Sunday, June 28, 2009

A-FURNACE PART 18



Busy weekend with family gatherings and finally not much rain, so painting my house.  I did get a few hours in modeling tonight.  It was one of those nights that I spent about ten or fifteen minutes staring at things trying to pick a place to start, with so much to finish.  As I was looking over my plans I saw the drawings for the clay gun for A-Furnace.  About an hour and a half later I had a pretty decent representation of the gun shown in the plans.  I have no pictures to go on so I might be a little off with some of the details but again, I'm trying not to get bogged down counting rivets.

I also spent a few minutes correcting the h-column supports for the blast furnace stack - I used some styrene strips to space the bottoms of the columns away from the stack so instead of the vertical look there is a slight outward angle to them like the prototype.  

Thursday, June 25, 2009

A-FURNACE PART 17


I added the mixer line between the cold blast main and the hot blast main.  In the prototype this pipe, in conjunction with a valve yet to be built, was used to regulate the temperature of the hot blast.  The pipe is 3/8" styrene tubing and the supports are Tichy platform supports.  Most of the cuts are 11 degree angles.  

Monday, June 22, 2009

A-FURNACE PART 16




Platforms and Stairs - I started adding the stairs and platforms to the stoves.  There are many more to come.   The stairs around the end stove look a little mashed up, but they follow the prototype to the exact stair count.    For the access hatches I am using castings I made of a modified commercially available hatch.  Normally I would just purchase and use these parts, but they appear to have been discontinued

Sunday, June 21, 2009

A-FURNACE PART 15




All I hear lately is "when is it going to stop raining?" - as far as I'm concerned keep on pouring, especially on the weekends.  It gives me the needed  excuse to duck out of painting the exterior of my house and spending my days model railroading.  At this point 95% of the honey do list is exterior related.   The down side to this was that I spent Saturday morning in a downpour building a wheelchair ramp.  My company does occasional pro-bono work on weekends and this was one of those occasions - only a few of us showed and once we started we were committed, especially as we demolished the only existing staircase out of the trailer we were working on before the rain started.  Other than being completely soaking wet and cold and having to reset the GFIs every two minutes, the five of us had the ramp, the landing, the stairs, and all the railings built in three hours - so fast that a photographer from the local newspaper showed up after we were finished and gone.     
I continued to work on the 3 pass stoves for A-Furnace.  I secured the resin tops that I cast on saturday.  The upper platform was cut out as one piece from .030 styrene and I used .060 square strips to frame the bottom.  After securing this to the tops with ACC I used a pipe cutter to score seam lines in the stacks for each stove.  According to the plans, these were about 3/4" apart.  This type of cutter is the easiest method for making these lines - a serious improvement over hose clamps and whatever other methods are used.  They do make these cutters large enough to do up to 3 or 4" tubing, such as the Walther's stoves,..etc.    Before securing these stacks into their holes on the stove tops I glued ladders to the sides - pre-OSHA ladders, but correct for the era.  You certainly couldn't have gotten me up there to climb that ladder.  With the stacks secured I moved onto the cold blast valves that I had fabricated in an earlier post.  I had to saw off about a 1/4" of these to get them to fit tight to the stove top and match the prototype - the key is the cold blast piping needs to be pretty much centered over the walkways.  
With the valves secured I used 1/2" Evergreen tubing for the cold blast line - sorry Plastruct but I like that Evergreen is styrene.  I built a jig to enable me to cut the 11 degree angles in the tubing - shown in photo.  The model miter box that I use doesn't have the 11 degree cut needed and it it did it isn't deep enough to accurately cut the 1/2" tubing.  Just remember that you need to mark the opposing sides dead center for alignment of the cuts and when glueing up the pieces.   Everything fit together nicely, with a little filling needed at the three way connection in the corner.  I still need to extend the cold blast line from the bottom corner along the front of the blast furnace and eventually making its way to the blowing engine house.

Saturday, June 20, 2009

FATHERS DAY - My Dad



Some years back I read a book by Chuck Palahniuk and a sentence from a diatribe on religion struck me -  he wrote:  " If you're male and you're Christian and living in America, your father is your model for God."    I realized that, for me anyway, this was pretty accurate.  
On a cold, rainy March day in 1978, my father dropped me off at school.  We sat there for a second or two in his green Volkswagen Bug  as we always did and he said I love you and kissed me goodbye.  At eleven I remember I was beginning to feel uncomfortable with these public displays of affection, especially within clear site of my middle school classmates.  I'm glad now that we still had those moments, as two hours later my father, the center of my world, collapsed and died of a cerebral aneurysm.   He was 41 years old.  
From my perspective, my father seamed infallible.  He was kind and gentle and loved us unconditionally.  He was smart and alway knew the right answer, and more importantly, the right thing to do.   He was a graduate of the University of Pennsylvania, Wharton School.  After a stint in the US Army as a Lieutenant he worked in the finance departments of the Budd Company, Mannington, and a few others.  When he died, he was the Vice-President of the fifth largest insurance brokerage in the country, Frank B. Hall.    Outside work, he was a Deacon at the Pleasantville Presbyterian Church, the Cubmaster of Hawthorne Pack One,  and a leader in the Indian Guides.   His hobbies included woodworking, electronics, model building,  boating, and model railroading.  
These hobbies are what I remember and are how we spent most of our time together.    In one corner of my bedroom stood a 4' tall model Saturn V rocket that he built for me.  On my shelves were pirate ships, Columbus' three vessels, the Mayflower, and numerous battleships and aircraft.  My favorite was probably the Visible V-8 - a clear model of a working V-8 engine - all the cams, cranks, and valves operated, with flashing lights for the spark plugs.   In our guest room he built a large two level diorama that had all the Aurora Dinosaur Kits from the 70's built and painted, their bases designed to interlock with each other to form this prehistoric world.  Everything was built with a precision and attention to detail that I aspired to growing up.   
The warmer weather we spent a lot of time outside, whether it was traveling in the station wagon, spending time down at the Jersey shore, or working in the garage.  I remember handing tools to my Dad while he worked on the engine of his old Bug.  Thinking back, I'm sure he must have taken some flak at work over that - certainly not a vehicle befitting an executive at a major corporation.  My Dad loved backyard railroads, and I suspect at some point he might have built one, but to sate that desire he built a boxcar, gondola, and caboose that he would tow in a train behind his tractor and we, along with kids from the neighborhood, would ride in.  
But the basement was the hobby command center.  About 75% of it was taken up by a large HO scale layout.  My dad had been working on it since before I was born.  I loved sitting at the control panel running trains through all the tunnels and over the bridges.     I would help him with the structure kits.  Shortly before my Dad died I had been helping him wire lighting for the layout and he had explained the differences between running the lights in parallel or series. My Dad was also a big fan of Heathkit electronic kits - we had Heathkit televisions, stereos, organs, weather stations, garage door openers,...etc.    A television kit would come with 10 manuals and thousands of components.  Every circuit board had to be built one resistor at a time.  One of my tasks was to organize resistors, capacitors, diodes,...etc  by their colors or markings into trays.  Every time I solder something the small reminds me of those times we spent together in the basement.  
My Dad liked real trains too.  In fact, a portion of his childhood was spent living on the second floor of the Swathmore, PA train station, where his father was stationmaster.   On trips we would stop at every tourist railroad we could find.  One year taking the Autotrain to Florida, another riding the Cog Railway up Mt Washington.  
In someways I am fortunate in that I have this positive image of my Dad.  It was untarnished by what I'm sure would have been teenage rebellion and disagreements.   I had yet to let him down with bad grades, trouble at school, ...etc.    On the other hand the bar was set high for me.  As my children grew up into teenagers I find myself more and more asking what would my Dad have said or done, and constantly feeling I could do better.   I also am saddened at times that he isn't around to be my children's grandfather.  My daughter Emily no doubt would have been the apple of his eye, and my son, Jimmy would have taken over for me as his model railroad assistant.    I do miss him so,  and not a day goes by since that rainy march day that I haven't thought of him.   
 

A-FURNACE PART 14






Worked on the stove complex today.  I allowed the silicone mold of the top section to dry overnight.  It is a one part mold and in hindsight I used way too much expensive RTV in making it.  I could probably knock someone out with the finished chunk of rubber.  The only problem was in removing the master from the mold the section that extended into the top making a recess for the stack broke off.  At first I was a bit upset but after casting I realized that this might have been a weak spot prone to deform and possibly make it difficult to insert the stacks.   I still used a recess but I just marked the center of the casting and drilled the hole on the drill press.   The stacks are 5/8" Plastruct tubing.   I also cut out the platform that runs between the tops out of .030.  I will need to frame this with .060 square stock but for now I just placed it on top to check the alignment.   This platform was cut from a single sheet of .030 styrene - its not hard if you just take your time to mark everything out and then score the lines using an Xacto and circle cutter.

Friday, June 19, 2009

A-FURNACE PART 13




I revisited the stove tops last night and tonight.  Originally I had started inserting .050 rivets individually into the wood master but they looked way too big, especially for HO scale, so I scraped them off and filled the holes.  It seamed to plain without any detailing so I opted for my method used on b furnace the application of styrene rivet strips that I made using .010 styrene and a pounce wheel.  I'm only moderately happy with the results and will have to see how the individual pieces come out before passing absolute judgement.    I built a mold box and glued in the master, coated it with release, and poured in a RTV silicone material from a two-part mix.  In hindsight I should have made a round form for the mold or clipped the corners as it ended up using a lot of material - almost 32 ounces.    Tomorrow I'll strip the master from the mold and try a resin casting to see how I like it.