Engine 557 Restoration Company
Progress Report January 2019

 

January 3, 2019 broke clear and cold as the “Hurricane Turn” flag stop train came by the engine house in dawns early light about 9:20 a.m. Two MAC70s, baggage and five coaches may seem like over kill. It makes sense that they utilize the regular passenger consist for the Anchorage to Fairbanks train that operates on a reduced winter schedule. The cars are kept warm to meet the needs for this flag stop adventure into the back country on a Thursday. Thanks largely to the hospitality of Conductor Warren Redfearn, the “Hurricane Turn”, which is literally a trip to no where for most passengers, is very popular with visitors. It operates as a flag stop train from Anchorage to Wasilla, Talkeetna and reverses direction in the middle of the Hurricane Bridge for the return to Anchorage. It serves all the folks who live “off the grid” and provides tourist a unique visit in the back woods.

As we recondition parts for 557 we come across transplant donor components from earlier overhauls. Recently while re-bushing an S-2 spring rigging component we found one stamped 550. As the last of the 550 class S-160 locomotives on the Alaska Railroad, 557 sports a number of donor parts, from the cab to side rods, drivers and now spring rigging.

Paul Dalleska is directing manufacture of new washout plugs from 922 Boiler Bronze as replacements for several of the old plugs that had iron cores. The iron cores no longer meet code but they are nice paper weights. We have a collection for sale as 557 memorabilia. The smaller 2” are $50.00 and the larger 3” clean outs with iron cores for the arch tubes are $75.00. All proceeds go to making the new ones.

When 557 was converted to burn oil in 1954, the three old arch tubes were left in place. While replacing the firebox sheets we deleted the arch tubes to complete the conversion. That left us with three perfect 3” wash out plugs in boiler bronze that are still serviceable. They are available to a new home for $125.00 each.

Beginning with 922 boiler bronze there is a 7 step process to arrive at the new plug, compared with one of the old ones.  The stamped D indicates the hole to which it is fitted.   922 is the spec for the bronze and X7152 is the heat number on that batch of material. Originally during WWII, 557 was specified with iron core bronze plugs which are not allowed in service today.  Seven of the 10 plugs we are making, replace those old iron cores that were still in service, the other three are spares. We have ordered 1 inch drive 1-5/16” 4 point sockets as dedicated tools for installing and removing the plugs for regular service washouts.

There is a 7 stage process in development of the new wash out plugs. Terry Douglas cut new blanks from 922 boiler bronze round stock, faced the ends and center drilled both ends on the lathe. Next off to the Bridgeport mill to cut the four faces on the square drive end. Doug VanWingerden, Ken Elmore and Ron Dudley then machined the flats for the drive on the mill. The fillet is left behind after a final pass with a ball end mill.

Then the 1 in 12 taper was machined by Paul Dalleska, using our old Atlas lathe, set up with a simple tapper attachment on the cross feed to do the final 12 TPI.

With over 420 flexible stay bolts to install It seams like a never ending journey. Terry Douglas, Tom Walker, Dean Sawyer, Ron Dudley and Jeff DeBroeck all take turns in the firebox doing this heavy work. They take breaks by hammering rigid stays. All this in preparation for having Robert Franzen of Steam Services of America back to adjust, trim and hammer the flexible stays.

The last of four tapered frame bolts holding the pilot deck brace bracket have been reamed. The bolts are machined fit for each hole. The taper reamer was hanging in the hole waiting for the crew.

The original throttle rod was just mild steel and when removed was heavily pitted. When measured at 144 inches in length it was 4 inches shorter than either of the two blue print drawings in our collection. While considering a replacement we decided to dry fit the old components and determine the optimum length. Paul, Ron and the crew assembled all the parts. Paul’s research came up with a page in the Baldwin Standards that addressed these throttle rods which were originally made from pipe or solid rod. It further specified that future replacement should be made with “Carpenter No.5 Stainless”. We are currently shopping for “CarTech 416 (No.5)”. I am sure the 150 inch piece of 1.25 inch stainless rod will not be cheap, considering transportation costs to Wasilla.

557 Board Member, John Combs, recently purchased this image of 557 which is new to his collection.  The detail is great and it will be used in future promotions.  The scene is in Whittier Alaska when 557 was in regular service.

JJ Kovich was engineer for the day when his Granddad, Ed Kovich, came by for a visit to 557. Ed is a long time model railroading friend and a strong supporter of engine 557. JJ will be just the right age to participate in the first 15 year FRA inspection of 557. We believe in early recruitment!

Robert Franzen, our Professional Engineer with Steam Services of America, left a to do list after his last visit here with Bob Gold. We are working it down and look forward to having Robert back to adjust, trim and hammer the remaining flexible stays in April or May of 2019. To that end the crew keeps working four days a week, reaming, tapping and threading stay bolts. Also on the agenda is installing the four bottom corners in the firebox, caulking and welding the new sheets to the mud ring. Our friends at Roteq Alaska are prepared to do the stress relieving of the four corner pieces after they have been fitted in preparation for welding and rivets.

The days are getting longer and it is now daylight when the crew shows up at the engine house. It snowed 6 inches last night. Come visit at the 557 engine house when you come by our way.

Richard Morris makes regular updates at Engine 557 Facebook if you need more timely information.
For the history of 557 and her s-160 sisters in Alaska go to: Engine 557 - Restoring Alaskan History

Patrick J. Durand, President

 

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