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Stuhr
Museum Railcar Restoration Shop:
Florence & Cripple Creek #65 January 17th,
2002 
Right side, B end. Side sill and end beam have eroded by rot causing
body to settle unevenly on steel frame.
January 17th,
2002 
Right side of body showing water damage to compression truss over
needle beam.
January 17th,
2002 
Close-up of butt splice between remaining side sill and replacement
made of 2 by X construction lumber. No gussets were installed and
all of the tenons were loose.
January 17th,
2002 
Seats and stoves stripped from B end of car. The blocked windows
on right were removed when stoves were installed.
January 17th,
2002 
Detail of trim in corner below the clerestory. Quarter sawn White
Oak and small "egg and dart" trim at right are original,
while the trim and veneer at left are not.
January 17th,
2002
Windows 12-16. Walkover seats were fabricated by museum in 1976.
January 30th,
2002 
Removal of floor in progress. The original floor was covered with
¾" particle board and ¾" T&G Red Oak.
February 2002 
Car body lifted and blocked over steel frame showing deformation
of steel.
June 28th, 2002 
Side view of car body inside new restoration shop on jack stands
with the steel frame removed.
June 28th, 2002 
Steel frame removed and de-trucked. Note lack of cross members and
gussets. Body was attached by welds on each end of the top bolster
plate remaining in body.
June 29th, 2002 
Preparing to block body at proper the height on a passenger truck
to begin measuring for the platforms.
July 9th, 2002 
DO NOT TRY THIS
AT HOME!
Transporting
Douglas fir timbers from supplier to shop. The top bundle contains
40-foot long structural members and the bottom bundle contains flooring. July 9th, 2002 
The 40 foot long
bundle stripped and rolled into shop on a pair of D&RG freight
trucks. Preparing to sort and begin layout of frame timbers.
July 30th, 2002 
Side, intermediate, and center sills with mortises cut to accept
intermediate blocking.
July 30th, 2002 
Intermediate blocking cut to length and tenoned. The longitudinal
sill and intermediate blocking are Douglas Fir.
August 1st,
2002 
Tenons cut on ends of sills to mate with end sill.
August 1st,
2002 
Jim Green beginning to assemble frame for test fit.
August 6th,
2002 
Drilling mortises on inside face of end beam to mate with tenons
on frame sills. Mortises will be squared by hand chisel. End Beams
are White Oak.
August 6th,
2002 
Frame assembled. The over all length is 39' 6" and 96"
wide. The frame is currently held together with 11, 5/8", tie
rods running side to side.
August 23rd,
2002 
Side frames and outer transoms of truck frames being test fit. All
of the wood components are white oak.
August 27th,
2002 
Inner transoms and brake hanger beams added.
August 27th,
2002 
The brake hanger beam brace shown being marked for cutting. The
mortises and dados are cut individually adjust for variation in
stock dimensions and to insure a tight fit.
August 27th,
2002 
Wooden portion of truck frame shown completely assembled. Frame
will be disassembled for painting and to install the metal components.
September 9th,
2002 
The truck frame has been reassembled with side plates, tie rods,
pedestals and equalizers. The pedestals have been located in tram
and are being attached.
September 19th,
2002 
Axles, journal boxes, bearings and coil springs in place. Opening
in middle will accept truck bolster, spring plank and elliptic springs.
December 18th,
2002 
Platform components form Florence and Cripple Creek #60, borrowed
from the Friends of the Cumbres and Toltec Scenic Railroad, in position
to begin continue design work on platforms. These pieces confirmed
that the car had a bent drawbar and the depth of the platform.
April 17th,
2003 
The white oak timbers for constructing the platforms are on hand,
and the test platform has been constructed. The large timbers in
foreground will become the end beams and measure 7"x9"x120".
May 15th, 2003 
Construction on platforms is well under way. The draft sills, draft
beam, platform sills, and platform sill extensions are cut and in
place. The platform sill extension ends will be cut to the final
contour after the platform beam is cut and in place.
June 4th, 2003
Cutting the platform beam on the 42" band saw with a 2",
1.3 pitch, blade. The beams were laid out, drilled, mortised and
fitted in square form before the tapers were cut.
June 6th, 2003 
Side view of platform with all of the wooden components cut and
in place.
June 6th, 2003 
End view of platform. The scroll work on the platform sill extension
will be cut when the platform is disassembled to install the bolster
tie rods.
June 18th, 2003 
The bolster tie rods are being installed. Of six rods on each end
four hold the draft beam, and two hold the platform beam, against
the upper bolster plate.
June 18th, 2003 
Platform as viewed from the top showing all the tie rods in place.
June 18th, 2003 
Carrier iron and coupler body in place to check measurements and
clearance under platform beam. (It cleared!)
June 27th, 2003 
The test platform has been laid out in exploded form for Member's
Only, Behind the Scenes Night.
June 27th, 2003 
Test platform from back side showing mortises.
July 16th, 2003 
Truss rods, queen posts and related hardware installed and supporting
body.
July 16th, 2003 
Close-up of truss rod between queen posts showing turnbuckle and
the string line used for bending the truss rods parallel to body.
July 16th, 2003 
Platform railings test fitted on platform beams ready for welding.
July 16th, 2003 
Close-up of needle beam showing main queen posts and braces (fabricated)
needle beam queen post (cast) and truss rod.
September 17th,
2003 
The lower portion of the body and been lowered onto it's trucks
and rolled outside for the first time.
October 7th,
2003 
The sub-flooring is complete and the truss plates have been cut
and fit into the side walls. To add rigidity of the body a layer
of 5/8" Baltic Birch plywood was added to the floor of the
car body.
October 7th,
2003 
The wall blocking is being cut and fit into the side walls. The
original had blocking in the first five openings. The entire wall
will be blocked to add additional strength to compensate for the
larger growth rings in the wood currently available.
October 21,
2003 
The truss plates have been removed to apply the glue blocks to the
back side of the wall blocking. The darker glue block are originals
savaged from the coach, most are poplar but oak, fir and black walnut
are also present.
December 28,
2003 
New body ready for old roof
Getting ready to lift roof off old body
Roof lifted off old body
Setting roof on new body
January 15,
2004 
Mating old roof to new body
February 15,
2004 
Siding on body, roof repairs underway
February 29,
2004 
Roof repairs
March 30, 2004 
New metal on roof
Clear story roof repairs
June 1, 2004 
Interior work started
June 6, 2004 
Painting of exterior started
August 15, 2004 
Exterior view showing car painted and ready for lettering
August 20, 2004 
Windows installed with hardware
August 27, 2004 
Interior view starting to install window shades
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