Shay Boiler - Mounts &
Nelson Riedel Nelson@NelsonsLocomotive.com
Initial: 11/14/03 Last
The boiler was fabricated by a professional as discussed
elsewhere. It was supplied with the major cutouts in the smoke
box for the smokestack and exhaust but without mounting screw holes, water
feed holes and the various holes in the backhead. Drilling these
approached carefully because mistakes might be difficult to
repair. The first thing done on the boiler was to install the
throttle valve as described in the Throttle page. It was then
decided to finish drilling all the remaining holes ---- it's too hard to repeatedly
remove the boiler to drill a hole. The mountings/supports were
finished and then all the holes for the plumbing
and other functional fittings were drilled. The cosmetic fittings including lagging, jacket, handrail, etc
were deferred until after the locomotive has been fully tested.
|Rear Support: This shows the rear support on Cass No
5. The angles appear to be bolted to the boiler.
The holes in the angles accommodate the the ends of the stays.
The angles are clamped to the frame.
|This photo shows one of the rear support angles. The angles were
moved up 1/4" to drop the cleanout holes below the bottom of
the frame. The strap and 6-32 screw are temporary. The
side of the boiler will probably be covered with lagging and the
boiler jacket. The bottom of the angle is at the same height as the
running boards. I will probably make a clamp that
resembles the angles in the previous photo to fit over and hold down
the support angle.
|Fire Pan: The fire pan will be discussed in a separate
page describing the burner system. The task here is to drill
and tap the four holes for the studs that hold the pan to the bottom
of the firebox. The boiler was placed upside down on the workbench
and the holes drilled with a hand
|The Big Squeeze: Friend Dan Staron has an identical boiler
and told me the smoke box was oval shaped, not round and the smoke
box front didn't fit properly. My smoke box was also out
of round by about 1/16". This was fixed by
squeezing the front of the smoke box in a 10 ton press. (Those of
you that have been to an IRS office might recognize the press; they use
same kind.) Once the front was made round, the boiler was placed
with the backhead on the floor and the 4 holes for the smoke
box front studs drilled with a hand
|Smokestack & Exhaust Flanges: The mounting holes for
the smokestack and exhaust flanges were drilled with the drill press
------ the smoke box is small enough to fit in the bench top
drill press as shown in photo on right. The studs to retain
the smoke box front can also be seen in the photo.
Water Feed Holes: The water feed holes each side of the
boiler were also drilled with the drill press. Care was taken
to limit the drill depth to prevent drilling into a boiler tube.
|Firebox Door: The boiler was moved back to the
floor with the backhead pointed up. Four holes were then drilled
to mount #2 studs for the fire box door as shown on the
.Water Gauge: The hole was then drilled for the lower end
of the water gauge. The hole was positioned so that the bottom of the
visible part of the glass is 3/4" above the crown
|Throttle Angle: The last hole in the backhead
is for the throttle pivot. Before making that hole, the
boiler was placed on the frame as shown on the right. The
brass rod on top the boiler is meant to simulate the steam turret. The steam brake valve mounts on the ledge over the
rear cylinder. The brake handle will be above the top of the
reverse lever and below the throttle
lever. This mockup helped in picking a good
angle for the throttle.
This finishes the holes in the boiler. The next step is to
do some plumbing ----- run the steam and exhaust lines to
|Update 2/16/2004: The walkways have been
completed so it was a good time to make the rear boiler
clamps. The boiler jacket will be supported by 1/4"
square rod spacers tack welded to the boiler. The spacers adjacent
to the front of the cab and on the sides over the rear boiler mount angles were tacked in place first. The clamps were
then fitted over the rear mount angles and against the jacket
spacers and holes drilled through the clamp, walkway and the flange of the
frame I beam. The holes in the I beam flange were tapped 4-40 and
the holes through the clamp and walkway were enlarged to #4
clearance (#33 drill).
The photo shows the right side clamp made from 1"
|The right side clamp is hidden behind the engine so no effort was
made to simulate the prototype clamp. The left side clamp
is out in the open so an effort was made to spruce it up a bit as
shown in photo on right. The four screws in the vertical leg of
the clamp are screwed only into the clamp and are for
decoration. The four screws in the horizontal leg go into the
I beam flange the same as on the right side.