.

The 10.5 mile (17 kilometer) tramway plus the two Shay locomotives and all
rolling stock were owned by the Maroochy Shire Council. The line was never
financially viable and was subsidized by the rate payers.

Several thousand Shay locomotives of various sizes were designed and built by
the Lima Locomotive Company of Ohio on the United States from 1879 to 1944.
The Shay locomotives were quite unlike conventional steam locomotives as they
had two vertical cylinders and two four-wheeled bogies. While the local Shay
locomotives were heavy coal users, slow and needed a lot of maintenance, they
were particularly suited for steep winding tracks."



"The locomotives were used to haul sugar cane, milled timber and logs, small
livestock, cream, fruit, general goods and passengers. Heavier loads could be
carried on the down run to Nambour.

The service operated Monday to Saturday, leaving Mapleton in the morning.
branch lines meant that the locomotives could shunt up to the Mapleton
shops/tavern and the sawmill. Because there was no turntable, the locomotive
made the trips to and from Nambour facing Mapleton.

After the closure of the Mapleton Tramline in 1944, the Moreton Sugar Mill
purchased the locomotives, rolling stock and track. In 1948 the sugar mill built
one locomotive using the parts from Dulong and Mapleton with the rebuilt locomotive
being named Shay. The Shay worked at the Moreton Mill until 1965.

The preserved Shay locomotive can now be seen at the Nambour and District
Historical Museum."

Cheers Dan
ShaylocoDan

Offline b.lindsey

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Re: Shay Locomotive
« Reply #93 on: November 02, 2015, 06:33:30 PM »
That is great Dan and it's nice you had a part in it too!!  Thanks for posting the pictures of the event.

Bill

Online Dan Rowe

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Re: Shay Locomotive
« Reply #94 on: December 16, 2017, 07:58:21 PM »
This project is not dead just slow. I drew Shay gear #6 in 3D cad and sent the file to a friend that is building an early Shay in 16mm scale who has a printer. The pinions are small so they were printed with a material that could be burnt out so they came out fine. The 7/8 gears could not be done the same way so a mold was made. The gears made with the mold looked good, but there was no way to get the gear face and the rim to both run true. Oh well off to the remelt pile.



Two of the gears were printed by another guy as a test. They did not look as good as the print lines can be seen but they were a direct burnout and I had already made a special expanding mandrel so I gave them a go on the lathe.



I chucked the back flange in the 4 jaw chuck and the flange and gear face ran true. You can see the indicator in the tailstock behind the lathe. I took a light cut to true up the inner bore.



I modified an expanding mandrel with a hex bolt so that it can be taken up blind. The expanding screw was originally simply tapped into the mandrel body and there was no way to tighten it blind.



The mandrel with gear ready to go in the lathe.



Ready to face the back flange.



Finished back flange.



The pinion was a simple job to drill and ream 5/32".



The pinion was mounted in the tool block with a 5/32" drill and the gears ran under power just fine.   :cartwheel: :cartwheel: :cartwheel:

Now I have a proper set of #6 Shay gears.... time to finish the trucks.

Cheers Dan
ShaylocoDan

Offline crueby

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Re: Shay Locomotive
« Reply #95 on: December 16, 2017, 08:00:44 PM »
Very nicely done, glad to see this one active again!

Online Dan Rowe

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Re: Shay Locomotive
« Reply #96 on: December 16, 2017, 11:46:49 PM »
Chris, did you take a good look at the lathe? The 4 jaw chuck is a Sherline and the lathe is  Levin with a 3C headstock and a 10mm collet tailstock. I have several other goodies like a 3C collet closer and a production cross slide to do repetitive work. The tool block is the small Aaa Multifix
https://www.ebay.com/itm/worldwide-smallest-Quick-Change-Tool-Post-system-Multifix-QCTP-size-Aaa

The expandable mandrels I am using came from this ebay store:
https://www.ebay.com/sch/thirdwheelrider/m.html?_nkw=&_armrs=1&_ipg=&_from=

He also sells the screws so you can make your own. The 8 piece set has free shipping in the US so it is a good deal.

Cheers Dan
« Last Edit: December 16, 2017, 11:51:37 PM by Dan Rowe »
ShaylocoDan

Offline crueby

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Re: Shay Locomotive
« Reply #97 on: December 16, 2017, 11:54:11 PM »
Chris, did you take a good look at the lathe? The 4 jaw chuck is a Sherline and the lathe is  Levin with a 3C headstock and a 10mm collet tailstock. I have several other goodies like a 3C collet closer and a production cross slide to do repetitive work. The tool block is the small Aaa Multifix
https://www.ebay.com/itm/worldwide-smallest-Quick-Change-Tool-Post-system-Multifix-QCTP-size-Aaa

The expandable mandrels I am using came from this ebay store:
https://www.ebay.com/sch/thirdwheelrider/m.html?_nkw=&_armrs=1&_ipg=&_from=

He also sells the screws so you can make your own. The 8 piece set has free shipping in the US so it is a good deal.

Cheers Dan
Neat setup - I had not noticed that the chuck was a Sherline. How do you like that Levin lathe?

Offline b.lindsey

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Re: Shay Locomotive
« Reply #98 on: December 17, 2017, 12:09:46 AM »
Very nice to see more on this project Dan. Handsome looking Levin as well.

Bill

Online Dan Rowe

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Re: Shay Locomotive
« Reply #99 on: December 20, 2017, 11:05:34 PM »
How do you like that Levin lathe?

I like it a whole lot anyone need an older Cowells ME 90 with attachments?

I ordered a sheet of nickel silver to make new rims if needed. I hate to melt the gears if they can be used.

Here is the lathe with one of gears that were directly burned out. There were a few more that just got to me today.



I set up the 5C indexer vertical in the mill and drilled a wheel center and the gear flange.



Here is the first one bolted up. Notice the gear rim diameter is just a tiny bit shy of the wheel center diameter. The metal shrink made it too small. The new prints will have extra metal so the rim can be machined to the proper size.



Cheers Dan
ShaylocoDan

Online Dan Rowe

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Re: Shay Locomotive
« Reply #100 on: December 22, 2017, 10:33:29 PM »
I am using 1.5" schedule 160 SS pipe for the tires here is the setup to face the ends before using the band saw to cut blanks.



The rest of the gears are bolted to wheel centers and the left side centers are with the tire blanks.



Now to face the tires.



I am waiting on an expanding mandrel to profile the tires.

Tomorrow I will make the half brass bearings.

Cheers Dan
ShaylocoDan

Online Dan Rowe

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Re: Shay Locomotive
« Reply #101 on: December 24, 2017, 11:06:48 PM »
The first step in making the half brass wheel bearings was to drill a 3/16" hole in a section of 5/16" square brass stock. These sections were milled with a 3/16" rod inserted to keep the vise pressure from distorting the section when it gets thin.



The bearings installed in the left and right side pedestals, notice the left one is in a bit deep this is because the thrust pad has not been made yet.
the thrust pad is the next item on the list.



Cheers Dan
ShaylocoDan

Online Dan Rowe

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Re: Shay Locomotive
« Reply #102 on: December 26, 2017, 07:48:16 PM »
The thrust pad is a 2.25" square section 1/16" thick with one half round side. It is small so I made a clamp with file buttons to make the round bottom side. One thrust pad is shown finished in the photo and another finished one is in the filing fixture.



The wheel axle rides on the thrust pas on the left side and the adjusting bolt will actually work to take up wear. This photo shows the cover removed and the thrust pad installed.



Cheers Dan
ShaylocoDan

Online Dan Rowe

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Re: Shay Locomotive
« Reply #103 on: December 30, 2017, 06:23:47 PM »
The tires were bored to the finished diameter on the Levin lathe then the new mandrel was turned to that diameter on the South Bend.

Now to have fun with the profile tool....  I rough cut the tread half the width first to reduce the load on the tool. I set the carriage depth stop to use for the second half of the wheel tread.



Then finished cut for the tread.




The final operation was to cut the back flange radius.



There was a small amount of chatter with a South Bend Heavy 10 lathe. It only took a bit of polishing to remove it. I do not think I could have used the profile tool with a light hobby lathe.

Cheers Dan
ShaylocoDan

Offline crueby

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Re: Shay Locomotive
« Reply #104 on: December 30, 2017, 06:31:29 PM »
Tires are looking good!

 :popcorn: