Building the 2.5" Scale Shay

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Soot n' Cinders
Posts: 664
Joined: Wed Jun 27, 2012 5:24 pm
Location: Marietta, Georgia

Building the 2.5" Scale Shay

Post by Soot n' Cinders » Thu Jan 03, 2013 6:39 pm

As some of you may know, me and my Dad have been building a 2.5" scale, 7.5" gauge Class A shay from John Buckwalter's (http://www.ngshay.com) plans and castings. I have decided that we have made enough progress to share it with everyone.
The frame was mostly finished during a summer camp with John, there's a thread about that somewhere on the board. A few brake hangers still have to be welded on, then the frame can be sandblasted and primed.
IMG_0008.JPG
The frame upside down with the truss rods installed
The next six months were spent getting our shop set up to continue building a shay.
The trucks' bar stock frames were finished Christmas Eve night,
IMG_0011.JPG
The bar stock truck frames
and the lower bolsters were finished four days later.
IMG_0014.JPG
The frame with a lower bolster
Two of the center columns and both spring bolsters were finished last night. Today, so far one center plate has been finished and the front truck was assembled with all the completed parts.
image.jpg
The assembled front truck
The other two center columns and the center plate are top of the list for tomorrow and the journals will hopefully be started too.
Last edited by Soot n' Cinders on Thu Jan 03, 2013 8:14 pm, edited 1 time in total.
-Tristan

Projects
-2.5" scale Class A 20 Ton Shay

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Harlock
Posts: 3621
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Re: Building the 2.5" Scale Shay

Post by Harlock » Thu Jan 03, 2013 7:12 pm

Thanks for posting this build series. The locomotive is simple in construction and the castings and plans are reasonably priced. Probably one of the most economical big heavy engines out there. I am looking forward to seeing more.

-Mike
San Lorezo Flume & Lumber Co. #2 - "Felton"
Live Steam Photography and more - www.mikemassee.com
Contributing Editor, Live Steam Magazine
Webmaster, Allen Models of Nevada

Soot n' Cinders
Posts: 664
Joined: Wed Jun 27, 2012 5:24 pm
Location: Marietta, Georgia

Re: Building the 2.5" Scale Shay

Post by Soot n' Cinders » Thu Jan 03, 2013 7:41 pm

John's plans are nice, the boiler plans even show what kind of weld to use where. I've only machined one of the castings so far, but the cast iron didn't have any unexpected hard spots. He also releases updates to any erroneous drawings. Having driven his shay, the thing runs like clockwork. It steams well on oil, but I'm planning on burning coal so I will have to get some help here on making a coal fired boiler. The thing has plenty of power, enough to pull 6 of Kevin Doe's 2.5" scale DRG&W cars with power to spare, and the 2:1 gear ratio makes it quick enough to keep up with all the other locomotives on the track.
-Tristan

Projects
-2.5" scale Class A 20 Ton Shay

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Lovesthedrive
Posts: 234
Joined: Sun Dec 18, 2011 10:52 pm
Location: Downeast Maine

Re: Building the 2.5" Scale Shay

Post by Lovesthedrive » Thu Jan 03, 2013 11:05 pm

There is no difference in boilers whether you burn coal or oil. The only change you will need to do is to beneath the firebox. A coal burner will need grates and a ash pan.
1952 John Deere model 60

Wanted: Half size steam tractor. Will trade land in Maine

Soot n' Cinders
Posts: 664
Joined: Wed Jun 27, 2012 5:24 pm
Location: Marietta, Georgia

Re: Building the 2.5" Scale Shay

Post by Soot n' Cinders » Thu Jan 03, 2013 11:21 pm

Lovesthedrive wrote:There is no difference in boilers whether you burn coal or oil. The only change you will need to do is to beneath the firebox. A coal burner will need grates and a ash pan.
That's what I meant, I'll need advice on ash pan construction and optimal grate height. But that's a thread for another day.

No major updates tonight, I quit after my 60 year old southbend 13 through the part I was turning into the chip tray from the chuck. Apparently old machines don't like working late hours at their job anymore than anyone else.
-Tristan

Projects
-2.5" scale Class A 20 Ton Shay

Soot n' Cinders
Posts: 664
Joined: Wed Jun 27, 2012 5:24 pm
Location: Marietta, Georgia

Re: Building the 2.5" Scale Shay

Post by Soot n' Cinders » Sun Jan 06, 2013 9:26 pm

Made two of the side bearings for the trucks today and almost finished the last center column. Went to start assembly on the rear truck to find out that the upper frame bars had two holes where the bit had walked, so I'll have to weld those in and redrill the holes. I'll get some pictures up tomorrow evening sometime.
-Tristan

Projects
-2.5" scale Class A 20 Ton Shay

Soot n' Cinders
Posts: 664
Joined: Wed Jun 27, 2012 5:24 pm
Location: Marietta, Georgia

Re: Building the 2.5" Scale Shay

Post by Soot n' Cinders » Mon Jan 07, 2013 10:51 pm

More progress done today, despite it being the first day back from Christmas Break.
I finished the other center column today and assembled the bolster.
image.jpg
Both trucks, sprung and awaiting more part for further assembly
The front truck showing off its springs, center plate, and one of two side bearings.
image.jpg
Once the other three side bearings are done and the erroneous upper frames corrected, I'll be onto the journals.
image.jpg
All eight journals awaiting machining
Also thought I'd show off my little machine shop.
image.jpg
1950's vintage Bridgeport 9x42 J head and Southbend 13
1940's vintage Logan 11
And a new Jet 4x6 bandsaw
-Tristan

Projects
-2.5" scale Class A 20 Ton Shay

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Harlock
Posts: 3621
Joined: Tue Jan 23, 2007 1:19 am
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Re: Building the 2.5" Scale Shay

Post by Harlock » Tue Jan 08, 2013 1:44 am

Nice job on the truck assemblage. Do you plan on welding the pieces together in addition to the bolts, or just lots of loc-tite? :D
San Lorezo Flume & Lumber Co. #2 - "Felton"
Live Steam Photography and more - www.mikemassee.com
Contributing Editor, Live Steam Magazine
Webmaster, Allen Models of Nevada

Soot n' Cinders
Posts: 664
Joined: Wed Jun 27, 2012 5:24 pm
Location: Marietta, Georgia

Re: Building the 2.5" Scale Shay

Post by Soot n' Cinders » Tue Jan 08, 2013 10:07 am

Harlock wrote:Nice job on the truck assemblage. Do you plan on welding the pieces together in addition to the bolts, or just lots of loc-tite? :D
Thank you! I was planning on using loc-tite so it can be taken apart easily when I need to. I may have to weld it if the 10-24 machine screws can't hold the trucks together, but I doubt that will be a problem.
Last edited by Soot n' Cinders on Sat Jan 19, 2013 2:28 pm, edited 1 time in total.
-Tristan

Projects
-2.5" scale Class A 20 Ton Shay

Soot n' Cinders
Posts: 664
Joined: Wed Jun 27, 2012 5:24 pm
Location: Marietta, Georgia

Re: Building the 2.5" Scale Shay

Post by Soot n' Cinders » Sat Jan 12, 2013 10:23 pm

Finished the side bearings and assembled both trucks today. The side bearings all had to be done without a power feed. Our bridgeport has the old mechanical power feed and the idler gear inside is beyond worn out, so no power feed until we can replace the gear.
I cleared off the work bench and set the frame on the trucks. For reference, the bench is 8ft long
image.jpg
The frame and trucks

For those of you who have never seen John's shay, here it is.
image.jpg
Buckwalter Shay
-Tristan

Projects
-2.5" scale Class A 20 Ton Shay

Soot n' Cinders
Posts: 664
Joined: Wed Jun 27, 2012 5:24 pm
Location: Marietta, Georgia

Re: Building the 2.5" Scale Shay

Post by Soot n' Cinders » Mon Jan 21, 2013 12:19 pm

Well, mostly finished one of the fireman's side journals. Waiting on a boring head to arrive to finish the radius on the inside. Also finished turning one axle so its now ready to have to woodruff key seats cut. I'll post some pictures later
-Tristan

Projects
-2.5" scale Class A 20 Ton Shay

Soot n' Cinders
Posts: 664
Joined: Wed Jun 27, 2012 5:24 pm
Location: Marietta, Georgia

Re: Building the 2.5" Scale Shay

Post by Soot n' Cinders » Mon Jan 21, 2013 11:17 pm

As promised

The journal mounted in the truck frame.
image.jpg
The one axle that I have finished.
image.jpg
Not sure when I will be able to finished the rest, I need to find replacement wipers for my south bend 13's bearings. The ones that are in there are probably the original one and are beyond shot.
-Tristan

Projects
-2.5" scale Class A 20 Ton Shay

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