Shay - Boiler Cosmetics - Part II
The task here is to do the jacket and bands. The following photo of Cass 5 jacket and bands is repeated here to keep the goal in mind.
The plan was to position the boiler on the frame and mount the cab before cutting the rear jacket piece. However, when the boiler was positioned it was found that something was holding the boiler above the correct position (I knew things were going too smoothly). The angles under the front jacket piece were against the top of the front truck bolster cross channels. That problem was solved by relocating the front screw holding the two angles together so that it was between the two channels. The part of the angles directly over the channels were then cut back to eliminate the interference. The next problem was that the boiler rested on the new frame cross brace just to the front of the fire box. Rats! I forgot that the bottom of the boiler jacket is about 1/8" below the top of the frame. A recess was ground in the center of the cross brace to eliminate the interference. That worked well. The 1.25" high cross brace could have been aligned with the bottom of the frame I beams like the truck bolsters to eliminate this problem. However, I like the brace in the higher position where it's more noticeable from the sides.
Bands: Before starting the rear jacket section described above, brass strips were ordered for the bands. The first though was to use 1/4" wide strips. However, review of some Cass photos suggested the bands were wider. Measurements of the bands on the photos and some calculations indicated the bands are about 2 inches wide, which would scale to 1/2" As a double check, 1/2" strips of blue masking tape were put on the model, a photo taken and then edited so that the boiler length was the same length as the boiler in a photo of Cass 5. The two photos were overlapped and positioned so that a band and a piece of tape lined up. The following is this combined photo. The bands indeed should be about 1/2" wide. However, I think the tape looks too wide. I ended up ordering 3/8" wide bands and a couple pieces of 1/4" and 5/16" in case I want to use a narrower band on the front. The bands came from Special Shapes.