Needle Beam Assembly Car 0252/470
Posted: Wed Mar 23, 2016 3:30 pmThere are many challenges in the restoration of a car when you have little and sometime no reference to the details of construction in the year 1889. We had the original needle beams which were removed during the car tear down but their ends had deteriorated. Craig McMullen was successful in remaking the ends for both beams from white oak. To enhance the structural abilities of the beams a 1-1/2” x 3/8” steel channel was routed into the top of each beam. The beam channel rests directly against the steel angles of the center sills when assembled. The intermediate and outside sills have a 1-3/8” steel spacer to make up the difference between the wood sills and the beam. The beam is secured to each of the interior sills by a 3/4” Grade 8 bolt. Fortunately, we were able to find an actual resource to compare with in our backyard, that being a sister car, last numbered 0250 resting on cribbing at the Colorado Railroad Museum (CRRM). It is the only car of the same purchased lot by D&RG that was not salvaged, thus a reference with physical substance as it still contains all of the undercar intricacies. The first picture is an enlargement from the side view of car 466, the fifth car in the manufacturing series, taken by Pullman as a manufacturers’ photograph prior to shipment from the Detroit factory. We have used this photo enlargement to confirm the authenticity of needle beam construction on car 0250. During our visit to the CRRM the second photo is of a needle beam taken from under that car. From details obtained, drawings were made for manufacture of both standards and queen posts, images 3 thru 9. With a great deal of help from Marshall Smith who, from his shop in San Marcos, Texas, used the drawings to fabricated duplicates of both the standards and queen posts. The remaining photos show the process of assembly with the standards supporting the needle beam truss rod and the fitting of queen posts to the beam. Compare the two pictures of the original and the restored; see if you can tell the difference? Thanks for the fine work done by Marshall Smith, Craig McMullen and the COS restoration team in the assembly of the car needle beams. Photos provided by Tom Simco.
470 Needle Beam & Queen Posts.pdf- Enlargement of Car 466 side view showing a complete needle beam. The two car truss rods are shown in the lower part of the picture going over the queen post. On the needle beam you will see the two standards which support the needle beam truss rod, tightening is done by a nut located on beam cap plate at each end.
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- This picture is taken from a side view of car 0250, showing the actual under side of the needle beam, its truss rod standards and queen posts. Measurements were taken from these standards and queen posts to replicate both for car 0252/470.
- Detail 1 Standard.pdf
- This shows a side view of the needle beam standard and measurements for its construction. There are two of these standards which support the truss rod for the beam. Note the pins in two of the hole placements, these keep the body of the standard from rotating while under tension.
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- Detail 2 Standard.pdf
- This is a top view of the standard, pins are located in two of the opposing corners the other two are holes for lag bolts which mount the standard to the beam. The dashed line represents the saddle which holds the truss rod on top of the standard. The steel angles that hold the saddle are welded on all four sides and to the base plate.
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- Detail 1 Queen Post 470.pdf
- The queen post is a bit more detailed as you can see in the next five images. This image shows a side view of the post and base plate along with a top view of the base plate. The post is schedule 80 3/4" black pipe. The pipe penetrates the base plate and is welded to it on the top and bottom. The plate is 3/8" steel.
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- Detail 2 Queen Post 470.pdf
- This image shows a change that required support post to be welded both on the top and bottom of the mounting plate. The mounting plate attaches to the two 5/8" grade 8 stub bolts that pass through the outer sill, through the 1-3/8" steel spacer, through the needle beam and base plate, held in place by a square nut and lock.
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- Detail 3 Queen Post 470.pdf
- In this image you see a side view of the support arm, you will also see a splice where two legs extend from the arm and that each to a foot, has the rod split over its end of the foot and welded on all edges. The post end is a ring that goes completely around the post. There is a 45 degree angle bend into the arm just past the ring. The balance of the angle is taken up in the leg and foot which is bent to about 40 degrees.
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- Detail 4 Queen Post 470.pdf
- This is the ring end of the arm showing both a top and side view. note in the top view the ring is welded together to prevent separation under stress. From the side view you will see that the ring sits just below the saddle which is a 1-1/4" schedule 80 pipe cut in half. The saddle is tacked only until the car truss rod is installed to allow centering of the saddle. After installation of the truss rod both the saddle and the ring will be welded completely around the post making the support rigid.
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- Detail 5 Queen Post 470.pdf
- This view is of the top and side of the legs from their splice point. The legs separate for stability and top cross over the top of the needle beam truss rod. Note the two holes for mounting if the feet, they attach with lag bolts to the beam. The balance of the angle from the post to the feet is taken up in the in the positioning of the two legs.
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- Duncan Burdick is aligning the bolt holes for the sill, spacer and needle beam. You can see the splice made to the end of the needle beam for repair the angled mark on the side was to align the drill bit for drilling out for the truss rod hole.