The journey begins, Shay cylinder construction

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Well it is time for me to start employing my motto, "I can't afford it, so I have to build it". I will be starting with the cylinders, to buy the castings was over $650, so I bought some dura bar for $100 and started construction today.

Here is the Durabar chucked in the lathe so I can part it off into 4" sections. That bar weighs 67 pounds and is 5" round.

Here is the cylinder layed out for rough machining.

Starting to square up the edges an and rough machine the cylinder shape.

Here is where I finished for the day I am getting close to the rough shape of the cylinders. I am going to finish the bore on the lathe before I do the final machining so I can use it as a referance for the rest of the cylinder.

Edited by PhilC - Feb 15 2010 at 10:35pm

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Steve C Members Profile Send Private Message Find Members Posts Add to Buddy List Groupie Mr Steam Joined: May 16 2009 Status: Offline Points: 96	Post Options Post Reply Quote Steve C Report Post Thanks(0) Quote Reply Topic: The journey begins, Shay cylinder construction Posted: Feb 10 2010 at 8:32pm
	Well it is time for me to start employing my motto, "I can't afford it, so I have to build it". I will be starting with the cylinders, to buy the castings was over $650, so I bought some dura bar for $100 and started construction today. Here is the Durabar chucked in the lathe so I can part it off into 4" sections. That bar weighs 67 pounds and is 5" round. Here is the cylinder layed out for rough machining. Starting to square up the edges an and rough machine the cylinder shape. Here is where I finished for the day I am getting close to the rough shape of the cylinders. I am going to finish the bore on the lathe before I do the final machining so I can use it as a referance for the rest of the cylinder. Edited by PhilC - Feb 15 2010 at 10:35pm

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tom d Members Profile Send Private Message Find Members Posts Add to Buddy List Senior Member Joined: Nov 15 2008 Location: lakewood,ca Status: Offline Points: 156	Post Options Post Reply Quote tom d Report Post Thanks(0) Quote Reply Posted: Feb 12 2010 at 3:59am
	Hey Steve what is Durabar ? Edited by Steve C - Feb 12 2010 at 8:12am

PhilC Members Profile Send Private Message Find Members Posts Visit Members Homepage Add to Buddy List Admin Group Joined: Nov 03 2008 Location: Torrance Status: Offline Points: 129	Post Options Post Reply Quote PhilC Report Post Thanks(0) Quote Reply Posted: Feb 12 2010 at 4:26am
	Durabar is continuous cast iron bar stock. Check it out. It is neat stuff. http://www.dura-bar.com/ Phil Edited by PhilC - Feb 12 2010 at 4:28am
	I used to be a rocket scientist, now I am just a space cadet. ------------------------------ You only need three tools in life - WD-40, Duct Tape, and a Hammer. If it doesn't move and should, use the WD-40. If it shouldn't move and does, use the duct tape. If you can't fix it with a hammer, you've got an electrical problem.

Steve C Members Profile Send Private Message Find Members Posts Add to Buddy List Groupie Mr Steam Joined: May 16 2009 Status: Offline Points: 96	Post Options Post Reply Quote Steve C Report Post Thanks(0) Quote Reply Posted: Feb 12 2010 at 8:16am
	Phil beat me to it. Nice thing is it is available in so many different shapes and sizes it can be used to eliminate the need for castings. Of course it takes alot longer to machine a part out of a solid compared to finishing a rough casting.

tom d Members Profile Send Private Message Find Members Posts Add to Buddy List Senior Member Joined: Nov 15 2008 Location: lakewood,ca Status: Offline Points: 156	Post Options Post Reply Quote tom d Report Post Thanks(0) Quote Reply Posted: Feb 12 2010 at 11:49am
	what material are you going to use for liners and pistons

RioGrande464 Members Profile Send Private Message Find Members Posts Visit Members Homepage Add to Buddy List Newbie Joined: May 31 2009 Location: Torrance Status: Offline Points: 39	Post Options Post Reply Quote RioGrande464 Report Post Thanks(0) Quote Reply Posted: Feb 14 2010 at 9:19pm
	Great work Steve. Glad to see your already working on it! Will be cool watching the valve gear and cylinders run on air! lots of moving parts on these locos but they arent realy as compex as they seeem. The guys at roaring camp always told me that getting to know what a shay looks like and how it runs is alot better than a rod engine as everything is hidden especialy with stevenson valve geer. this will be a great loco though and a good puller!

jfulkerson Members Profile Send Private Message Find Members Posts Add to Buddy List Newbie Joined: Mar 20 2010 Location: Redondo Beach Status: Offline Points: 1	Post Options Post Reply Quote jfulkerson Report Post Thanks(0) Quote Reply Posted: Mar 20 2010 at 4:27pm
	I am new to the forum and saw your post on the shay that you are starting to build. I have just started a three truck shay using the castings and plans from Ken Schroeder. Are you familiar with him? I am also using the Nelson Riedel web site: http://www.nelsonslocomotive.com/Shay/shay.htm. I am doing my work at El Camino College's machine shop on Tuesday and Thursday nights. I would love to connect and compare notes on the shay project.
	Jim Fulkerson Redondo Beach, CA 310-370-2323

Steve C Members Profile Send Private Message Find Members Posts Add to Buddy List Groupie Mr Steam Joined: May 16 2009 Status: Offline Points: 96	Post Options Post Reply Quote Steve C Report Post Thanks(0) Quote Reply Posted: Mar 23 2010 at 2:52pm
	I almost purchased the castings from Ken but, I wanted to build a little larger loco. I am using the prints from Rich Ulin as a guide and I will be using some of his castings along with producing some of my own. Have you ever visited SCLS or are you a member of any other clubs in the area? If you have never visited you should come down sometime.

sally Members Profile Send Private Message Find Members Posts Add to Buddy List Newbie Joined: May 04 2011 Status: Offline Points: 2	Post Options Post Reply Quote sally Report Post Thanks(0) Quote Reply Posted: May 04 2011 at 6:57pm
	Nice thing is it is available in so many different shapes and sizes it can be used to eliminate the need for castings. Of course it takes alot longer to machine a part out of a solid compared to finishing a rough casting.

railroadtrac2 Members Profile Send Private Message Find Members Posts Add to Buddy List Newbie Joined: May 09 2011 Status: Offline Points: 2	Post Options Post Reply Quote railroadtrac2 Report Post Thanks(0) Quote Reply Posted: May 09 2011 at 5:27pm
	Amazing really helpful