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The brace/pin and shackle holes in the front flue tube sheet are blanked off. In order to ensure a good fit for the flue tubes, the holes on both the front and rear flue tube sheets are bored using air tools, then cleaned well with a degreaser. This is another important step of preparation of the surfaces before the flue tubes are placed in the holes and rolled. During this time, the inside of the boiler is cleaned and painted with a special protective product.
PHOTO: BOB YUILL
Another time consuming task starts: the lapping of every seat of all gaskets around the boiler. This includes the turret, throttle valve, delivery pipes, check valves and many more. Using three different grinding compound grades, coarse, medium and fine, the two matching parts are rubbed together until the surfaces appear very smooth. This task is performed to obtain a perfect seal between the seats of the two matching parts.
PHOTO: STEVE JENSEN
The flue tubes arrive in the shop and 258 tubes are cut to size. Due to the shape of the flue sheets, every tube has a different length. As they are measured and cut, the flue tubes are placed in the boiler and by August, they are all in place. Using special air tools, the tube ends are rolled so that they stay in place.
PHOTO: STEVE JENSEN
September is an important month for all involved in the restoration process. The final hydro test is performed. Water under 225 pounds of pressure is held inside the boiler. By now, all leaks have been repaired and the boiler of Locomotive 98 passes the hydro test. Now everything else can be installed and put back in place, including the engine's frame and cab.
PHOTO: STEVE JENSEN
During the month of October, work on the engine's frame begins: cleaning, painting and needed repairs are finished. The frame is then placed back under the boiler. During the last three months of the year, all sorts of tasks are completed. The new ash pan arrives in the shop, and it has to be fitted onto the frame. This requires a considerable amount of cutting, bending and welding.
PHOTO: GISELA VAZQUEZ
Every mark on the old smokebox is transferred to the new one; holes are made for the stack, handrails, blower and builder's plates. Due to severe wear, the casting at the point where the delivery pipes connect to the steam chest need to be built up. More lapping of gasket seats goes on.
PHOTO: STEVE JENSEN
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