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Trolley Fare Fort Collins Municipal Railway Society News Volume 31, Number 1, May 2011 www.fortnet.org/trolley/

Car 21 is back on the rails! When you read the last Trolley Fare, Car 21 was up on blocks and its power truck was in pieces in the Mountain Ave. barn. We were looking for an AAR-certified wheel and axle shop to turn new axles and re-contour the wheels which had shown noticeable wear in the past 12 years. Since then, volunteers have organized fund-raising events to help cover costs to rebuild the wheelsets and refinish or replace worn components on the car. Other volunteers stepped forward to completely refinish the interior of the car (see page 2). After talking to various local and distant machine shops, we found a, AAR shop that understood what we needed: Lyons Industries, Inc. Roger Mitchell developed a drawing of the axles and obtained a quote for the needed work, which the FCMRS Board approved in early October. We loaded the damaged wheelsets on a City trailer in early January, to be transferred to a dedicated trucker that Brad March found to haul the wheelsets to Pennsylvania. Lyons took about six weeks to document the wheelsets, pull the wheelsets apart, machine new axles, re-assemble the wheelsets, and re-contour the wheels.

New wheelsets ready for assembly in the power truck.

While the wheelsets were out, an enthusiastic team of volunteers descended on the barn to clean, inspect, repair, replace and repaint parts on the power truck. The team working through cold, damp weather in our unheated barn included Jim Thake, Charlie Rock, Alan Cram, Andy Conrak, Bob Browning, Chuck Bade, Roger Smith, Ron Fey, Moose Shattuck and Al Jackson. Work also occurred under the car, repairing air leaks, components in our wheel-lubricating system, and insulation on the controller-cable bundles. During the winter, Roger Mitchell removed and repaired the compressor’s motor, including machining the commutator and installing a new head gasket on the air pump. We re-installed the compressor after the power truck was rebuilt and remounted under the car in April.

One of the surprises we found were broken leaf springs in one of the truck’s four spring bundles. A local spring shop searched far and wide for new material to match our car’s springs, finally ordering it from a supplier in Pennsylvania. While rebuilding the spring bundle, a fourth spring broke, so the shop wisely replaced all springs, providing a new bundle just in time for us to re-assemble the truck when the new wheelsets arrived in early April. (Close examination reveals that the remaining three spring bundles have had various leafs replaced in the past, so we’re now considering having all leaf springs rebuilt and replaced during our off-season.) The new wheelsets arrived on March 17 and were transferred to the barn by a City crew. With all the parts on hand, we rebuilt the power truck in early April and mounted it to the car body on April 13. Bob Browning took the car out that evening for a brief, successful test run, to the delight of an exhausted crew. You can see a part of that first run plus lots of other pix on Facebook: www.facebook.com/fortcollins.trolley In addition to the new carmen team, the assembly crew included Jeff Cleverley, Brad March and Gary Thomas. To keep us making progress that week, food and refreshments arrived thanks to Gary, John Beckett, Moose Shattuck, and Carol Tunner. After a few adjustments, Car 21 was ready for motormen training and certifications the following weeks. As of this writing, we’ve operated the car for a month with no serious problems. Motormen say it runs and sounds better than ever, thanks to the small bunch of dedicated volunteers and lots of generous donors. It’s estimated that volunteers contributed about 3000 hours and the project cost about $15,000.

Volunteer carmen rebuilding the power truck in April 2011.

(l to r) Charlie, Al, Alan, Chuck, Brad, Jeff, Roger M)

The day before beginning our regular operating season, Bob Browning lead a team of CSU volunteers who cleaned the interior and washed windows inside and out. Some say the car now looks and runs better than new! See the photo on the cover page.

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Refinishing Car 21 by Bob Browning A team led by Jim Thake and Bob Browning, augmented by Alan Cram and Roger Smith, used the unplanned down time due to the broken axle to perform needed maintenance on Car 21's body. Car body maintenance included:

Roof:

• Superstructure cleaned and painted. • Canvas skin cleaned, sealed, painted. • Power poles cleaned and painted. Exterior body:

• Crack by B-end door filled, sanded, repainted. • Sills repainted and A-end sill caulked. • Metal door actuator poles cleaned, primed, repainted. • Step frames, hinges, and scuff-plates cleaned, primed,

repainted. • Steps stripped to bare wood, stained, varnished (3 coats). • Safety catchers:

o Metal frame cleaned, primed, painted. o Wooden slats cleaned, sanded, painted.

• Safety catcher triggers: o Metal frame cleaned, primed, painted o Wooden slats cleaned, sanded, varnished (3 coats).

• Exterior destination roller box doors removed, stripped to bare wood, stained, varnished (4 coats).

• Exterior side of window sashes stripped to bare wood, caulked, stained, varnished (5 coats min.).

• Side letterboards clear-coated. Interior/exterior:

• All windows removed, stripped to bare wood, caulking removed, caulked, stained, varnished (min 4 coats exterior side/min 3 interior). o Window tracks removed, stripped to bare wood,

cleaned, stained, varnished (min 3 coats). o Supporting structure cleaned, stained, varnished. o Windows and tracks waxed prior to reinstallation.

• Doors removed, disassembled, caulk removed, caulked, stained, varnished (min 8 coats). Logos reapplied. Bump stops reconditioned.

Interior of Car 21 gleams with refinished woodwork and cleaned/repainted brightwork. Photos by Bob Browning.

Interior:

• Interior window sashes stripped to bare wood, stained, varnished (min 3 coats)

• Buzzer-button strips removed, stripped to bare wood, varnished (2 coats). Buttons removed and reinstalled.

• Crew/passenger seats: o Hardware removed, support screws tightened o Cleaned, stained, varnished (2 coats)

• All remaining varnished surfaces (motormen areas A and B), advertising areas, "smoking on end seat" supports, and door frames varnished.

• A-end metal wall cleaned and repainted to repair damage from souvenir box and coin box.

• Sand boxes cleaned and painted. • Controller stand box covers:

o Disassembled, stripped to bare wood, stained, varnished (3 coats).

o Vermiculite-impregnated fiberglass arc shields installed.

o Controller boxes cleaned out. • Stanchions cleaned and painted.

Bob Browning and Jim Thake added a layer of heat-resistant insulation to protect the refinished controller covers from damage by arcing. They also applied the same protection to

Car 25’s controller covers after refinishing them.

New maintenance team and procedures A new team of streetcar carmen emerged from rebuilding and reconditioning Car 21. While the team is learning its craft, they’re also developing written checklists and procedures to ensure that the car receives regular weekly and semi-annual maintenance, and a thorough annual inspection. The Car 21 carmen are lead by Chuck Bade and includes Jim Thake, Charlie Rock, Andy Conrak, Roger Smith, and Al Jackson. Long-time Car 21 mechanic, Roger Mitchell, is lending his expertise and skills to keep the team on track. Recent helpers are student conductors Howard Lowell and Asad Aziz. Chuck will coordinate routine maintenance, ensuring that the car gets regular care each week. He has also taken over development of the Car 21 maintenance manual. A number of improvements are also underway to improve shop efficiency and safety.

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Car 25 reconditioning status To accomplish the work needed on Car 21, the Car 25 team moved to the Mountain Ave. barn to help Roger Mitchell in early January. So the team has little to report on Car 25 since the last newsletter. We hope to resume work this summer. Projects awaiting our attention are: • Finish replacing air piping under the floor. • Finish running new under-floor electrical conduit. • Prime and install new floor shims. • Prime and paint all under-floor details. • Install new sub-flooring.

(l to r) Andy Conrak, Al Jackson and Reid Jacob discussing the

best way to re-install electrical conduits under the floor of Car 25. Photo by Deb Stith.

For the time being, we’ll be either in the Mountain Ave. barn or the Howes barn on Saturday mornings. You’re welcome to stop by and see our progress.

Depot gets a facelift Conductor in training Dave Thompson spiffed up our depot in City Park this Spring. First he cleared out some wasps that were living above the ceiling. Then Dave power-washed the inside and outside and caulked the exterior. After getting paint specs from the City, Dave painted the exterior and trim just in time for our opening day. Before the depot was stocked with souvenirs for the new season, the carman helped Deb Stith move unneeded stuff stored there to the barns.

Our depot in City Park.

New crew scheduler on board Connie Nelson-Cleverley is now our crew scheduler for regular weekend operations on Car 21, freeing up Craig Stith for more presidential-like duties. Welcome, Connie.

Jim Thake refinishing a controller top plate in Car 21.

New Birney appliqués were added to Car 21’s doors after refinishing.

Andy Conrak and Chuck Bade working on the power truck.

All photos above by Bob Browning.

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Welcome new members and donors These members joined our Society this year and/or donated to reconditioning Car 25 and/or Car 21 (local residents except where noted): Robert & Dorothy Adel Duncan Allen, Needham, MA Ferah/Asad Aziz Ruth Bezel David & Carol Budge Brent Carmak Community Foundation of No. Colo Tim Davis, Detroit, MI Jim Ehernberger, Cheyenne, WY James & Marleigh Ells Len & Susan Epstein Dick & Margaret Erickson Derry & Lois Eynon Robert Goodwin S. C. Griffith, Ashton, IL Chuck & Pearl Hagemeister Dick Harrison, McMinnville, OR Dave & Barbara Hawes James Hayes James Heaton Sonia Immasche John Beckett & Associates Greg Koch Family Douglas Long, New Concord, OH Robert Mahar, Philadelphia, PA Mary Rowan & David Hodge Robert & Eunice Miller Catherine Orr Marian Pike Charlotte Rehnberg Rocky Mountain Railroad Club Michael Rowe Robery Samual Steve Schaeffer Ed Slattery, Denver Grace Stith, Fitchburg, WI Craig & Debbie Stith Wayne Sundberg Family Simon Turner Bob Viscount, Prescott, AZ Ronald Wartinbee, Denver Gayle & Sally Watkinson David Williams Donald Woeber Frank & Joanne Yockey Charles Young, Philadelphia, PA Peter Zimmermann, Los Angeles

Here are more pix of us rebuilding and re-installing the truck:

Al Jackson preparing to install a journal bearing.

Sean Jackson and Alan Cram preparing to lift the B-end motor.

Jim Thake and Ron Fey guiding the motor onto

the B-end axle, while Charlie looks on.

Charlie Rock taking a break from cleaning and

rebuilding brake hangers for Car 21.

Brad March installing the stop collar on the axle.

Photos by Bob Browning.

After the truck was rebuilt, the shop team rolled it out of the barn…

..and down to the switch (with retainers set up)…

…and back on track 1 (after 8 months)…

Want more FCMR? In addition to the photos on the next pages, you’ll find more pictures of us and see what our riders and fans are saying about us on Facebook: www.facebook.com/fortcollins.trolley

You can also read about us on Trams Stop Here: www.tramsstophere.wordpress.com/2011/05/15/fort-

collins-rolls-again/

…and under the car body. All photos here by Bob Browning.

Two teams worked together to carefully lower each end of the car body

onto the truck; Brad March and Jeff Clevereley on the right side with Charlie Rock and Al Jackson on the left side.

Trolley Fare is published for members and friends of the Fort Collins Municipal Railway Society.

FCMRS Staff President: Craig Stith, 498-0286 Vice-president, Moose Shattuck, 472-1071 Secretary: Carol Tunner, 484-3957 Treasurer: John Beckett, 482-0130 Directors Brent Carmack, 416-2702, Mary Krbec, 225-2188, Brad March, 482-4322, Roger Mitchell, 207-9295, Gary Thomas, 482-7125 Departments Advertising on Car 21: John Beckett Car 21 maintenance: Chuck Bade Car 25 reconditioning: Al Jackson Crew scheduling: Connie Clevereley, Gary Thomas Charters: Gary Thomas, 482-7125 Conductor & depot-agent training: Carol Tunner Maintenance of way: Al Jackson, Roger Smith, Alan Cram Membership, Trolley Fare & website: Al Jackson Motormen training: Bob Browning, Roger Smith Public Relations, Wayne Sundberg Souvenirs: Deb Stith

Fort Collins Municipal Railway Society P.O. Box 635 Fort Collins, CO 80522

CSUnity students spiffed up Car 21 on April 30, the day before we began operating this season.

Their reward was the first excursion on our reconditioned car. Photo by Bob Browning.

U.S. Postage Paid Fort Collins, CO Permit No. 237 Non-Profit Org.