Shay Cab Sides & Front
Nelson Riedel Nelson@NelsonsLocomotive.com
Initial: 11/11/03 Last
The plan was to put off the constructing the cab to the very
end with the other cosmetic details. The locomotive will operate
without the cab. On a recent visit to Cass I was told that they
had done a several mile test run of the recently reconditioned Heisler without
the cab ----- as I recall the boiler lagging hadn't been applied
However, when trying to layout the various controls and
plumbing around the backhead it became clear that the cab walls would
be very useful to get a correct perspective. So, I decided to make the
two sides and front now and finish the cab later.
|Cass No 5: Before making the cab some photos of
shay cabs were examined. This is the right side of Cass No.
5. This cab has single windows on each side whereas Kenneth's
design used double windows on each side. Both designs were
common in the 1900 -1920 era. Other photos can be viewed at
|This is the left side of Cass No 5. It seems the cab has had several patches ---- maybe a fender bender or two ........
|This shows the inside of Cass No 5. Note that the back side
of the cab is behind the doors, against the coal bunker.
Kenneth's design has the back side in front of the door
|The sides are made from 0.064" steel plate. The two
sides were soldered together at the corners and cut at the
same time using a band saw. The saw was run through the top
edge to cut the windows. The cuts in the top were later silver
soldered closed. The sawed edges were finished with a
file. The rivet holes for the front and bottom were located
using the same drilling fixture as used for the tanks.
Only half the holes in the fixture were used --- rivets were stuck
in the holes not used. (The same 1/16" OD rivets as
used on the tanks will be used on the cab.) The cutout for
rear cylinder on the
right side was made after the two sides were unsoldered.
|Square stock was riveted to the bottom and front edges of the
sides. Every third or fourth rivet is a 1/4" long
1/16" brass rivet that holds
the square stock. The other rivets are 1/8" long
1/16" copper that only go
through the sides. The brass rivets were too short to go all
the way through the squares so 3/32" holes were drilled half
way through the inner side and the rivet was peened over inside the
hole using a 3/23" punch. The squares on the front edges were set back the width
of the front. That made the rivet holes close to the
edge of the squares, so close that some of the 3/32" holes went
through the sides of the squares as shown in upper photo on
right. The lower photo shows the shows the outside view.
|This photo shows the the front and left side before the boiler
opening was cut in the front. The front is held to the side
with #1 button head cap screws that closely resemble the 1/16"
rivets. The screw holes were marked with Whiteout when the rivets
were installed. The little white patches are still
visible. The dark stripe in the front is an area not reached
by the pickling
solution. (I need a larger glass or ceramic baking dish
to hold the pickling solution for the flat plates. Maybe
that would be a good Christmas present for the wife.)
|The right side with cutout for boiler.
|The left side of cab.
|Update 1/23/04- New Front: Shortly after I started to
install the pipes through the cab front I realized that the window
placement was not good. The windows needed to be moved toward
the corners by about 3/8" and the lower edge of the windows
raised somewhat. I waited until all the pipes were installed and then
made the new front pictured on the right. The first
front was used as a drilling template for the this second front making
the job easy.
The cab front and sides are complete at this point except for
the window frames.