Building Time : 363,75 hours

Weight : ca 63 kg

Date

What happened ?

Working hours

17.05.2012

After another long break, I come back to the Shay project and did some progress on the cylinder collumns. I also made a mounting plate for the cylinders.

7,0 h

28.01.2012

The boiler arrived today !!!!! This gives some motivation to get more progress done =)

13.10.2011

The back site of the column is taking shape. I also posted some photos of the boiler in progress.

1,5 h

11.10.2011

Some more sections were milled of on the second column. There's a new photo posted showing both colums with cylinders to get a feeling of the final engine size.

1,0 h

09.10.2011

The sceond column is bored to 28mm for the cross head and the recess for the cylinder is also done. I started to mill off the first areas at the round end of the collumn. While the lathe was running on half automatic operation, I milled some more metall off of the first column. I'll make photos of this steps when I finish up the second one.

8,0 h

08.10.2011

I made good progress today. After finishng the pre cuts on the mill, I chucked the second column to the lathe and turned the outer cylinder to size. Once this was done, I pre bored the cross head guide to 23mm.

4,75 h

07.10.2011

I recieved the new steel/brass order today and I started with the second column by milling of the area where the round cross head guide will take place.

1,0 h

06.10.2011

I milles out the rip on the side of the cylinder column and it turns out great. The corners are made with an ball end mill, so the piece will look like a cast iron part. I hope to get the new block for the second column soon.

2,5 h

01.10.2011

I started to mill the outer shape of the first cylinder collumn. There's a lot of steel to be removed by milling and sawing. I opened up the cross head bore and start to mill out the rip on the side of the crank shaft support.

5,5 h

29.09.2011

Yeah - I got it!!! The first cross head bore is done. I tried a new way to make them and I'm very happe with the result.

I got also news from the boiler maker. Maybe the boiler will be finished in the next few weeks. That sounds great. I'll now try to get the Shay ready for a first steam up at the big indoor convention in January 2012.

3,0 h

25.06.2011

Okay, I gave up on those damn cross head bores. I didn't get them bored and had a lot of trouble with damaged tool bits and other stuff... Now I'm looking for new ideas...

2,0 h

14.06.2011

I worked on the columns today, but I also started work on the slide valves.

2,0 h

13.06.2011

More splinters are made from the cylinder columns...

2,25 h

11.06.2011

I made some more progress on the cylidner columns. To bore the cross head guide is much more work as assumed.

4,25 h

09.06.2011

As I'll recheck the slide valve settings, I did some work on the cylinder collums. The slide valve will be machined when the correct size is known.

3,5 h

08.06.2011

I converted the drain cocks and drilled the holes for them on the cylinders. I also made the pistons.

3,5 h

06.06.2011

Both cylinders are filed to round shape and I mounted the steam chests. The piston rod stuffing nut is also done.

4,0 h

05.06.2011

The steam ports are milled and I made good progress on the outer shape of the cylinders.

1,25 h

04.06.2011

Steam chests are done and the cylinders got the steam ports drilled and I started to mill the outer shape.

3,5 h

02.06.2011

The steam chests are mostly done and I made the stuffing nuts. The rear steam entrance is still missing.

2,5 h

31.05.2011

This morning, I drilled the cylinders and I can go forward with new progress soon.

1,75 h

30.05.2011

I made some progress on the second valve chest and I made the new cylinders to replace the damaged ones. Only the screw holes are missing and I'll be on the same progress status as last week.

5,0 h

26.05.2011

Well, due to a mistake, I've to make a new cylinder. I ordered a new cast iron block and spend the day for the steam chests.

3,0 h

23.05.2011

Both cylinders are bored to final bore and ready for the next steps.

2,25 h

22.05.2011

I started with the cylinders today and finished the covers and made good progress on the cylinder blocks.

6,25 h

10.03.2011

The brake valve was finally installed, but doesn't work proper at the moment. I think I should renew the piston seals on the brake cylinder and maybe I've to do some more adjustments till the brake will work...

2,5 h

09.03.2011

Two water pipes have been added and I start to install the brake valve. The valve itself was modified and I made the steam pipes to install the valve. Actually I'm working on the mounting bracket for the valve.

2,25 h

20.02.2011

I did some more progress on the water tank today. Some plumbing was preinstalled and I mounted the water valves below the run boards. They are connected to the valve handles on top of the tender.

4,0 h

16.02.2011

The tank has been soldered and I added rings to mount the plumbing.

2,0 h

14.02.2011

34 pounds of metal stock arrived at my workshop last week so I can start with the water tank and steam engine. The tank is already in progress.

2,0 h

20.01.2011

I made the steam manifold today.

2,5 h

20.12.2010

The boiler is on order at my boiler maker. The delivery is announced for April 2011!!!

22.09.2010

The crank shaft is assembled now and I start work on some detail stuff and the eccentrics.

4,5 h

19.09.2010

The cranks have got there final shape and are nearly finished except for some filing and holes.

5,25 h

16.09.2010

I parted of the crank discs and drilled the shaft holes.

1,5 h

15.09.2010

Did some lathe work on the cranks.

0,25 h

12.09.2010

I did some smaller progress during the last days. I preinstalled the water and pressure gauge inside the cab. I also made the tender water valve handles.

Finally, I started with the crank shaft of the steam engine. While I killed the index bit of my parting tool, I have to wait for new bits to continue. Actually, my mill is out of order too in fact of a toothless spur gear :-(...

5,75 h

08.09.2010

I finally mounted the head lights after installing the glasses. I also added the bell cable.

CONGRATULATION !!!
Today, I completed 250 hours of work on my Shay. Cheers to the work done so far. Here is some statistic counts about the project:

250 work hours / 937 screws / 245 nuts / 1005 std. parts and ready-to-mount parts / 2684 drilled holes / 771 cuted threads / 661 self manufactured parts / 2848 pieces over all

1,0 h

07.09.2010

I tried to bend the bell holder to a new shape and finally broke it. So I made a new one yesterday.

I also installed the lubricator on the run board in front of the steam engine and made the head light supports from sheet brass.

4,5 h

06.09.2010

The last weekend, I finished the head lights except for the glasses and interior. I also made the dummy boiler feed pipes. The actual feed pipes will be installed inside the cab.

9,5 h

25.08.2010

The smoke stakes get milled to there tapered shape.

2,0 h

22.08.2010

The feeds of the head lights are done and I'll continue with the smoke stacks.

3,0 h

21.08.2010

I made some more progress on the head lights today, but there's still a lot of work to be done.

3,0 h

18.08.2010

The head light bodies are nearly done and I cut some pieces to make the head light foots.

2,5 h

16.08.2010

Today, I started with the head lights from steel pipe and steel discs.

3,5 h

08.08.2010

I started with the hinges on the smoke box door to get this chapter finished soon. The number plate is now painted and looks great.

2,0 h

07.08.2010

Whistle mounted on cab and windows glazing added. Also installed are the hand rails, the steam engine cover and I built the front number plate from brass.

5,0 h

04.08.2010

I added the roof on the cab and mounted the pole pockets.

3,0 h

03.08.2010

New progress was done today. I made pole pockets from brass and painted the type plates. Next I'll add some more detail stuff.

2,0 h

22.04.2010

I started with the smoke box front/door assembly today.

4,5 h

19.04.2010

The sand dome was finished during the last days and I added the sand pipes. The parts have been painted black and the dome is waiting for lettering.

5,5 h

14.04.2010

Today, the ordered material for the sand dome an lower steam engine parts arrived. I started with the sand dome and made good progress on the first 2 parts.

2,0 h

12.04.2010

I lettered the water tank and placed the name plates on the cab.

0,5 h

05.04.2010

I made more progress on the cab and build the bell.

5,5 h

04.04.2010

I painted the water tank and placed them on the frame together with the sandbox
Finally I came back to my first version of the Shay and build a std. wooden cab.

6,0 h

02.04.2010

The water hatch was build and installed. The sandbox was completed with a lot of detail stuff and got the paint on.

7,5 h

24.03.2010

I build the support for the sand box.

2,0 h

21.03.2010

After a long break, I'm back on my Shay project and did some good progress the last weekend =)

- I placed the first tank on the junk yard and started a new one. The old tank was close to the prototype construction, but bad for operation and handling on a live steam locomotive.
- The new tank was build from plywood and sheet aluminum and is nearly done.
- I added a hand brake to the frame, acting on the rear truck.
- I started construction of the rear sand box.
- I build a cab moke up from card board and checked final dimensions.

17,5 h

13.09.2009

More work done on the water tank. The first halve has been riveted and looks great. Can't wait to ghet the rest of the tender done.

-/-

12.09.2009

Continued the work on the water tank by finishing the bottom sheet and starting with the side walls.

-/-

11.09.2009

I stained the wooden parts of the frame to a dark brown. This gives a fine nobly look.

I also good the material to start with the water tank. The first parts have been machined today.

2,5 h

31.07.2009

Some time has passed and I was busy with some other projects and work. But I found some time to complete the main frame by mounting the cab steps and end beams hand rails.

I also made some progress on my boiler moke up. Next step will be the tender tank and rear sand boxes.

3,0 h

13.07.2009

I just milled some parts foot plates for hand rails on my cnc-mill. I also fabricated the cab ladders so the frame chapter is nearly completed.

1,5 h

12.07.2009

Both universal slip joints have been finished and mounted on the Shay. First test runs have been very successful and even tight curves with 3.6m radius can be handled without problems. The drive shaft runs very smooth and I hope it will also work with the steam engine some day. I also finished the run boards.

6,0 h

11.07.2009

I bought a new propane torch and soldered the female slip joints for the next steps. I also machined the male joints.

5,5 h

06.07.2009

I started with the first universal slip joint, but had some trouble while silver soldering the parts for the female joint. I'll try is again within the next days. Maybe I'll give this to an friend for soldering.

1,5 h

01.07.2009

NEW PROGESS DONE !!! Today I installed the steam piping on the brake cylinder. Next I'll continue with the run boards. I'm also working on the steam engine drawings. It's not easy to fit the engine on this small engine.

1,5 h

02.06.2009

I started with the run boards today and milled the first of two segments to match with the frame. The larger segment for the rest of the frame will follow next.

1,5 h

01.06.2009

After a long break, I'm back on my Shay project. The last weeks, I only drilled some missing holes to the frame and nothing more. But know I ordered some more stuff to make major progress within the next time.

2,0 h

18.04.2009

The break cylinder was made and mounted to the frame. The break system was tested with air and works great.

11,5h

10.04.2009

The break rigging on the frame was added. I also added the missing girder between the frame and end beams on the engineers side and the whole frame was painted.

5,25 h

08.04.2009

The end beams are finished and mounted to the frame. Now, the final length including the couplers is known0 with 110cm (43 3/10 ").

3,0 h

07.04.2009

I've done some progress today by starting with the end beams and couplers. I'll continue with them tomorrow.

2,0 h

31.03.2009

After a long break, I final made some progress on the frame. I added the truss rods.

4,5 h

08.03.2009

I worked on the frame and added the run board supports and other things.

7,0 h

05.03.2009

I got the laser parts the last days and finished the trucks with break rigging and the missing covers. Tomorrow, they will be finally painted, so I can continue with the main frame.

8,5 h

01.03.2009

The mainframe has been assembled, but I killed some of my M3 tap drills so I've to take a small break to order new ones.

4,5 h

28.02.2009

I got new material the last days. So I start work on the main frame today and did also some touches on the trucks. The ordered laser parts do not arrive today, so I hope they will come on Monday

8,5 h

21.02.2009

The first universal joint is working very well.

4,0 h

20.02.2009

I finished the universal joint rings so I'll start with the coupling horns tomorrow.

3,0 h

19.02.2009

I start work on the universal joints.

2,5 h

17.02.2009

Today, I finished the second truck to and installed the line shafts with the bevel pinions.

Later that day, my dad was here for our weekly work session and we made the break rigging. But I'm still waiting for the laser parts. The laser guy is ill so it will need some more time.

I'm also OOM (Out Of Material) and will order more stuff the next days.

5,0 h

16.02.2009

The first truck is nearly completed !!!

1,5 h

15.02.2009

The last days, I spend many time on new bolster stands. Finally, I could finish the bolsters and made major progress on the arch bars. I also drilled missing holes for the journal covers on the pedestals. Wheel sets and pedestals have also been painted.

16,5 h

12.02.2009

Well, my first try on the bolster stands ended in the scrap box :-( But I've a new idea.

2 h

11.02.2009

I raw cut the parts for the bolster stands and pre shaped them by milling.

1 h

10.02.2009

I did some milling work on the lower bolsters.

1,5 h

08.02.2009

The pedestals are nearly done, only the gear and journal cover are still missing.
I also stared work on the lower bolsters.

5,0 h

07.02.2009

The axle pump has been finished and works very fine. Now I'll come back to the pedestals.

3,0 h

06.02.2009

The axle pump is taking shape. Tomorrow I'll get my new thread taps so I can finish some more pedestals this weekend.

2,5 h

03.02.2009

I need a break from the pedestals, so I made the eccentric ring for axle pump from brass.

2,5 h

01.02.2009

Another weekend has past without major progress on my Shay. Maybe I'll have some time the next days.

1 h

28.01.2009

Spare time is rare at the moment, so I've done no new progress within the last days. In the future, I'll update this website weekly each Sunday evening, except for special events and progress. The last days, I could only drill some holes.

1,5 h

21.01.2009

I machined more parts for the pedestals today. Most are done and I'll start assembling soon.

1,75 h

18.01.2009

I machined the uprights for the egineer side pedestals and set one of them together for a test run.

3,0 h

17.01.2009

I milled groves into the foot and header plates of the pedestals.

2,5 h

16.01.2009

After a break for some days, I was back in my workshop to make some progress. I cut and milled all flat bar pieces for the pedestals to length and pre shape. The first pedestal was assembled and looks very good.

3,0 h

08.01.2009

I got my new milling machine today, so my workshop is nearly complete now. I added a new website, showing my machines.

03.01.2009

HAPPY NEW YEAR !!!
I finished all other journal boxes during the last days and will wait for my new milling machine.
I'll continue the work on the pedestals next week.

6,5 h

31.12.2008

The first set of journal boxes have been pre-finished.

1,5 h

28.12.2008

All wheel sets have been finished, so the first chapter has been completed
Chapter I : 9 hours - 5,92 kg weight - 154 parts (including screws).

3,25 h

27.12.2008

First wheel set has been finished and all parts for the other wheel sets are ready machined.

2,5 h

26.12.2008

I did some more progress on the wheel sets.

1,75 h

19.12.2008

This webpage was redesigned.

18.12.2008

I received 30 pounds of steel and screws for the trucks today.

15.12.2008

The first wheel set was machined and looks very good.

1,5 h

08.12.2008

The gears arrived. Also parts for the break rigging.

06.12.2008

I got the wheel sets, so the first parts for the Shay are here.

18.11.2008

I decided to revive my old plans, to build a Shay locomotive.