Stair Construction Car 0252/470

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Stair Construction Car 0252/470

Unread postby John Engs » Sun Apr 10, 2016 10:06 pm

The restoration of Car 0252/470 to its original factory condition presents many challenges and one of those is the construction of stair steps to the platform. Craig McMullen has taken on that challenge over the last couple of weeks spending many hours in research reviewing pictures, drawings and taking field measurements of other like cars in the fleet to determine the distance appropriate from bottom step to ground and the distance necessary for each step in reaching the platform. As always there is confusion as to details. One of those details was the number of steps used in the stair set. The first image is the actual Pullman floor plan 701, used in manufacture of the 10 car lot purchased by the D&RG in 1889 from the Pullman Palace Car Company. Both platforms are drawn with a three step staircase typically used on standard gauge cars. In the actual manufacturers’ side view photograph (a glass plate negative) two steps are clearly installed. When looking at the car photos it is important to remember that the cars were on standard gauge trucks with 30-inch wheels. In years following the wheel were changed to the D&RG standard of 26-inch which is the size the car is being restored to but using the original Pullman truck components of the 6-foot wheel base. Craig next created a prototype design, followed by numerous test fittings to obtain a proper size and fit to the car. Size was important as they must flush to the center platform sill which has a ½” steel angle wrapping the sill and must also match the end sill again dressed with a 3/8” steel angle on its face. The only wood to wood mounting is to the buffer beam on the rear of the platform. After achieving the proper fit a drawing was created and materials determined. Craig indicates that construction and assembly of the four stair sets was the simplest part of the job. Thanks to Craig McMullen for the marvelous craftsmanship and Tom Simco for the photos; The Illinois Railroad Museum, Pullman Library for Pullman Plan 701 and to the California Railroad Museum for the Pullman (manufactures’ production) photograph of car 466.
FPlan-701- Lot 1612 Car Floor plan.tif
Copy of an original car floor plan #701 for Lot 1612 (10-cars purchase by the D&RG) used in the construction of those cars at Pullman Palace Car Company, Detroit, Michigan, narrow gauge manufacturing facility.
Car Step Construction 466.jpg
Enlarged section of a glass plate negative from the original Pullman manufacturer’s car photograph (side view car 466) the sixth car in the lot. Enlarge the PDF to see what’s in the windows: the men’s room on the end and water station to the right. Refer to the floor plan for details.
Car Step Long Side View.jpg
This is an enlarged section looking from the long end; count the steps to the platform. When you enlarge the PDF you can see a seat back and wall through the rear window, just to its left in the second window is the coach open door and the Baker heater in the far corner. In the next window you can see the last birth post on the near side and door hinge of the door to the women’s room on the far side.
IMG_1594.JPG
Assembling a prototype design from reference information gathered. The prototype will be fitted a number of times before it can be considered correct.
IMG_1594.JPG (138.78 KiB) Viewed 3731 times
IMG_1598.JPG
Fitting the prototype stair set on the car. Looking from the rear you can check lower step protrusion from side of car.
IMG_1598.JPG (122.12 KiB) Viewed 3731 times
IMG_1597.JPG
Looking at the left side of the stair set note that it is low on the end sill. It is determined that an angle bracket will be needed. The angle will be mounted to the underside of the end sill and attached to the stair riser.
IMG_1597.JPG (107 KiB) Viewed 3731 times
IMG_1599.JPG
From the front you can see the relationship of the platform to the top toe board. The platform extends over the top of board. You will also notice the platform pitch is to the rear.
IMG_1599.JPG (101.84 KiB) Viewed 3731 times
IMG_1600.JPG
You can see the right riser is flush to the top of the buffer beam allowing direct wood to wood attachment.
IMG_1600.JPG (115.57 KiB) Viewed 3731 times
Design Drawing Steps Car 470.JPG
After completion of all adjustments to the prototype it’s necessary to complete a drawing of the actual measurements of all the pieces.
IMG_1647.JPG
Each piece of wood is cut to correct size. Like pieces are cut at the same time, rabbets on the rails are made with a dado. Lumber for the rails and steps is white oak, the toe boards are of fir. Support rods are cut to length from 5/16” steel rod and threaded.
IMG_1647.JPG (109.16 KiB) Viewed 3731 times
John Engs
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