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Adding a gypsy winch to my Forney steam locomotive

Started by Waldbahner, August 04, 2009, 04:24:56 AM

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Waldbahner

Hello again,

parallel to my Shay project, I began to redesign my 2"-scale Forney steam locomotive into a real logging Forney, inspired by some detail kits from several manufactureres in smaller (On30) scales.

At first I ordered a steam engine kit from PM Research, including a vertical bottle style frame one cylinder steam engine in 1:8 scale. The kit includes only rough castings, some stock material, screws and a plan with all the parts. My first thought was : oh my god... But there was also a lot ambition to get this engine build. So I started with some easy parts. The flywheels for example. With every part I made I got more common with the high quality castings and machining this kit was very easy and finaly a lot of fun. I can really recommend this kit to any live steam newbie but will also recommend that you need a good workshop with a lathe and milling machine.

The photos below are showing the content of the kit (except the smaller flywheel that was chucked on the lathe).


Click on thumbs for large pictures.

After one and a half weeks, the box was empty and the engine starts running on compressed air. There's a clip at YouTube :
=> http://www.youtube.com/watch?v=rpsXcTdGUbw


Click on thumbs for large pictures.

Here's the whole story with many progress pictures and all the details :
=> http://www.gerds-modellbahn.de/BCRR/5BI/5BI_e.htm

With the steam engine running on air, I set up a test winch with some plastic toy gears (gear ratio 4:1) and tested the strength of the engine. Sadly the toy gears were the weakest parts of the set up so heavy load test were not possible. But the result of this test run was very successfull.

So I start to mount the steam engine to the front pilot of my Forney. I had to cut away some sections of the end beam to place the steam engine between the pilot and steam cylinder. I also added a new steam pipe from the back head manifold to the front of the boiler. Next I'll add a lubricator and the missing steam pipes. After determining the final gear pairs, I cut moke up gear assemblies from plywood to test the winch set up. To spur gears (15/30 teeth) will power a blind shaft near the frame. From this blind shaft another pair of gears (15/70 teeth) will power the main shaft. The total gear ratio will be 9.32:1. The large gear will be mounted on a hollow shaft together with the gypsy head drum on the left side. Inside this hollow shaft, I'll place a static shaft with a standard donkey engine drum, complete with ratchet pawl, clutch and clutch levers. This drum will be located in front of the smoke box.


Click on thumbs for large pictures.

Starting the steam engine, the gypsy head will continue run and can be used to skid logs through the woods or to move cars. The winch can be used like a single drum donkey engine for several loading and unloading activities.

I'll also add a box for cable equipment like shackles, hooks, chains and other stuff on the run board. Some hooks around the water tender can be used to hang up cables used on the gypsy head.

I hope you enjoy this rebuild.

Bye, Gerd

lab-dad

Neat!
I looked at all the steam kits, and the thing that worried me was the machining of the bottle.
I see I was not alone but it can be done!
I really enjoyed the SBS and thank you for taking the time to make it.
I will have to look at the videos when I get home.
Very cool and impressive.
-Marty
\

Ken Hamilton

VERY impressive, Gerd.  That fits in there nicely.
Great job!
Ken Hamilton
www.wildharemodels.com
http://public.fotki.com/khamilton/models/

Waldbahner

Good morning,

I build the displacement lubricator from copper pipe and brass yesterday and made some test runs with boiler pressure (still compressed air). The steam engine got some paint.


Click on thumbs for large pictures.

The lubricator will be filled with steam oil (removing the cabscrew). The steam pipes runs through the body and has a 1mm bore at the side in side the lubricator. Steam will escape into the lubricator body and condense to water and set up on the buttom. The oil will swim on top of the water and mix up with the steam to lubricate the cylinder. To drain the water, a simple drain cock is attached to the bottom with a drain pipe.

Next I'll add the steam pipe from the steam engine to the smoke box. Í hope the gears will arrive today.

At last another clip at Youtube : http://www.youtube.com/watch?v=hcniVKOqo8c

Bye, Gerd

Waldbahner

Hello again,

last week, I run the first steam test on the steam engine. I steamed up the loco with char coal for this test. The winch steam engine works great and also the lubricator. The spur gears arrived on Friday, so I'll continue with the winch the next days.

Here's a clip at Youtube : http://www.youtube.com/watch?v=zBUETb9FHRc


Click on thumbs for large pictures.

Cheers, Gerd

Ken Hamilton

That's just TOO cool.
Thanks, Gerd.  Congratulations on a great piece of work!!
Ken Hamilton
www.wildharemodels.com
http://public.fotki.com/khamilton/models/

Waldbahner

Quote from: Ken Hamilton on August 10, 2009, 03:26:31 AM
Congratulations on a great piece of work!!

And it's not finished yet ;-)

Good morning.

Yesterday, I added the first shaft with 2:1 gear ratio. I also milled the supports for the main shaft and did some work on the main drive gear. The gear got a wooden disk on the right side for the clutch between the gear and the drum. I also placed a brass bearing in the gear. More about this will come later.
At last, I set up all parts for some preview photos. Looks good so far. Next I'll finish the main shaft bearings and install the main shaft with drive gear and gypsy head. Some problems are expected during winch construction as I need a ratchet pawl, clutch lever mechanism and band brake system.

BTW, I made a small test with lowest steam engine speed and all the gears in place. The total reduction of 9:1 gives so much strength that it seems to be impossible to hold on the large gear with your fingers. I guess I'll get some nice power to the winches.

Here are the latest photos :


Click on thumbs for large pictures.

Cheers, Gerd

Waldbahner

The gypsy head works !!!

Good morning.

I finished the main bearing block yesterday and installed the main drive gear and gypsy head.
The steam engine has now problem by pulling a vice over the floor in my workshop. This is a big milestone as the test shows that the final winch will have a lot of traction power.

Here are two new pics and the latest video : http://www.youtube.com/watch?v=25MX0RQaOMs


Click on thumbs for large pictures.

Bye, Gerd

marc_reusser

Just great!

......you remind me of some kind of turn-of-the-century mad scientist. ;) ;D


Marc
I am an unreliable witness to my own existence.

In the corners of my mind there is a circus....

M-Works

marklayton

Gerd -

I'm impressed by the power.  Properly geared down, that little steam engine can do real work!

Mark
He who dies with the most tools wins.

Waldbahner

#10
Hi Mark,

wait until you've seen the newest video... YES he can do real work !!!

@Marc... hmm.. is that good for me or bad ??

Hello all.

It's done!! I added the winch drum with all the mechanical stuff like clutch lever, band brake system and so on. Finally I had to manage some troubles with the steam engine it self (broken water feed valve on the boiler and so on) but today, I took the engine out into the back yard and made a large number of test runs.

Details about the final construction are posted on my website. Just follow this link : http://www.gerds-modellbahn.de/BCRR/Winch/Winch_2e.htm

Here are some photos of the new backwoods logging Forney


Click on thumbs for large pictures.

And now, the Bear Creek Lumber & Railroad proudly presents : "The Big Logging Show"
http://www.youtube.com/watch?v=wVgPQraFoSk

Have fun, Gerd

PS.: Just for comparision : THIS... Yeah right!! THIS is the same loco 3 and a half years ago as I bought here second hand !!!

Frederic Testard

Quote from: Gerd afraid he might be mad
@Marc... hmm.. is that good for me or bad ??
Knowing Marc as we now know him, I'd say it's good...

I really like the winch. And it's really interesting to see the comparison between the two 'versions' of the loco...
Frederic Testard

Waldbahner

Quote from: Frederic Testard on August 17, 2009, 01:42:02 AM
Knowing Marc as we now know him, I'd say it's good...

Well, I hope so... for me and for him *lol*

There have been 5 more stages of this little steamer until she turned out in the actual version. You can read the whole story here => http://www.gerds-modellbahn.de/BCRR/Fahrzeuge/Christine/Geschichte/Geschichte_e.htm

Bye, Gerd

Ray Dunakin

Beautiful! You've done a great job on that loco!

Visit my website to see pics of the rugged and rocky In-ko-pah Railroad!

Ray Dunakin's World

MrBrownstone

hello Gerd,

really great work...you fabricate very well  ;D

looking at your works.. makes me want to go hang out at my friends machine shop  ;D ;D

Great results on that winch.. I will be watching for more of your postings.

Mike