2-1/2" NG class A shay.

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Brian Hilgert
Posts: 302
Joined: Mon Jan 21, 2013 8:35 am
Location: Pittsburgh, PA

Re: 2-1/2" NG class A shay.

Post by Brian Hilgert »

It's been a while since I have updated this build. I have spent more time traveling for work that I expected, but I was still able to get down in the shop every once in a while.
Cross Drilling the U joints.
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To machine a counter-bore within the hole for the bronze bushing to sit against, I purchased a back spotting cutter from ebay and made my own holder and guide.
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The last bit of work on the U-joints was the outside radius. Below is a picture of the radius cutter that I quickly machined up to complete the task.
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Finished radius. needs a little polishing to get the machining marks out.
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Brian Hilgert
Posts: 302
Joined: Mon Jan 21, 2013 8:35 am
Location: Pittsburgh, PA

Re: 2-1/2" NG class A shay.

Post by Brian Hilgert »

Working on the U-joint yokes, I got a little lazy with the picture taking.
The first picture below is after I turned the inside of the yoke body, broached a keyway, cross drilled and soldered the yoke pin in. I am just cutting off the excess material of the yoke down to the pin.
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Machining out the material between the pins. The square stock is just for holding the yoke during machining.
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Machining the angles on the sides.
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Finished yoke, after some filing and sanding.
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Brian Hilgert
Posts: 302
Joined: Mon Jan 21, 2013 8:35 am
Location: Pittsburgh, PA

Re: 2-1/2" NG class A shay.

Post by Brian Hilgert »

The yokes for the square shafts were machining in a similar fashion as the yokes for the round shafts.

I machined down the one end so that I can braze a round boss onto the square shaft.
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Boss brazed on
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Set up in the mill for cross drilling for the pin
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Machining the angles on the sides
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Back into the lathe to turn down the center section
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Once again, I got lazy with the picture taking. After the center was machined down, the end was machined back to the edge of the pin and then I used a belt sander, files, and dremel to smooth out the rest. I will try to remember and take a pic of the final part when I get in the shop tonight.
Brian Hilgert
Posts: 302
Joined: Mon Jan 21, 2013 8:35 am
Location: Pittsburgh, PA

Re: 2-1/2" NG class A shay.

Post by Brian Hilgert »

I am very close to having the steam engine turn the wheels on my shay. The only parts left to make are the female square shafts. I was going to use square tubing, but I did not like the slop between the male and female sliding shafts. The opportunity came up to have the square holes cut out by a wire EDM machine. So once again, I cheated and took advantage of the opportunity. The 6" long blanks were mounted up, a program was written, and I pressed the button.
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nice square hole.
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The sliding fit is so nice, it's almost X rated. :shock:
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I also completed the brake linkages for the trucks but, once again, forgot to take pictures. :roll:
Brian Hilgert
Posts: 302
Joined: Mon Jan 21, 2013 8:35 am
Location: Pittsburgh, PA

Re: 2-1/2" NG class A shay.

Post by Brian Hilgert »

Below is a picture of one of the finished male square shafts.
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I was able to make a little more progress on the female square shafts.
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I have been getting frustrated lately, I go down to the shop and seem to only get a couple simple operations done before 3 hours fly by. :shock:
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NP317
Posts: 4557
Joined: Tue Jun 24, 2014 2:57 pm
Location: Northern Oregon, USA

Re: 2-1/2" NG class A shay.

Post by NP317 »

Nice work, AND progress, despite how it feels to you!
You are working on tedious pieces, so time flies unexpectedly.
Keep enjoying the good work. And thanks for sharing.
~RN
Brian Hilgert
Posts: 302
Joined: Mon Jan 21, 2013 8:35 am
Location: Pittsburgh, PA

Re: 2-1/2" NG class A shay.

Post by Brian Hilgert »

Thanks RN,
I appreciate the words of encouragement!

B
Brian Hilgert
Posts: 302
Joined: Mon Jan 21, 2013 8:35 am
Location: Pittsburgh, PA

Re: 2-1/2" NG class A shay.

Post by Brian Hilgert »

Below are some much needed update pictures

Cross Drilling the Female square shafts
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Profiling the Ends After soldering the Pin in.
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Brian Hilgert
Posts: 302
Joined: Mon Jan 21, 2013 8:35 am
Location: Pittsburgh, PA

Re: 2-1/2" NG class A shay.

Post by Brian Hilgert »

Below are some pictures of the finished slip joints before I machined the recessed section.
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Recessed section complete, square shafts mounted on the Loco.
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Brian Hilgert
Posts: 302
Joined: Mon Jan 21, 2013 8:35 am
Location: Pittsburgh, PA

Re: 2-1/2" NG class A shay.

Post by Brian Hilgert »

Now that I have the shafts finished, I can mark another mile stone off of the list. The Shay ran on air, turning the shafts, gears, and wheels for about 2 days while on display at Cabin Fever. This pile of metal is starting to look like a steam loco. My next step is to finish all of the parts that are riveted onto the frame. After I have everything ready, I'll have a Rivet fest to finish the frame. Then on to the boiler. I just picked up all of the flat plate pieces for my boiler from the waterjet. What a time saver!

The Queen Posts are finished, The follow is a picture of the base during machining
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Finished bases
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Machining the other end, (not sure what it is called)
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Finished Queen posts.
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More to come, I just need to take pictures. I get busy machining and forget to snap a couple.
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shayloco
Posts: 264
Joined: Fri Mar 28, 2003 11:00 am
Location: Rhode Island

Re: 2-1/2" NG class A shay.

Post by shayloco »

Brian-
I saw your Shay at the 2015 Cabin Fever and admired the work you were doing. The square shafts and u-joints look great. Keep up the good work and keep posting photos.
-Larry
Marty_Knox
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Joined: Thu Jan 09, 2003 6:50 pm
Location: Michigan, USA

Re: 2-1/2" NG class A shay.

Post by Marty_Knox »

Brian, it was a pleasure to see you at NAMES. Yes. people DO read your posts - Keep up the good work!
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