2.5" Scale 36 Ton Class B Shay

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littleevan99
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2.5" Scale 36 Ton Class B Shay

Post by littleevan99 »

I'll start this off with a link to my other build that this project evolved from: http://www.chaski.org/homemachinist/vie ... 5&t=106921

I've made so many changes to the design that I think it deserves its own build log. This all started late last year when I got the bug to start working on my Shay again, and to build it the way I had wanted to for a few years. I did my research and started designing, and re designing parts for the Shay using Fusion 360. The goal was to keep it simple, and use as much of John's parts as designed or slightly modified. What I've ended up with is a fairly accurate representation of a 36 Ton Class B Shay. I've made some patterns, and had parts cast at a local foundry. So far that being the bottom bearing bracket for the engine, and I'm currently working on the pattern for the larger steam dome base. Future patterns being a new sand dome base for the extended wagontop boiler, and possibly a smokestack casting. At the moment the goal is to finish the engine first. So far I've machined the bottom bearing bracket, and it turned out quite nice for my first casting. This project will be a long drawn out one, but I'm happy with how it's looking so far.

The 3d model is a work in progress, but it is far enough along to give an overview of the Shay.
Early EXT Wagontop Boiler Taper Stack v15.png
Originally though I was planning on a wagontop boiler for this Shay, but moved on to the other one shown above. I still may build it this way if I change my mind down the road, but I figure this shows the evolution of the design as I've made changes to it.
36T Wagontop v4.png
Below are some pictures of work on the engine thus far.
277814778_5314954915228708_3329686096759037625_n.jpg
The wood pattern I made for the bottom bearing bracket. My first try at making one, and it turned out alright. Next time I need to locate the dowels to the back half of the pattern to get a better finish on the front. I'm also planning to modify it to have cores to eliminate most of the repetitive machine work to hollow out the casting.
277819406_5314954935228706_4106538983842659784_n.jpg
As machined the casting was quite oversized on the height and some other dimensions. I went back and had to increase the length of the main bearings to get them all the same size, thus increasing the overall length from the original plan. The height is due to me adding too much material with the pattern height. I was expecting it to shrink quite a bit, and it didn't as it was actually bigger than the pattern! I'm guessing that they had to wrap the pattern quite a bit to get it to release from the mold and that's something else I should probably fix.
301801498_5709673399090189_5107008940019306623_n.jpg
Lastly, the I've made the bearing caps for it out of 1018 CRS.
302076591_5709679505756245_1827957531752175612_n.jpg
That's it, more to follow.
Last edited by littleevan99 on Thu Oct 20, 2022 4:32 am, edited 5 times in total.
1.5" scale CliShay
1.5" scale 2-10-2T
2.5" 36 Ton Shay under construction
YouTube: http://www.youtube.com/user/littleevan99
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Steamer Al
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Re: 2.5" Scale 36 Ton Class B Shay

Post by Steamer Al »

Thanks for sharing your progress! Shay's will always have a special place in my heart. My grandfather used to fire a wood burning shay for a logging company just before the second world war. Look forward to seeing the progress!

Alex
Soot n' Cinders
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Re: 2.5" Scale 36 Ton Class B Shay

Post by Soot n' Cinders »

I cant wait to see where this goes! Ive toyed with the idea of making a 3 truck version. From what I can tell, Johns castings would make a nice 50-60 ton class C shay. But from what I hear, John isnt making any more castings so they're off the market till the business sells.
-Tristan

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-2.5" scale Class A 20 Ton Shay

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Pipescs
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Re: 2.5" Scale 36 Ton Class B Shay

Post by Pipescs »

Having reached the point in life I can start Johns Shay, I look forward to your post. Very interested in your Progress.
Charlie Pipes
Mid-South Live Steamers


Current Projects:

Scratch Built 3 3/4 scale 0-4-4 Forney
Little Engines American
20 Ton Shay (Castings and Plans Purchased for future)
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littleevan99
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Re: 2.5" Scale 36 Ton Class B Shay

Post by littleevan99 »

Haven't made any progress building the Shay in the last year. I got busy doing some other projects for other people with a boiler for my grandpa's Ken Schroeder Shay being one of them, and getting my 2-10-2T running. I had some downtime at the end of the year after a procedure that gave me the time to tinker with the design some more and allowed me to finalize it. The current running design is a ground up rebuild of the frame as I determined that the frame I had already built is too nice to cut up and attempt to splice back together with a spacer. That led into me drawing it up as a 42T Shay, and while I like it my crankcase is a little too short to make it look right. It's even too short for the 36T model, but I played around with some dimensions and got the proportions correct. It's very close to the Lima drawings minus the engine length being a little too short. Proportionally it looks correct when compared to the real thing.

Below are some photos that show the 36T and 42T model as well as the finished engine with all the reverse linkage included.
36T Wagontop v35.png
36T Wagontop v35.png (465.42 KiB) Viewed 66844 times
36T Wagontop v35 Engine.png
36T Wagontop v35 Engine.png (715.71 KiB) Viewed 66844 times
36T Wagontop v35 firemans side.png
36T Wagontop v35 firemans side.png (444.79 KiB) Viewed 66844 times
Screenshot 2023-04-20 100327.png
Screenshot 2023-04-20 100327.png (615.73 KiB) Viewed 66844 times
Lastly, I 3D printed some patterns for the steam and sand domes. I haven't gotten around to finishing them up yet, but they're on my to do list.
1.5" scale CliShay
1.5" scale 2-10-2T
2.5" 36 Ton Shay under construction
YouTube: http://www.youtube.com/user/littleevan99
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littleevan99
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Crosshead Guides

Post by littleevan99 »

Started working on the Shay again, and to start I farmed out the reverse links and die blocks to a friend in the hobby who will wire EDM them and get them machined up nicely for me. On the home front I started on the crosshead guides, and below are some pictures of the facing operation to get them to the correct heights. These castings had some pretty hard spots on the bottoms near the edges where they get bolted down. I originally tried flycutting them but the flycutter kept deflecting when it got to the chilled spots, so the facemill came out and worked much better. Next up is to get a center drilled into them so I can indicate and drill the mounting holes. Then, I can make a jig to turn the tops and get them bored out. My goal for 2024 is to try and have the engine running on air at some point.
Attachments
IMG_2655.jpeg
IMG_2655.jpeg (142.62 KiB) Viewed 64890 times
IMG_2654.jpeg
IMG_2654.jpeg (73.06 KiB) Viewed 64890 times
IMG_2656.jpeg
IMG_2656.jpeg (130.27 KiB) Viewed 64890 times
1.5" scale CliShay
1.5" scale 2-10-2T
2.5" 36 Ton Shay under construction
YouTube: http://www.youtube.com/user/littleevan99
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littleevan99
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Joined: Mon Feb 24, 2014 8:04 pm
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Crosshead Guides

Post by littleevan99 »

Got the crosshead guides all machined up a few days ago, and they turned out great! I'd say they're on par with the crankcase casting in time to setup and machine. At some point I need to cut the reliefs for the connecting rods, and the mounting spots for the mounting bracket to the frame. Some day, but up next is the main bearings then the crank.
Attachments
IMG_2694.jpg
IMG_2694.jpg (541.37 KiB) Viewed 61998 times
IMG_2693.jpg
IMG_2693.jpg (492.43 KiB) Viewed 61998 times
Boring in the old Cincinnati Lathe. If I was doing this again I'd make a big boring bar out of some hardened drill rod to avoid the flex from the long stick out. I had some chatter after this that I took care of with a flex hone.
Boring in the old Cincinnati Lathe. If I was doing this again I'd make a big boring bar out of some hardened drill rod to avoid the flex from the long stick out. I had some chatter after this that I took care of with a flex hone.
IMG_2702.jpg (361.81 KiB) Viewed 61998 times
Drilling the holes for the cylinder studs.
Drilling the holes for the cylinder studs.
IMG_2684.jpg (430.35 KiB) Viewed 61998 times
Flycutting the mounting pad for the valve rod guide.
Flycutting the mounting pad for the valve rod guide.
IMG_2688.jpg (547.71 KiB) Viewed 61998 times
Setup I used for cutting the reversing shaft bracket mounts, and the pocket for the cylinder studs.
Setup I used for cutting the reversing shaft bracket mounts, and the pocket for the cylinder studs.
IMG_2691.jpg (553.51 KiB) Viewed 61998 times
1.5" scale CliShay
1.5" scale 2-10-2T
2.5" 36 Ton Shay under construction
YouTube: http://www.youtube.com/user/littleevan99
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Dick_Morris
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Re: 2.5" Scale 36 Ton Class B Shay

Post by Dick_Morris »

I'd make a big boring bar out of some hardened drill rod to avoid the flex from the long stick out.
My understanding is that there isn't a big difference in rigidity for different types of steel. Solid carbide bars are more rigid, as are steel bars that are a larger diameter. Another option is to mount the workpiece on the cross slide and mount the boring bar between centers.
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littleevan99
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Re: 2.5" Scale 36 Ton Class B Shay

Post by littleevan99 »

Dick_Morris wrote: Sun Jan 07, 2024 12:34 am
I'd make a big boring bar out of some hardened drill rod to avoid the flex from the long stick out.
My understanding is that there isn't a big difference in rigidity for different types of steel. Solid carbide bars are more rigid, as are steel bars that are a larger diameter. Another option is to mount the workpiece on the cross slide and mount the boring bar between centers.
I was leaning more towards a large diameter steel boring bar. I have one on hand, but it was about 3" too short.
1.5" scale CliShay
1.5" scale 2-10-2T
2.5" 36 Ton Shay under construction
YouTube: http://www.youtube.com/user/littleevan99
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