Building a Kitsap Caboose - Revision history

Dnevil: /* External Links */

2024-12-30T14:45:05Z

External Links

← Older revision		Revision as of 09:45, 30 December 2024
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	** [https://web.archive.org/web/20020407171348/http://kitsaplivesteamers.org/caboose.html 2002 Version of Caboose webpage, <i>Archive.org</i>]		** [https://web.archive.org/web/20020407171348/http://kitsaplivesteamers.org/caboose.html 2002 Version of Caboose webpage, <i>Archive.org</i>]
	* [http://discoverlivesteam.com/2016/07/29/realistic-caboose-door-knob-on-the-cheap/ "Realistic Caboose Door Knob on the Cheap", <i>DiscoverLiveSteam.com</i>]		* [http://discoverlivesteam.com/2016/07/29/realistic-caboose-door-knob-on-the-cheap/ "Realistic Caboose Door Knob on the Cheap", <i>DiscoverLiveSteam.com</i>]
			* [https://www.chaski.org/homemachinist/viewtopic.php?t=113951 "Kitsap Steel Caboose $400", <i>Chaski.org</i>]

Dnevil: /* External Links */

2016-10-16T21:55:28Z

External Links

← Older revision		Revision as of 16:55, 16 October 2016
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	* [http://kitsaplivesteamers.org/content.aspx?page_id=22&club_id=96970&module_id=149171 Kitsap Live Steamers S.P. Caboose webpage]		* [http://kitsaplivesteamers.org/content.aspx?page_id=22&club_id=96970&module_id=149171 Kitsap Live Steamers S.P. Caboose webpage]
	** [https://web.archive.org/web/20020407171348/http://kitsaplivesteamers.org/caboose.html 2002 Version of Caboose webpage, <i>Archive.org</i>]		** [https://web.archive.org/web/20020407171348/http://kitsaplivesteamers.org/caboose.html 2002 Version of Caboose webpage, <i>Archive.org</i>]
			* [http://discoverlivesteam.com/2016/07/29/realistic-caboose-door-knob-on-the-cheap/ "Realistic Caboose Door Knob on the Cheap", <i>DiscoverLiveSteam.com</i>]

Dnevil: /* Hand Rails */

2016-02-23T04:14:49Z

Hand Rails

← Older revision		Revision as of 23:14, 22 February 2016
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	<gallery widths="300px" heights="300px" perrow="2">		<gallery widths="300px" heights="300px" perrow="2">
	File:KitsapCabooseHandrail.jpg\|I wanted a nice wide-radius curve on the handrails. I found a small pully with a ~~grove~~ that was perfect for 1/8 inch diameter steel rod.		File:KitsapCabooseHandrail.jpg\|I wanted a nice wide-radius curve on the handrails. I found a small pully with a groove that was perfect for 1/8 inch diameter steel rod.
	</gallery>		</gallery>

Dnevil: /* Brake Wheel */

2016-02-23T04:13:59Z

Brake Wheel

← Older revision		Revision as of 23:13, 22 February 2016
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	File:KitsapCabooseBrakeStandFront.jpg\|The front side of the brake stand.		File:KitsapCabooseBrakeStandFront.jpg\|The front side of the brake stand.
	File:KitsapCabooseBrakeStandFinished.jpg\|The brake stand has been painted and installed. Four 5-40 by 3/4 inch bolts secure the brake stand to the bumper.		File:KitsapCabooseBrakeStandFinished.jpg\|The brake stand has been painted and installed. Four 5-40 by 3/4 inch bolts secure the brake stand to the bumper.
			</gallery>

			== Hand Rails ==

			<gallery widths="300px" heights="300px" perrow="2">
			File:KitsapCabooseHandrail.jpg\|I wanted a nice wide-radius curve on the handrails. I found a small pully with a grove that was perfect for 1/8 inch diameter steel rod.
	</gallery>		</gallery>

Dnevil: /* Painting and Lettering */

2016-01-16T16:13:25Z

Painting and Lettering

← Older revision		Revision as of 11:13, 16 January 2016
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	<gallery widths="300px" heights="300px" perrow="2">		<gallery widths="300px" heights="300px" perrow="2">
	File:KitsapCabooseSprayPaint.jpg\|I found this ~~"Van Sickle"~~ brand of enamel spray paint at a farm and ranch store named "Atwoods" in Greenville, Texas. Only the red and white was used on the caboose; yellow vinyl was used for the large "Santa Fe" logo instead.		File:KitsapCabooseSprayPaint.jpg\|I found this [http://www.vansicklepaint.com VanSickle] brand of enamel spray paint at a farm and ranch store named "Atwoods" in Greenville, Texas. Only the red and white was used on the caboose; yellow vinyl was used for the large "Santa Fe" logo instead.
	File:RustoleumComfortGripSprayCanPistolGrip.jpg\|I highly recommend using a spray can pistol grip, such as this Rustoleum "Comfort Grip". This will help you make nice even coats of paint.		File:RustoleumComfortGripSprayCanPistolGrip.jpg\|I highly recommend using a spray can pistol grip, such as this Rustoleum "Comfort Grip". This will help you make nice even coats of paint.
	File:KitsapCaboosePrimerPaint.jpg\|The car body was removed to an outdoor table where it was sprayed liberally with "Easy Off Oven Cleaner" to degrease the surface before painting. The degreaser was washed off thoroughly with water. Self-etching primer is then applied to the dry surface. The two different colors of primer resulted from running out of the gray and switching to a darker color.		File:KitsapCaboosePrimerPaint.jpg\|The car body was removed to an outdoor table where it was sprayed liberally with "Easy Off Oven Cleaner" to degrease the surface before painting. The degreaser was washed off thoroughly with water. Self-etching primer is then applied to the dry surface. The two different colors of primer resulted from running out of the gray and switching to a darker color.

Dnevil at 16:20, 1 January 2016

2016-01-01T16:20:26Z

Dnevil: /* Frame */

2016-01-01T16:18:52Z

Frame

← Older revision		Revision as of 11:18, 1 January 2016
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	=== Frame ===		=== Frame ===

	<gallery widths="400px" perrow="2">		<gallery widths="400px" heights="400px" perrow="2">
	File:Kitsap Live Steamers Caboose 1.jpg\|Laying out the base and other parts for the [[Kitsap Live Steamers]] caboose kit. Photo by [[Daris A Nevil]], April 2015.		File:Kitsap Live Steamers Caboose 1.jpg\|Laying out the base and other parts for the [[Kitsap Live Steamers]] caboose kit. Photo by [[Daris A Nevil]], April 2015.
	File:Kitsap Live Steamers 2.jpg\|The floor plates have been welded to the side beams. The center beam and bolster supports have been attached as well. The end beam has been welded to the end of the floor and the coupler pocket. The half rounds were previously brazed on the end beam. After looking at the prototypes closer I believe the end beam should have been turned around, with the flat facing out. It was difficult to tell from the drawings which way it was supposed to be mounted.		File:Kitsap Live Steamers 2.jpg\|The floor plates have been welded to the side beams. The center beam and bolster supports have been attached as well. The end beam has been welded to the end of the floor and the coupler pocket. The half rounds were previously brazed on the end beam. After looking at the prototypes closer I believe the end beam should have been turned around, with the flat facing out. It was difficult to tell from the drawings which way it was supposed to be mounted.

Dnevil: /* Frame */

2016-01-01T16:18:31Z

Frame

← Older revision		Revision as of 11:18, 1 January 2016
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	=== Frame ===		=== Frame ===

	<gallery ~~heights~~="400px" perrow="2">		<gallery widths="400px" perrow="2">
	File:Kitsap Live Steamers Caboose 1.jpg\|Laying out the base and other parts for the [[Kitsap Live Steamers]] caboose kit. Photo by [[Daris A Nevil]], April 2015.		File:Kitsap Live Steamers Caboose 1.jpg\|Laying out the base and other parts for the [[Kitsap Live Steamers]] caboose kit. Photo by [[Daris A Nevil]], April 2015.
	File:Kitsap Live Steamers 2.jpg\|The floor plates have been welded to the side beams. The center beam and bolster supports have been attached as well. The end beam has been welded to the end of the floor and the coupler pocket. The half rounds were previously brazed on the end beam. After looking at the prototypes closer I believe the end beam should have been turned around, with the flat facing out. It was difficult to tell from the drawings which way it was supposed to be mounted.		File:Kitsap Live Steamers 2.jpg\|The floor plates have been welded to the side beams. The center beam and bolster supports have been attached as well. The end beam has been welded to the end of the floor and the coupler pocket. The half rounds were previously brazed on the end beam. After looking at the prototypes closer I believe the end beam should have been turned around, with the flat facing out. It was difficult to tell from the drawings which way it was supposed to be mounted.

Dnevil: /* Frame */

2016-01-01T16:18:10Z

Frame

← Older revision		Revision as of 11:18, 1 January 2016
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	=== Frame ===		=== Frame ===

	<gallery ~~widths="400px"~~ heights="400px" perrow="2">		<gallery heights="400px" perrow="2">
	File:Kitsap Live Steamers Caboose 1.jpg\|Laying out the base and other parts for the [[Kitsap Live Steamers]] caboose kit. Photo by [[Daris A Nevil]], April 2015.		File:Kitsap Live Steamers Caboose 1.jpg\|Laying out the base and other parts for the [[Kitsap Live Steamers]] caboose kit. Photo by [[Daris A Nevil]], April 2015.
	File:Kitsap Live Steamers 2.jpg\|The floor plates have been welded to the side beams. The center beam and bolster supports have been attached as well. The end beam has been welded to the end of the floor and the coupler pocket. The half rounds were previously brazed on the end beam. After looking at the prototypes closer I believe the end beam should have been turned around, with the flat facing out. It was difficult to tell from the drawings which way it was supposed to be mounted.		File:Kitsap Live Steamers 2.jpg\|The floor plates have been welded to the side beams. The center beam and bolster supports have been attached as well. The end beam has been welded to the end of the floor and the coupler pocket. The half rounds were previously brazed on the end beam. After looking at the prototypes closer I believe the end beam should have been turned around, with the flat facing out. It was difficult to tell from the drawings which way it was supposed to be mounted.

Dnevil: /* Frame */

2016-01-01T16:10:11Z

Frame

← Older revision		Revision as of 11:10, 1 January 2016
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	=== Frame ===		=== Frame ===

	<gallery widths="400px" heights="400px">		<gallery widths="400px" heights="400px" perrow="2">
	File:Kitsap Live Steamers Caboose 1.jpg\|Laying out the base and other parts for the [[Kitsap Live Steamers]] caboose kit. Photo by [[Daris A Nevil]], April 2015.		File:Kitsap Live Steamers Caboose 1.jpg\|Laying out the base and other parts for the [[Kitsap Live Steamers]] caboose kit. Photo by [[Daris A Nevil]], April 2015.
	File:Kitsap Live Steamers 2.jpg\|The floor plates have been welded to the side beams. The center beam and bolster supports have been attached as well. The end beam has been welded to the end of the floor and the coupler pocket. The half rounds were previously brazed on the end beam. After looking at the prototypes closer I believe the end beam should have been turned around, with the flat facing out. It was difficult to tell from the drawings which way it was supposed to be mounted.		File:Kitsap Live Steamers 2.jpg\|The floor plates have been welded to the side beams. The center beam and bolster supports have been attached as well. The end beam has been welded to the end of the floor and the coupler pocket. The half rounds were previously brazed on the end beam. After looking at the prototypes closer I believe the end beam should have been turned around, with the flat facing out. It was difficult to tell from the drawings which way it was supposed to be mounted.

← Older revision		Revision as of 11:20, 1 January 2016
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	=== Body ===		=== Body ===

	<gallery widths="400px" heights="400px">		<gallery widths="400px" heights="400px" perrow="2">
	File:Kitsap Live Steamers Caboose 5.jpg\|Angle iron has been stitched onto the end wall, which is now positioned for test fitting. I used small brass hinges for the doors, and brazed them to the steel. In retrospect I wish I had used rivets.		File:Kitsap Live Steamers Caboose 5.jpg\|Angle iron has been stitched onto the end wall, which is now positioned for test fitting. I used small brass hinges for the doors, and brazed them to the steel. In retrospect I wish I had used rivets.
	File:Kitsap Live Steamers Caboose 6.jpg\|Preparing for welding the four sides together. The clamps are from Harbor Freight, and were made for wood projects, but I found they worked quite well for this project (and I already had them).		File:Kitsap Live Steamers Caboose 6.jpg\|Preparing for welding the four sides together. The clamps are from Harbor Freight, and were made for wood projects, but I found they worked quite well for this project (and I already had them).
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	=== Roof ===		=== Roof ===

	<gallery widths="400px" heights="400px">		<gallery widths="400px" heights="400px" perrow="2">
	File:KitsapCabooseBatteryBox8.jpg\|The Kitsap kit ships with three roof sections: a long section, the roof for the cupola, and the short section behind the cupola. I wanted a removable roof so that small children can ride in the caboose, so I took the advice given in the instructions to cut the long roof section into two parts as shown in this photo. This is where the Milwaukee metal cutting circular saw came in handy.		File:KitsapCabooseBatteryBox8.jpg\|The Kitsap kit ships with three roof sections: a long section, the roof for the cupola, and the short section behind the cupola. I wanted a removable roof so that small children can ride in the caboose, so I took the advice given in the instructions to cut the long roof section into two parts as shown in this photo. This is where the Milwaukee metal cutting circular saw came in handy.
	File:KitsapCabooseBatteryBox9.jpg\|I used a low-cost sheet metal brake from Harbor Freight to bend all the roof sections. Here is the long roof section after cutting into two parts. This is the longest section and the hardest to bend in this jig. I used all the C-clamps I could round up. The bending operation worked smoother by spraying lubricant (WD-40) on the sheet metal where it was being bent.		File:KitsapCabooseBatteryBox9.jpg\|I used a low-cost sheet metal brake from Harbor Freight to bend all the roof sections. Here is the long roof section after cutting into two parts. This is the longest section and the hardest to bend in this jig. I used all the C-clamps I could round up. The bending operation worked smoother by spraying lubricant (WD-40) on the sheet metal where it was being bent.
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	=== Battery Box ===		=== Battery Box ===

	<gallery widths="400px" heights="400px">		<gallery widths="400px" heights="400px" perrow="2">
	File:KitsapLiveSteamersCabooseBatteryBox.jpg\|I decided to model the caboose after the Santa Fe caboose #999187 located at the [[Comanche & Indian Gap Railroad]] railroad. I needed a battery box in place of the tool cellar. Here my nephew Stephen is setting up to weld the box together. Note that this battery box was built from scratch, and is not part of the Kitsap Live Steamer's kit.		File:KitsapLiveSteamersCabooseBatteryBox.jpg\|I decided to model the caboose after the Santa Fe caboose #999187 located at the [[Comanche & Indian Gap Railroad]] railroad. I needed a battery box in place of the tool cellar. Here my nephew Stephen is setting up to weld the box together. Note that this battery box was built from scratch, and is not part of the Kitsap Live Steamer's kit.
	File:KitsapCabooseBatteryBox1.jpg\|The dimensions of the box is 6-1/2 inches deep, 4-1/2 inches deep, and 3-3/4 inches high. After installation on the chassis the box looked a bit over-sized, so you may need to adjust for your taste. The battery box is large enough to hold a standard gel-cell battery. The battery will power the lights on the caboose. The two front braces were cut from 1/2 inch square steel tubing. It is cut down to about 1/8 inch high, so that the side ribs show prominently like the prototype.		File:KitsapCabooseBatteryBox1.jpg\|The dimensions of the box is 6-1/2 inches deep, 4-1/2 inches deep, and 3-3/4 inches high. After installation on the chassis the box looked a bit over-sized, so you may need to adjust for your taste. The battery box is large enough to hold a standard gel-cell battery. The battery will power the lights on the caboose. The two front braces were cut from 1/2 inch square steel tubing. It is cut down to about 1/8 inch high, so that the side ribs show prominently like the prototype.
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	=== Safety Chains ===		=== Safety Chains ===

	<gallery widths="400px" heights="400px">		<gallery widths="400px" heights="400px" perrow="2">
	File:KitsapCabooseBatteryBox11.jpg\|The instructions that came with the kit did not mention safety chains, so I had to decide where to attach the two chain hooks. I settled on welding a 1 inch by 1 inch steel angle on the center body beam, just behind the coupler attachment bolt. The eye bolts selected have long shanks, such that the eyes will be even with the end of the center beam. I later drilled holes for the eye shanks, but I wish I had drilled these holes before I welded the mount in place.		File:KitsapCabooseBatteryBox11.jpg\|The instructions that came with the kit did not mention safety chains, so I had to decide where to attach the two chain hooks. I settled on welding a 1 inch by 1 inch steel angle on the center body beam, just behind the coupler attachment bolt. The eye bolts selected have long shanks, such that the eyes will be even with the end of the center beam. I later drilled holes for the eye shanks, but I wish I had drilled these holes before I welded the mount in place.
	File:KitsapCabooseUnderframe.jpg\|The underframe with primer paint.		File:KitsapCabooseUnderframe.jpg\|The underframe with primer paint.
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	=== Interior Paint ===		=== Interior Paint ===

	<gallery widths="400px" heights="400px">		<gallery widths="400px" heights="400px" perrow="2">
	File:ValsparKoiPondSatin15310.jpg\|Valspar "Koi Pond Satin", part number 15310, is a close match to the light green color found in many prototype cabooses. ([http://www.thenewsleaders.net/2013/03/28/ub222-sartell-man-keeps-alive-legend-lore-of-trains/ Take a look at the photos here.])		File:ValsparKoiPondSatin15310.jpg\|Valspar "Koi Pond Satin", part number 15310, is a close match to the light green color found in many prototype cabooses. ([http://www.thenewsleaders.net/2013/03/28/ub222-sartell-man-keeps-alive-legend-lore-of-trains/ Take a look at the photos here.])
	File:KitsapCabooseInteriorPaint.jpg\|The caboose with a fresh coat of interior paint. This photo was taken with an iPhone in low light. The color is actually more green than the blue shown here.		File:KitsapCabooseInteriorPaint.jpg\|The caboose with a fresh coat of interior paint. This photo was taken with an iPhone in low light. The color is actually more green than the blue shown here.
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	=== Rounded Corners ===		=== Rounded Corners ===

	<gallery widths="400px" heights="400px">		<gallery widths="400px" heights="400px" perrow="2">
	File:KitsapCabooseCorner1.jpg\|The corners of the caboose are to be rounded (but not the corners of the cupola). This is accomplished by first filling the corners with Bondo, as shown here.		File:KitsapCabooseCorner1.jpg\|The corners of the caboose are to be rounded (but not the corners of the cupola). This is accomplished by first filling the corners with Bondo, as shown here.
	File:KitsapCabooseCorner2.jpg\|The corner is rounded by sanding. I used a grinder with an 60 grit sanding disk. Use gentle pressure and take your time.		File:KitsapCabooseCorner2.jpg\|The corner is rounded by sanding. I used a grinder with an 60 grit sanding disk. Use gentle pressure and take your time.
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	=== Mounting Brackets ===		=== Mounting Brackets ===

	<gallery widths="300px" heights="300px">		<gallery widths="300px" heights="300px" perrow="2">
	File:KitsapCabooseAirTankBracket.jpg\|The air brake reservoir is supported by a section of 1/2 by 1/2 inch angle steel welded on edge on the center beam. You should provide more space between the battery box and the reservoir bracket than shown here.		File:KitsapCabooseAirTankBracket.jpg\|The air brake reservoir is supported by a section of 1/2 by 1/2 inch angle steel welded on edge on the center beam. You should provide more space between the battery box and the reservoir bracket than shown here.
	File:KitsapCabooseAirReleaseSwitchMountingBracket.jpg\|A mounting bracket for the release switch from 2 by 2 inch steel angle, and welded to the edge of the underframe.		File:KitsapCabooseAirReleaseSwitchMountingBracket.jpg\|A mounting bracket for the release switch from 2 by 2 inch steel angle, and welded to the edge of the underframe.
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	<gallery widths="300px" heights="300px">		<gallery widths="300px" heights="300px" perrow="2">
	File:KitsapCabooseSprayPaint.jpg\|I found this "Van Sickle" brand of enamel spray paint at a farm and ranch store named "Atwoods" in Greenville, Texas. Only the red and white was used on the caboose; yellow vinyl was used for the large "Santa Fe" logo instead.		File:KitsapCabooseSprayPaint.jpg\|I found this "Van Sickle" brand of enamel spray paint at a farm and ranch store named "Atwoods" in Greenville, Texas. Only the red and white was used on the caboose; yellow vinyl was used for the large "Santa Fe" logo instead.
	File:RustoleumComfortGripSprayCanPistolGrip.jpg\|I highly recommend using a spray can pistol grip, such as this Rustoleum "Comfort Grip". This will help you make nice even coats of paint.		File:RustoleumComfortGripSprayCanPistolGrip.jpg\|I highly recommend using a spray can pistol grip, such as this Rustoleum "Comfort Grip". This will help you make nice even coats of paint.
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	=== Brake Wheel ===		=== Brake Wheel ===

	<gallery widths="300px" heights="300px">		<gallery widths="300px" heights="300px" perrow="2">
	File:HarryHaasSteelCabooseLiveSteamNovDec1995.jpg\|A closeup of the brake wheel of Harry Haas' steel caboose featured on the cover of [[Live Steam Magazine]], November/December 1995. I used this basic design for the Kitsap caboose.		File:HarryHaasSteelCabooseLiveSteamNovDec1995.jpg\|A closeup of the brake wheel of Harry Haas' steel caboose featured on the cover of [[Live Steam Magazine]], November/December 1995. I used this basic design for the Kitsap caboose.
	File:KitsapCabooseBrakeWheelStand.jpg\|The brake wheel stand is cut from 1/4 by 1/4 inch angle steel. The bevels were cut on a mill.		File:KitsapCabooseBrakeWheelStand.jpg\|The brake wheel stand is cut from 1/4 by 1/4 inch angle steel. The bevels were cut on a mill.