40HP Avery Phase III

[40avery]

After many hours of sand blasting "small" parts at Mark's shop and a lot of Marks Hours involved in painting - pallets of parts arrived at Larson Welding for the continuation of assembly.
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[40avery]

The drivers and bull gears were brought in also.

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[40avery]

Undercarriage was waiting for parts to be installed.

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[40avery]

Jim worked on the final touches for the rod bearings.

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[40avery]

Tom H. and Pete M. worked on getting the valve linkages, rods, and reversing gear installed.

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[40avery]

Some of the valve train installation needed more than two sets of hands.

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Jim making some adjustments on the new bearings.

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[40avery]

Rick H spent the day making gaskets and bolting on exhaust pipes and steam feed manifold.

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Steering brackets and worm, and the pedestals were installed by Pete, Tom, and Rick.

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[40avery]

Mark K , SD John, Kelly M, and Joe S all teamed up on attaching the bull gears to the drive wheels.

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[40avery]

No project can continue smoothly unless there is a high quality board of directors to hash out the fine details of the mission.

http://i265.photobucket.com/albums/ii219/353ric/2010averybuild/DSC07038.jpg

[40avery]

It was a great day.

Seeing the project start to come together was really fun.

As I was working on the Avery my thoughts strayed to when it was originally built and the people that originally built it at the Avery factory in Peoria. We do this for fun and recreation. They were doing it to keep food on the table. I wonder if they ever gave thought to the possibility that their craftsmanship would endure for anywhere near to 100 years!!!:thumb:

[M Kerkvliet]

It was a great day.

Seeing the project start to come together was really fun.



I agree!

I have only been around the steam part of WMSTR for 5 or 6 years. I am lucky enough to be one of the crew of Jim's 40 Avery, but was never part of building (restoring) it 20+ years ago.

Same goes for some of Mark's other engines... especially his 110 and 80 Case engines in New Rockford... both "ground-up" restorations that I have only seen the end result of.

It is a lot of work, but it is just "Way Cool !!!" to be involved in a ground-up project like Mark's 40. This will be one that (all of those involved in the project) will be standing there watching it go up the parade route at Rollag in 2011, will be able to say... "Hey, I helped build that engine!"

It is especially satisfying that I am learning so much about the engine I operate from those who have the knowledge to pull off a project like this, and are willing to share that knowledge with guys like me!

Thanks for the pictures Rick!

[CaseyD]

Thanks for the pictures and the story! Preserving history is one of the most important things we can do, and you are doing a job that is important to all of us. Look forward to seeing it on showgrounds this year!

[M Kerkvliet]

Look forward to seeing it on showgrounds this year!

:eek: :eek: :eek: :rof::rof::rof:

[CaseyD]

Oh come on! With as many talented engineers as you have working on it, that puppy will be done in time for steam school! ;)

[mrnewway]

Casy: I agree with you about the talanted people at Rollag and I know that a rebuild of this magnitude does take time, some times good things come with time, I'm sure it will be out in 2011.:thumb::thumb:
Good luck to all helping on this project for Mark.

[Jerry Mandt]

Have been cutting gear blanks for Marks 40 Avery. Have all four done and now need to cut the teeth.


http://i1000.photobucket.com/albums/af124/jerrymandt/Avery/0301001347.jpg

[M Kerkvliet]

Looks great Jerry! Now that you have this picture posting thing down, I am sure you will be posting dozens of them!

Looking forward to it!

Call me anytime!

[Mike McKnight]

Since it's been getting cold, any progress on the Avery so far this year?
Mike M

[40avery]

I think Mark and Kelly were working on pouring some bearings last week. I have not had the time to check in and see how things went. There is going to be more action soon so stand by for more pictures.

[40avery]

So OK it has been a year.:hide:

There has been a big push on Avery work again lately. Mark, Kelly, and others have been working hard on assembly work again and myself and others got a chance to help again this past weekend. Many pictures have been banked up and I will be working as I can to get them edited and posted.:thumb:

Thanks to Mark and others that have taken pictures and transferred them to me to get posted.

[40avery]

http://i265.photobucket.com/albums/ii219/353ric/2011averybuild/geartrain-1.jpg

Work on the running gear assembly has gone well. The gear manufacturing that Jerry did and was posted earlier is seen here mounted up on the drive train.


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The main drive shaft installed and waiting for the pinion gears.

[40avery]

Next door some of the boiler accessories were being installed prior to mounting it on the running gear.

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Kelly and Pete were working on getting the throttle linkage mounted and adjusted

[40avery]

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In a previous post we showed the throttle valve laying on the floor. Here it is installed in the dome.

[40avery]

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I got to install the heat shields in the smoke box.

I think this is the first time in my steam career that I have worked on an engine and not turned my gray hair to black. My cloths were even pretty clean when I went home!!

[40avery]

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Pete and I mount up the shifter linkage for the clutch/two speed drive.

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Differential has been rebuilt and mounted up.

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Bud buffs up some parts for the mount up.

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Boiler is ready for mounting and pushed off tot he side to get the running gear in place

[40avery]

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Running gear comes out of the lean to.

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Steel Wheels on really cold snow moves hard. Mark had to assist the forklift!

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In the shop and getting the spot right for the mount up.

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Boiler had to be re rigged a bit. Kelly being the smaller in stature usually gets the firebox duty.

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Going up.

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and up

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and over

[40avery]

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And down

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In line - Ready for final adjustments

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Mounting holes in line and ready to settle in.

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Front end lined up and ready to set in.

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First bolt in.

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Line up punches in and boiler is being secured.

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Mark K. using the force to torque up the mounting bolts.

[40avery]

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Bud uses a more conventional approach.

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Fitting up the mounting rod blocks.

[Darren Gunderson]

Thanks for all the pictures documenting this. It is really looking great. I bet it is a great feeling seeing it come together like that. I am really looking forward to seeing it in person. It is good to see another engine come back to life.

Darren

[s.d. jon]

EXCELLENT PICTURES of an EXCELLENT JOB:not_worthy:

[M Kerkvliet]

I wonder what I was doing with that die grinder up in the air like that? :confused:

This has been a really fun build. I am glad I get to have some part in it, as the 40 I help run (Bridens) went through the same process back in the late 1980's... before my involvement in steam. You hang around these folks, and you learn a lot! Most of the guys you see working on this engine throughout the 3 threads on the build have been there since it was nothing but a big parts pile!

Keep up the great work on the thread Rick! Thanks!!!

[40avery]

I know these weekends are not "official" donut tasting weekends but there have been a few that have kept up the tradition anyhow!:hide:

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And Mark couldn't find a Donut but he did find a cookie. I thought he was going to choke on it trying to get it down before I took the picture

http://i265.photobucket.com/albums/ii219/353ric/2011averybuild/cookie.jpg

[M Kerkvliet]

I have it on good authority that this engine came to life again on Sunday February 20, 2011! (on compressed air anyway...) The owner claims it runs PERFECT! As a matter of fact, he CLAIMS it runs better than Jim's!

I wish I could have been there to see it, and I sure hope someone there got some video (Louie???)

Pete Mandt worked long and hard on the timing. I have been told that Jim's 40 has some kind of timing issue, so guess who we are going to recruit to check it out on (if not before) steam school weekend!

Congratulations to Mark Pedersen and all who are involved in this project! It is getting close to being finished!

Here are a few pictures I took of the engine a few weeks back when it was sitting outside Jim's shop.

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[Pete Mandt]

Mark,
I will have to check my schedule before I help with any tuneup. I may not be able to fit one in until we have a chance to see which 40 Avery is the BIG 40 AVERY. :aetsch:

May the best Bulldog win!:dogrun:

Pete:praying:

[M Kerkvliet]

Some photos from Saturday re-riveting the eccentric strap / valve linkage. Can't remember for sure why they had to be re-riveted... :Shrugs:

Heating...

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Delivery...

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Quick Mark... :build:

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Finishing up...

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[M Kerkvliet]

Rick H, Kelly M, Katy and I got pressed into service this past weekend to make grate hangers, prep and install the grates in the 40 while Mark P was way up in Canada playing!

Mark decided to go with the "Field tested" grates that we have in Jim's 40! No sense messing with something that works... at least not for now! These same grates have also found there way into a lot of 80 Case boilers.

Rick and I built the set that are in Jim's 40 quite a few years ago, so this was round 2 for us! It was fun to build another set with him... this time we had something to copy!

It the first two photos, Katy and Ted Mandt take turns cleaning up the holes, all 966 of them!!! in the 7 grates. The holes are cast to end up 1/2", but the process leaves behind a lot of undesirable material so they are drilled out to 9/16 to clean them up and make a smooth surface for the air to travel through.

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The holes in the grates are cone shaped, so the air is actually accelerated as it us drawn through the grates with the draft. Ingenious design, and very effective!

Rick and I teamed up laying out and drilling the holes in the grate hangers. We started with 1/2" holes, then 1", and I think we ended up with something around 2-1/2" holes. The two hangers were welded together so we only had to lay it out and drill it once.

In this picture it looks like we are at the 1" step. We really were busy... we just got to sit for about 3 minutes while the drill press auto fed through the 2" thick material (2-1" pieces) and then we would have to re-set the work and drill the next hole.

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After the holes were drilled we cut out the tops of the holes with the band saw to form the "U" shaped cradle for the grates to set in. I then cut the two pieces apart and in the picture below Rick cuts the final shape into each hanger.

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While Rick was doing that, Kelly M (not pictured, sorry Kelly) were drilling holes in the rocker arms in the 7 grates. While only 3 of them will be hooked up to rock, 3 more of them will be bolted solid with these arms to keep them level.

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A finished grate hanger bracket ready to go into the boiler!

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The 4" long pieces welded to each end are by design. The hanger supports are narrower than the firebox to miss the rivets in the corners, but the hangers have to be closer to the outsides of the firebox to make room for the grates. The design is very similar, and were patterned after the original grate hangers.

[M Kerkvliet]

The grates are all installed in the boiler!

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A look underneath through the rear draft door.

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And a close up of the rocking linkage on the 3 grates that will rock. The only time we use the rockers are for cleaning out the firebox before we fire in the morning, or at the end of the season.

http://i155.photobucket.com/albums/s317/mbkerk/WMSTR/DSC09473.jpg

Rick and I ran out of time to finish up, but Kelly stayed and built the dead plates for the front and back of the firebox. The front one is something like 10" wide, and the rear about 4". I will get some pictures of all of that next time I am around the engine!

Thanks for taking up the slack Kelly!