October 27, 2004 After checking the blueprint specifications, Bill and I discovered the frames had been machined too thick. They were supposed to be .812, but…
27-Oct-04 Here we see Bill at the controls bringing the frame thicknesses a lot closer the blueprint specifications. This was the first serious amount of work…
17-Nov-04 Now that the frames are at the proper thickness, we check out the rest of the dimensions. Here Bill is indicating the top of the frame to make it…
17-Nov-04 A close-up of how the frame was 'indicated', which is to say we used a Dial Test Indicator which shows how far + or - 0.0005 (one-half of…
24-Nov-04 The sacrificial tool plate table has been bolted to the top of the table. Both frames are stacked on each other and have been pinned together to…
Dec-1 Machining the Axle box openings on the frames. You're looking at both frames, dowel pinned together and bolted to the table from the back of the…
Dec-1-04 Action shot of milling the axle box openings. This 2" long 1/2" milling cutter is just barely cutting into the sacrificial table below while we use…
8-Dec-04 Machining the pedestal binder ears to a uniform size. They all will end up small than what is shown on the print, and will different end for end, but…
8-Dec-04 Hanging the frames off the vice to complete the pedestal machining. Once I finish this opening, and drill the tail frame holes, the frames will be…
12-Jan-05 A small milestone: All the machining on the frames is complete! The pedestal binders have been made and bolted across the jaw openings, the frames…
3-Feb-05 More work on the frame group. The aluminum rear frame spreader was finished and match drilled in place. Also the brass frame extensions have been…
24-Feb-05 Drilling a hole in the brass front frame spreader. The stringy brass produces long chips.
24-Feb-05 Boring the pilot truck pivot hole in the front frame spreader. The hole needed to be 1.000 and I didn't have a boring bar big enough. Bill tried…
3-Mar-05 Putting a flat spot on the large brass tail cradle casting. The blueprint does not call for many machined surfaces, and we didn't have a way to hold…
3-Mar-05 Cleaning up the cab mounting bracket. With the machined surface bolted down to the table, we were able to come up a square surface.
3-Mar-05 Machining the tail cradle frame mounting points. Once again, the mighty 'T-Ram' Bridgeport proves its worth. After we machined the back of the tail…
10-Mar-05 Squaring the frame extensions in preparation for machining a radiused edge to match the tail frame cradle.
10-Mar-05 Putting a radiused edge on the end.
10-Mar-05 Bill puts a radiused edge on the other frame extension. Due to the way the casting was warped, we couldn't lay it on the table and securely clamp it…
Using a radius bit to round over the cradle side rail.
A challenging setup, machining the tailpiece cradle. We are trying to make the 'ears' on this piece parallel and the correct width for the side rails to bolt…
17-Mar-05 Using a homemade drill extension soldered to a twist drill, we make our own aircraft drill since the spindle cannot get close to the casting where the…
7-Apr-05 These brake hanger castings were hard to hold onto, with little reference surface to measure from. One of the first things to do is skim cut a portion…
7-Apr-05 A step block, clamp, and shim setup to machine the backside of the brake hanger brackets.
7-Apr-05 Tapping the holes used to mount the brake hanger to the frame.
22-Aug-07 Two years after completing these brake hangers, we discover that the link support brackets, which bolt on above these middle bracket, won't fit…
The set up used to machine the brake hangers. They still are difficult parts to hang onto.
22-Aug-07 While looking at the frame, it appeared that the forward frame crosstie bracket is interfering with the spring hanger arms on the #2 wheels. So two…