FEF-1 Union Pacific Project-Front Pilot Complete-Update 9/25

Love it ! Coming along well.

Wow that's cool good work

That is crazy good work.  Looks great!

You and Ron got some brass skills man!

Love to see stuff like this. Great job!

See above for partial pilot assembly update.  Should have pumps mounted tonight if all goes well.  

Looks awesome! Will be following this closely. Keep the updates coming.

Great job.

-Mario

Excellent!!  Looking forward to seeing your progress.  Thanks. Bill

9/16 Update: Pumps installed.

 

Weaver pump left, PSC pump right.  I choose to use the PSC pumps.

 

 

I had to move the pumps slightly away from the locomotive frame.  I used some brass stock to make mounts.  Plan was to solder these to the frame.

  

 

I cleaned, clamped, fluxed, and soldered the mounts to the frame.  Removed clamp and the pumps fell to the floor-they didn't stick.  Must have done that 6 more times before I gave up.  Thought I was doing something wrong and couldn't figure it out.  The frame must be bronze or something.  Wished I'd realized it earlier.  The frame rail wasn't 'flat' which didn't help either (tried filing but impossible to keep it perpendicular to frame). 

 

 Eventually, I got the pumps mounted.  I had to make another bracket not seen in the picture.  If the pumps fall off again, I'll drill a hole in bracket/frame and screw together-which is what I'd done today but I was out of the screw I needed. 

 

  

 

With the pumps mounted, I could solder up the shields/guards.  I cut these out the other day.

  

 Both sides assembled.

 

 

A little body putty to smooth the seams.  Will sand smooth tomorrow.  I'll also need to trim the height of the shield prior to final install.

 

 

 

Here's an idea of how they'll look installed, prior to trimming.  Not even close to the final position yet, I made them taller and slightly wider because I wasn't sure of the position of the pumps.  Nothing blows more than making a part twice or more because it wasn't the right size-easier to trim to fit.

  

 

The shields will attach to the "M" in the center.

 

  

  

 

Finally, I added some piping and details, more to come.   

 

 

Should wrap this up tomorrow night, a few details to add.  Then I'll make a set of rods, box the area under the cab, mount the Seller's exhaust, and run the 'sewer' pipe.

 

Anyone know where I can buy 'zero rake' drill bits for brass?  No store locally carries them. 

Here's the first attempt, it was a struggle:

 

  

It was a night like Ron and I understand-nothing but practice runs!  

 

Just after this picture, the pump fell off again.  I've already taken the front end apart and will drill/tap hole to screw pumps to frame.  The frame can't be brass, I can't get solder to stick.  With the screw, it won't matter.

 

While I have it apart (8th time), I'm rethinking this.  Learned a lot from the 'practice runs' to make it better.  

 

1. Shields from thinner brass.  

2. Find a better way to mount shields/measure angle.

3. Different pump mounts.

4. Add detail with boiler removed. 

5. Drink more beer if it falls apart again.

 

May do #5 either way...

Looks awesome.

Thanks!

 

I'm more than ready to finish up the front end.  

 

Ready to work on something else-Seller's exhaust.

Aaron, and on it goes. Great work. I'm drinking a beer for you now.

 

Ron

Great work! You sir are courageous and talented.

9/24 Shields Installed & Reworked Pilot Assembly.

 

Today started with some details.

 

Added 'wings' to the cow catcher (no idea what the tech name is?):

 

 

Cut from brass sheet....

 

 

...and soldered in place.

 

 

Next I focused on the pilot/mounts.  Cut new rails from brass sheet, drilled holes, and tapped for 2-56 screws.

 

 

The first side:

 

Second side:

 

Cut a brass piece for mounting the cow catcher to the frame rails, drilled/tapped holes and soldered-overkill, I'm kind of that way!

 

 

 

I was very careful to get it centered.

 

 

A small piece of brass covers the underside.

 

 

The mounted assembly:

 

 

Solder together the filters:

 

 

 

 

I reused my original pump shields.  They needed to be widened slightly, so I cut a brass piece, soldered together and cut off the excess. 

 

 

Left is widened piece, right is the original.

 

Then it was time to mount the shields.  I'm a patient person, but I hate to admit some nasty words were said in the shop today.  It was extremely difficult to keep them perfectly in place and apply solder.  I cheated; used a small dab of super glue to hold them while applying solder.  Didn't really think about how I was going to mount them prior.  I finally got them mounted, but it was a battle to the end.  I won...

 

 

Tomorrow I'll add the filter details back in place, make/install the center of the shields and add a brace.  This part has been a real challenge and I'm ready to work on something else.

Nice job, it will be worth it in the end. You have more talent then me. 

Aaron, it is really looking great.  The effort, talent and love of the hobby show and the end result exhibits all.

 

Jesse

Looking Really fine sir

9/25 Front End Complete

 

Glad you boys like it, it's been a long project!

 

Today, I finished the front end.  Here's the last of it.

 

 Reused the original brace I made.  I shortened it slightly to fit.  Left side soldered in place.

 

The other side:

 

 

Added the brace:

 

 

Installed the filters I made yesterday:

 

 

 

 

Installed the steps from the Weaver pilot.  

 

 

And finally, the front end is complete!

  

 

There's a lot of time in the pilot assembly.  I've had it apart at least 8 different times-stuff I've changed or literally parts falling off.  I knew when I started building an early FEF-1 the front pilot assembly would be the difficult part.  It didn't disappoint!  There were challenges along the way, but I'm happy with the results.  Best of all, I know how to build one for another future UP project.

 

IMHO, it looks like an FEF-1.  

 

Next project is adding boiler details.

Wow!

Thanks Ron.  I'm looking forward to another Cab Forward update!

 

Just came in from the shop.  Things are progressing quicker now, I have the whistle, check valves/plumbing installed, and several additional steps.

 

 

Aaron,

Check your email. Time sensitive.