2-1/2" NG class A shay.

Brian Hilgert · Post by **Brian Hilgert** » Wed Jun 25, 2014 11:57 am

I had to slow down working on the shay to do some other spring/summer activities... but I am still chugging away.

First test fit of the truck assembly

I had to purchase a different size broach sleeve and just received it today. Hopefully, I can broach the drivers and get them mounted on the axles tonight.. And if time allows.... clean up the shop!

Brian Hilgert · Post by **Brian Hilgert** » Mon Jun 30, 2014 8:32 am

I pressed the wheels onto the axles and started on the fireman side bearing blocks yesterday. The one axle on the far left has two eccentrics 180 degrees apart for the water pumps.

Brian Hilgert · Post by **Brian Hilgert** » Tue Jul 08, 2014 2:38 pm

Machined the bearing blocks this past weekend. My design is a little different than what John's shows on his plans, I decided to make bearing blocks that completely encloses the bearings. The bearing blocks also allowed me to incorporated roller thrust bearings to take the axial load created by the bevel gears.

In the Mill, blocks where trued up and the bearing centers located using a center drill. Next I moved to the Lathe and centered the blocks to bore out for the bearings.

Boring for the bearings (both radial and axial bearings)

Machining for the seat for the spring.

Machining the corner radius to match the radius in the journal casting.

Finished bearing blocks.

Brian Hilgert · Post by **Brian Hilgert** » Tue Jul 08, 2014 2:43 pm

Assembly of the trucks

I still have to makes the lower cross bars and the top diagonal bars.

Brian Hilgert · Post by **Brian Hilgert** » Wed Jul 16, 2014 8:36 am

Finished the top cross bars. Lima bent the ends of the bars over the side arch bars. I tried to duplicate that detail in my model.

It is a little tough to see in the photo.

FLSTEAM · Post by **FLSTEAM** » Wed Jul 16, 2014 11:38 am

Looking great...not long now before you will have it running.

John B

Bill Hanks · Post by **Bill Hanks** » Fri Sep 26, 2014 4:05 am

G'day Everyone,
I've just signed up to this forum having viewed it a number of times.
I recently purchased all of the castings and drawings for the 20 Ton Shay from John Buckwalter, I find that your various comments and methods most informative and will be of great benefit avoiding potential pitfalls. I'm underway with the engine unit and making good use of my vertical mill; the DRO is fantastic for its accuracy and makes drilling circles of holes a breeze. As I progress I'll make contributions to forum about things that you may not have yet covered. I look forward to the journey.
Regards,
Bill.

Brian Hilgert · Post by **Brian Hilgert** » Thu Dec 11, 2014 12:20 pm

Well, it's been a while since I have posted any progress, and there is good reason for that. It seems that my wife and I came to the conclusion that we will need an Engineer to run the shay. So.... my wife gave birth to our first child on October 16th.

Connor Louis Hilgert

He was a little early but is growing like a weed and is doing well now.

Between taking care of Junior and getting sleep when we can... I still managed to get down to the shop every once in a while.

I managed to finish the bearings for the side shafts.

The following is a photo of the test fit, I still had to machine the flats the on one side for the bearing cover.

I also managed to finish the brake hangers. I modeled this off of a Lima drawing that I had.

Brian Hilgert · Post by **Brian Hilgert** » Thu Dec 11, 2014 12:21 pm

Bill Hanks wrote:G'day Everyone,
I've just signed up to this forum having viewed it a number of times.
I recently purchased all of the castings and drawings for the 20 Ton Shay from John Buckwalter, I find that your various comments and methods most informative and will be of great benefit avoiding potential pitfalls. I'm underway with the engine unit and making good use of my vertical mill; the DRO is fantastic for its accuracy and makes drilling circles of holes a breeze. As I progress I'll make contributions to forum about things that you may not have yet covered. I look forward to the journey.
Regards,
Bill.

Welcome Aboard Bill, If you have any questions, Feel free to ask.

SilverSanJuan · Post by **SilverSanJuan** » Thu Dec 11, 2014 2:09 pm

Congrats, Brian! Glad to hear that all is going well with the new "Project".

And, good to see you continue to make progress on the Shay.

Todd

Brian Hilgert · Post by **Brian Hilgert** » Tue Dec 16, 2014 9:22 am

Thanks Todd, He is a real joy!

I spent some time this last weekend boring out the spur gears.

The next step is machining the boss that will be pressed and tig welded into the gear.

Brian Hilgert · Post by **Brian Hilgert** » Wed Dec 17, 2014 8:41 am

I finished the bosses last night. I made them with a .001" interference fit. I'm debating if I should Tig weld around the one end or drill and use a Dutch key.

The Home Machinist!

2-1/2" NG class A shay.

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