2020-????
Line Shaft Slip Joints (01/06/2020)
Well…it has been a while since I worked on WM6. Too many other things kept getting in the way. I’ve recently, however, fabricated the line shaft slip joints that connect the trucks together. I can only install the one between the tender truck and the middle truck since I don’t have the motor built yet. The outer slip shaft is 2 pieces of angle iron welded to form a hollow square. The inner shaft is 1″ square bar stock machined to have a round end to go into the universal joint. A similar round stub is welded into the end of the hollow tube so it will fit into the other universal joint.
Here are a few pictures.
Open end of outer slip shaft 
Universal joint end of outer slip shaft 
Various sizes 
Test fit of outer shaft 
Test fit of both parts
Eccentric Straps (03/06/2020)
It has been a long time coming but I finally got around to machining the eccentric straps for the motor. I cut out the blanks in 2007 and machined the inside races in 2009 but they have been on a shelf waiting for the final machine work ever since. No one will accuse me of rushing into this. Here are some pictures of the final eccentric strap and eccentric cam that will be pressed onto the crankshaft when it is fabricated.
Left side rendering by Hurco mill 
The setup 
Macining in progress 
The final product 
Test machining of cam 
Finished with eccentric cams
Motor Base (April-May 2020)
The machining of the motor base casting has started. There is quite a bit to do on it but it all seems to be manageable segments. I ended up needing an extra long 1″ diameter roughing end mill to be able to reach down into the lowest parts of the internal cavities. The goods news is that the machining is all done. Next up is the fabrication of the crank bearings and their holders.
Checking casting dimensions 
The machining begins 
Top is flat 
Bottom is flat 
Machine tool paths 
Test of machining program 
Holes drilled…ready for cutouts 
Cavities machined. They will “fall out” when underside is machined. 
Holes and slots for crank bearing holders 
First bay completed 
Carving the second bay 
Internal carving program tool paths 
Internal cavities completed
Burner Assembly (12/06/2020)
The burner assembly is completed. It has 18 burners, side draft protection, and an air flow control panel on the bottom. The arch is also complete and mounted in the frame. The boiler can now be mounted (for the last time).
Burner assembly 
Burner assembly (2) 
Burner assembly mounted in frame 
Burner assembler with arch
Miscellaneous (12/23/2020)
Now that I have the boiler mounted on the frame, I’ve started working on miscellaneous items while I wait for repair parts for the CNC mill.
Air pump output radiator 
Steam manifold shutoff valve 
Ready to mount steam manifold 
Adaptor ring 
Firebox door installed
Smokestack
The smokestack assembly is completed. The base still needs to be fly-cut to an arc that matches the smokebox diameter. That will have to wait until the CNC mill is fixed. I also added a rivet detail to the smokebox.
Smokestack with riveted lip 
Complete assembly 
Imbedded petticoat 
Smoke box detail – rivets
Boiler jacket, bands, and roof
Making progress on the boiler jacket. Also got the roof hinges installed. Once I get the jacket installed (without paint), then I can attach the generator, bell, and fit the domes. One step at a time.
First boiler jacket piece 
Tapered boiler jacket 
Boiler jacket bands cut out 
Rolled jacket bands 
Jacket bands completed 
Roof hinges installed
