Constructing "Old 99"

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Blog series by MrWoody updated 09-10-2008 12:29 PM 18 parts 24418 reads 40 comments total

Part 1: Starting the journey.

08-25-2008 02:49 PM by MrWoody | 6 comments »

A while ago someone requested a blog on the construction of my toys. I’ll start by warning you that writing composition is not one of my strong suits. Also I build everything from plans even if I have to draw my own. This project was actually started 6 months ago, then other higher priority projects or life got in the way. It is now complete and will be posted once all the blog parts are posted.I’ll try for one a day.TIME: I often get asked “How many hours did it take?”I believe a hobby is so...

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Part 2: Continuing the journey

08-26-2008 02:41 PM by MrWoody | 3 comments »

I’ve jumped to page 5 of the plans for 2 reasons. First reason and most important, I felt like doing some lathe work. Secondly some of the next parts have to be fitted between the base and the boiler.Now I should point out that I’m not an expert on the lathe. I’ve never had any instruction, just read a couple of books, watched Norm Abram and Tim Yoder on TV.I managed to turn 3 of the 4 glue-ups without incidence. On the 4th I was tired or over confident I’m not sure, but I got a catch and de...

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Part 3: A bumpy ride.

08-27-2008 01:59 PM by MrWoody | 4 comments »

Unfortunately I got involved in the next part and forgot to take pictures. The camera is now in the shop. I’ll do my best to explain what I did.After re-reading this, I decided that even I couldn’t understand what I did, so I used a piece of scrap poplar and made the cuts so I could take pictures. Back to page 2 of the plans. I mentioned earlier that a piece needed to be fit between the turned boiler and the base. On page 3 there is another piece that needs to fit on top of the boiler. To s...

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Part 4: Sitting on the by-pass.

08-28-2008 01:05 PM by MrWoody | 1 comment »

Today is Biker Betty’s birthday. She and her SO are coming to dinner so I only have the morning to work in the shop.I have a box with pieces of left over stock that I used for my other train projects.Looking through it I realized that I didn’t have any 3/8” material that I was going to need soon. I decided that I had better go over the plans again and check that I had enough of the other thicknesses that I’m going to need; I didn’t. I picked a few of the longer pieces of stock that were close...

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Part 5: Rolling along

08-29-2008 01:45 PM by MrWoody | 4 comments »

I sanded the cove on the front wheel assembly first thing this morning. Front and rear wheel blocks. The wheels for the engine drive need holes drilled 9/16” from the center of the axle hole. From past experience I know it’s important that these holes are as accurate as possible. So I took a small piece of axle dowel and found center and put a wheel on it. From center I marked 9/16”. A tip: when you want to remove the dowel from the wheel, wrap the dowel with sand paper a...

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Part 6: An easy push.

08-30-2008 01:08 PM by MrWoody | 5 comments »

Last night I photocopied a few parts from the plan and glued them to some 1/8” and 3/16” stock using Elmer’s rubber cement. If you put this stuff on just one part to glue it just rolls off when you need. I tried spray adhesive but found it too messy.I’m making the counter weights for the wheels and the parts for the cow catcher. The picture shows the triangles glued to 1/8” stock. I had to peel them off and glue them to 3/16”. At the band saw I cut the pieces close to the line. Then us...

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Part 7: The bell tolls

08-31-2008 01:21 PM by MrWoody | 0 comments »

The counterweights mentioned in the last installment were done the same way as the cowcatcher parts. Substituting a spindle sander for the belt sander to sand the inside arc. They were centered on the wheel across from the small hole and glued. I also glued one wheel on each axle. I photocopied the bell bracket and glued it to a piece of 1/4” walnut. I cut and sanded part way down the piece on the outside line each side. Then using my jewelers drill I eyeballed the spot for the ...

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Part 8: The cabin

09-01-2008 01:10 PM by MrWoody | 0 comments »

On page 4 of the plan we have 2 assemblies, tracks and the cabin for the locomotive.I already made enough track when I built my other locomotive. If you want to see how it’s made you can go here.For the cabin we have a front wall, 2 side walls, a roof, a boiler door and some trim.I started with the boiler door. It’s a block 2 7/8”x2 7/8”x 1 1/2” with a rounded top.Then I cut the sides and front to size from1/4” stock. I marked and drilled the sides for the windows. I then cut the windo...

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Part 9: The cabin part 2

09-01-2008 01:36 PM by MrWoody | 0 comments »

I had a late start this morning. The power was off and I didn’t have any light in the shop.I cut a piece of 1/2” stock to the required dimensions. While I was using the table saw I cut a foot long piece 1 1/2” x 2” scrap 45° along the length for use later. I then drew a lot of layout lines to mark where the curve should start and end. I stuck the roof to the scrap piece that was prepared earlier using double sided tape. I want the end of the piece to sit on the top of my spindle sander...

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Part 10: Up hill and a strong head wind

09-02-2008 12:36 PM by MrWoody | 0 comments »

Today I’m finishing the cabin. A piece of 1/8” x 1” square and a piece of 1/8” x 1 1/4” square sandwiched together form the roof vent. The plaques for the sides were done the same way as the triangles for the cowcatcher. Then I took a piece of 1/8” maple and ripped a 1/16” piece using my thin strip jig. I then glued it all on the cabin. I now need two 1 1/4” long pieces of 1” dowel. I cut the dowel and wasn’t happy with the colour. It was cheap dowel from the lumber yard. I checked aga...

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Part 11: Building steam

09-03-2008 12:38 PM by MrWoody | 0 comments »

After dry fitting all the previously made pieces I decided that I didn’t like the look of the 1/8” thick plaques on the sides of the cabin so I pried them off and made new ones. I also decided that the walnut cylinders weren’t right either.I photocopied the side trim pieces again and glued them to maple and walnut 1/16” stock. I then used a Sharpie and made the lines on the walnut thicker inside. These were then cut out the same way as the originals and glued to the cab. Nex...

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Part 12: Spacing the wheels

09-04-2008 12:40 PM by MrWoody | 2 comments »

It’s time we start gluing up some of the parts we have made. I drilled the 1/8” hole in the ends of the cylinders and glued a 3 1/2” piece of dowel in. I glued the rest of the wheels on to the base using a spacer to allow them to ride on the rails. NOTE: The larger drive wheels are not glued at this time. I glued the front and rear assemblies to the base. I used a piece of packaging plastic with a slot cut in it between the assembly and base. This allowed me to pound the axle pi...

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Part 13: Coasting downhill

09-05-2008 12:31 PM by MrWoody | 3 comments »

I started this morning by cutting some 5/16” and 3/8” black walnut big enough to get 2 pieces for each plus a finger saver added to the length.These have dados cut so that there is 1/8” material left.The picture shows one of them cut to length. The other has the finger save left on. They were then ripped to 5/16” wide to create the connecting rod and wheel linkage. I created a piece of stock 7/8” X 3/8”much longer than I actually needed to make 2 piston connectors. I cut ...

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Part 14: Full steam ahead

09-06-2008 01:54 PM by MrWoody | 1 comment »

I made a tool box that will go on the base between the boiler and the cowcatcher.The plan calls for 7/8” X 5/8” X 1 5/8” with a peaked top and a 1/16” saw kerf to simulate the dividing line. I have never had much luck using a saw kerf as a dividing line, so I made 2 pieces 7/16” X 5/8” X 1 5/8”. I sanded the peak on the belt sander. Then sanded a small round over where the 2 pieces would meet then glued them together. We now move on to page 7 of the plan. We’re building the tender. I c...

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Part 15: The couplers

09-07-2008 02:06 PM by MrWoody | 3 comments »

Before I left the shop last night, I drilled a 5/16” hole at the inside of the car coupler. This morning I cut, sanded, sanded, and sanded some more to shape both couplers. I cut 4 axles to length and glued one wheel on each axle. Now I need 4 trim spacers. They are 1 3/8” X 5/8” X 3/8” with a 7/32” hole and a 45° cut on one end. Now I need to make four wheel trims. On the plan there are 9 dimensions and 2 diameters and I could do the layout. But these are full size plans...

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Part 16: Trimmin' the wheels

09-08-2008 12:37 PM by MrWoody | 4 comments »

This morning I cut and drilled the wheel trim pieces. Looking at the 3/8” square cuts I thought that I would try not using the scroll saw. So I dug out my 3/8” hollow mortising chisel and took the auger out. Using a soft blow mallet I tried chopping out the squares. It didn’t work. There was a lot of tear out on the back side. Four more photocopies, more drilling and on to the scroll saw. I used diagonal cutters to shorten the 5/32” axle pins to a little over 1/8”. ...

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Part 17: Into the home stretch.

09-09-2008 12:22 PM by MrWoody | 1 comment »

Last night I photocopied the side trim pieces for the tender and glued them to 1/16” maple and black walnut stock. Then I cut the pieces for the side panels, back, side rack, back rack and the water tank. The side panels and back from 3/8” stock and the side and back rack from 1/4” stock. The water tank is a block 3 3/8” long X 2” wide and 2 1/4” high. After laying out several lines I drilled two 7/8” by 1 1/4” deep. I then cut and sanded the angles for the water tank. ...

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Part 18: End of the line

09-10-2008 12:29 PM by MrWoody | 3 comments »

The first thing I did this morning is glue the side and water tank assembly to the base and set it aside to dry. Next I cut out and sanded the side trim pieces the way I did them for the cab.On pages 5 and 6 of the plan we skipped the dowels. I set up a board with a V groove and guide marks on the drill press. With a centering bit I found the center and clamped it firmly. I need eight boiler rail posts 3/16” dowel 3/4” long with a 3/32” hole drilled 1/8” from one end. Fro...

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