Welcome to the July 2015 progress report for Engine 557. The June report concluded with our Professional Engineer, Robert Franzen of Steam Services of America and Gary Bensman working with our volunteers in preparation for riveting the new firebox sheets to the mud ring.  After a break for the July 4th holiday we all returned to the job of final fitting the five sheets that make up the inner firebox. No small task, as a years worth of preparation allowed for the fitting to proceed, with all five sheets being brought into position for final trimming to fit. All 1043 stay bolt holes on the new sheets also had to align with the 1043 holes in the outer wrapper of the boiler.

After final fitting all five sheets were laid out to receive a 6 mill layer of Apexior 1 paint on the water side. This followed removing and trial fitting the sheets a multitude of times under direction of Robert Franzen and our CMO Jeff Debroeck. Art Chase from Fairbanks came down to work for three days with the crew and here puts the final touch on the angled edge of the crown sheet to allow for full penetration welding.

With all the sheets fitted and bolted to the mud ring, Gary Bensman is tack welding the sheets together. Note the temporary bolts in the crown sheet supporting it in position. As work progressed, the volunteers were constantly in the process of relocating work platforms for the work as visitor, Spencer Arntz caught in these photos.

The big day came on July 11 when all was ready and the decision was made to install the mud ring rivets and secure the new sheets. Nine volunteers were on hand to support our contracted helpers. First step was determining the required length of the rivets and Ron Dudley cut them on the band saw and used the arbor mounted wire brush to remove surface rust. A firebrick oven fired by propane was set up to preheat the rivets. Stewart Sterling made sure there was a ready stock of rivets in preheat and passed them off to the next station. Heated rivets were moved to the forge oven for final heat, attended by Mike McKervey and Art Chase.

Soon a well choreographed process was in place. Jerry Cunnington would remove the next bolt to be replaced by a rivet. The hole was then flushed with a hot torch to burn and blow out any possible contaminants. Art used tongs to move the hot rivets from the forge and insert them into the cleanly prepared hole in the mud ring. Jeff Debroeck and Dean Sawyer managed the air operated bucking bar inside the firebox. Gary Bensman would then use the air hammer and set the rivet on the outside sheet forming the head. The right side of the mud ring showing the mud ring rivets and head detail.

The throat sheet rivets at the bottom of the rear flue sheet exemplify the quality of the job performed. The crew started at about two in the afternoon and finished about eight pm. The rivet crew at the end of a 12 hour day were still ready to go. Those pictured left to right are: Stewart Sterling, Gary Bensman, Ron Dudley, Mike McKervey, Art Chase, Robert Franzen, Ken Morton, Jeff Debroeck, Patrick Durand, Dean Sawyer and Jerry Cunnington. During the 23 days of June and July that we had professionals working the volunteers came in 7 days a week and 17 individuals worked 1,142 volunteer hours. In addition to those named above were, Ken Elmore, Jerry Christensen, Casey Durand, Lynn Willis, Jim Keene, Gary Eddings, and Rus Rudolph.

August 18th is the three year anniversary of Engine 557 Restoration Company beginning work on Alaska Railroads last operational steam engine. After a complete tear down to the bare frame and boiler, evident wear, damage and failures have been discovered and are being addressed. Many major components have been remanufactured, the 57” drivers, air compressor, power reverse, and many electrical components are ready for installation. New tubes and flues have been delivered.

In review, replacing the firebox interior was a $400.000 unexpected expense and set the project back by a year. Our professional engineer, Robert Franzen of Steam Services of America produced the new flue and door sheets and SteelFab provided the crown and side sheets. We have turned the corner to reassembly of 557 and I estimate the project is now 55 percent complete.

On July 2, 2015, world renowned train photographer, Philip Wormald, and two of his London based fellow train chasers, Ian Thurman and Kevin Coumbe, made their way to the 557 engine house. I have known Philip for over 10 years now and he makes regular visits with tour groups here in Alaska. He is trying to keep his que for the first passenger trip behind 557. They got the tour and left a nice donation behind as well. Philip could not resist shooting this train on the fly as it appeared going past the engine house.

On July 14, 2015 the engine house was invaded by a group of 14 veterans and family members from the Alaska Veterans and Pioneers Home over in Palmer. Celia Conrad organizes the trips and I do enjoy introducing them to another Alaskan G.I. veteran, 557. To quote Celia, “Our “fundraiser on wheels” Army veteran, Roy Hooper was so tickled with the monetary donations and took his mission very seriously. He continues to receive donations and looks forward to reaching the $557.00 goal.” Roy was diligent and presented 557 with the fruits of his fund raiser. In recognition I meet with Roy Hubbard and presented signed print #48 of Engine 557 Returning as a gift to the Veterans and Pioneer Home. Roy came by the engine house again with his daughter and grandson with a second installment on the fundraiser. We thank Roy and everyone who contributed to the 557 restoration effort.

Last month the Arntz family visited 557 and they sent us several photos for the archive, including this one of their grand daughter ringing our bells. We encourage family visits and appreciate the candid photos.

Additional guests during July included, Joe Prax and son, Ed & Joyce Bisson and Jen and TM Degan, John Tobin, Joe Polowy, Dan Gulickson and Martin Gutyoskie of Fairbanks, Anna & Lanny Nelson, Jason and Terry Quarrels, Ron Cresap, Harvey Warren of Winnipeg, Ole and Corinne Olson of Salem, Oregon, Carol Hill, Jim Jansen, Jim and Connie Gale.

The Alaska Community Foundation final report to the Rasmuson Foundation was prepared by Penny Gage shown here on a visit to 557 with intern, Lauren Heyano on July 16th. Engine 557 Restoration Company completed raising the matching funding for the very generous $350,000.00 Rasmuson Foundation grant last December. The restoration never would have gotten off the ground without their initial financial support.

Engine 557 Restoration Company and the Anchorage Municipality Parks and Recreation Department entered into a mutually beneficial agreement that allowed 557 to obtain the tender buffer components from sister locomotive 556 on the Anchorage Park Strip. 556 less the buffer showed a large gap which was soon filled with a fabricated buffer and chaffing plate, installed by Dick Morris. In addition 557 volunteers fabricated a whistle and two safety valves for 556 to replace those that had been missing for many years.

I am asked when will it be done and how much will it cost to finish? The adage “time is money” comes to mind. With the dedication shown by our volunteers I estimate that we can do steam tests in 2017 and be operational in 2018. We need to raise an additional $400,000.00 to make that happen. Could the job be done sooner with a full time experienced contracted crew of 6 to 8 as a proposed option? Yes. Now the adage is “Money can buy time”. That option in my estimation would cost another $800,000.00.

You are welcome to visit the restoration floor. Please schedule your visit with a call at 907 350 4340. Donations are accepted on line through Pay Pal by visiting the 557.alaskarails.org web site. A host of options for providing financial support are available there, including purchase of 557 fine art. You can also sponsor a memorial flue or tube in support. Those 1042 stay bolts will soon be looking for sponsors as well.

My personal thanks go to all the volunteers, in-kind donors and financial sponsors who have a vision for 557.

Patrick J. Durand, President
Engine 557 Restoration Company

Click here for some of the ways you can help out.

Make all donations to: Engine 557 Restoration Company at the above address.
An Alaskan 501(c)(3) Nonprofit Corporation, EIN 46-2663256

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