25 Hopper Interiors Completed

Slowly but surely over the last few weeks I’ve been working on completing the interior detailing on all of the Walthers hoppers I’ve stripped so far. That’s a total of 25 cars currently in progress at the same time. (This actually represents a little under half my current fleet of these cars.)

These twenty-five cars now have the interior bracing and the treatment to the top chord completed. I explain the modifications a bit more in this previous post, but the process basically involves patching the holes on the inside of the body (where the solid bulkhead part from the stock model was fitted) with body putty, adding the extended lip over the end of the car, filing the top of the sides smooth, instead of the peaked side on the model representing an angle iron for stiffening, and finally installing the new interior bracing. On the older cars I did, I fashioned the bracing from .040″ brass wire, but I’ve now taken to using 3/64″ (.047″) styrene rod from Evergreen to make these, as it’s far easier to file and work with, and the welded styrene-styrene bond is stronger and more flexible than the brittle CA bond to glue the brass to the plastic body.

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Now i just need to get the other twenty end platforms all up to the same point…

Notes on an old Slide Collection III: Michipicoten Branch

A few more from the collection. This batch is all related to the Michipicoten subdivision branchline west of Hawk Junction.

The Michipicoten branch runs 26 miles from Hawk Junction west to Wawa and the harbour on Lake Superior at Michipicoten. Primarily serving the Algoma Ore Properties (a subsidiary of Algoma Steel) iron mines and sinter plant at Wawa, this line was the domain of the ore trains.

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East of Wawa, winter 1980-81. Photographer unknown. Chris vanderHeide collection.

An empty ore train westbound between Hawk Junction and Wawa. East of Wawa there is a significant area where the landscape has been ravaged by the fallout of nearly a century of iron ore processing in the area. Those familiar with north-central Ontario will be aware of the similar treeless blackened landscape that made the Sudbury region [in]famous before INCO built the “super-stack” there to disperse (and thereby dilute) emissions over a larger area, and a concerted environmental remediation program was undertaken.

Here we see the ore train snaking through the rocky terrain of the treeless zone. The winter contrast of white snow against the black rocks only increases the starkness of the scene. I guess on the plus side, you get a pretty good view of the entire train, which isn’t very common on the remote lines twisting their way through the northern Ontario forests.

Look closely and note in particular the first four cars of the train – not ore hoppers but empty flatcars and a gondola for pulpwood loading at a log spur west of Wawa.

This location can be deduced to be Trembley, a siding approximately 3-4 miles west of Wawa. The timetable additionally lists two loading spurs at Trembley, one operated by Abitibi Paper (later St. Marys Paper) and the other by Newaygo Forest Products (a company that also had significant operations at Mosher and Mead on the Northern Subdivision).

Close inspection of the photo shows one of the spurs curving off far in the background to the left of the engines of the train. Based on the sequence of slides in this batch, and also comparing the layout to the traces left behind and visible on overhead satellite imagery, this photo is taken at the east end of Trembley siding from the caboose of the same train as the ore train seen above. The train is westbound to Michipicoten harbour and standing on the main track at Trembley. The engines visible in this photo are NOT from the same train however. Close inspection of both photos shows a pair of SD40 type locomotives on the head of the ore train, and there are at least 3 GP7 locomotives on the pulpwood extra seen here. (Note that timetables through the 1970s and ’80s did not list any regular trains on the branch, and all trains were run as extras.)

While the above photo at first glance may appear to show an arriving train pulling into the siding, there are a number of things that don’t make sense about that, not the least of which is that it appears to be showing a *loaded* train of pulpwood arriving from the east, and pulpwood loads should be heading back in that direction. Clearly this train was likely already here and waiting in the siding for the arrival of “our” train and has resumed actively switching the Abitibi spur in the distance, while our train has stopped on the main track to set off those 4 empty cars for pulpwood loading seen at the front of the train in the first photograph.

The branch is mostly known for the ore related traffic, and solid trains of hoppers, but this photo really shows the scale of pulpwood operations here; clearly there was enough traffic to be running both a pulpwood extra and an ore extra (which also had 4 more empty cars to drop off for pulpwood loading!) The 1978 Time Table lists car capacities of the Abitibi and Newaygo spurs at Trembley at 45 and 24 cars, respectively (at 50′ per car), and in addition to the 44 car passing siding, instead of a car capacity in the house track column is the notation “Yard”, suggesting the presence of perhaps two or more side tracks for car storage in addition to the identified customer spurs. This definitely expands the operational possibilities on the branch line, and for pulpwood loads in general.

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Wawa, winter 1980-81. Photographer unknown. Chris vanderHeide collection.

Wawa. The primary raison d’être of the Michipicoten branch of the Algoma Central Railway was to serve the iron mining of the Wawa area. The mining industry in the area has had a rocky history, with various operations stopping and re-starting in the early part of the 20th century.

From its incorporation in 1899, the Algoma Central was built to move iron ore from a large deposit discovered near Wawa to a harbour built at Michipicoten Bay on Lake Superior. The harbour featured a elaborate wooden ore dock and a commercial dock where passenger boats called and other ships loaded pulpwood. Ore and pulpwood was shipped south over the lake to the various industrial interests in Sault Ste. Marie. The ACR also (slowly) pushed north from Sault Ste. Marie but the 1903 financial crash of the industrial empire of which the ACR was a part brought things to a halt with construction not beginning again until 1909. It was only in 1912 that the main line reached what is now Hawk Junction and connected Wawa to the Sault directly.

The first iron ore sintering plant at Wawa was built in 1939, and was significantly expanded several times over the next 50 years. By the 1980s, ore from the MacLeod Mine (a 2000 foot deep underground mine located adjacent to the site of the original 1899 Helen open pit mine) was delivered directly to the sinter plant via the world’s tallest single-lift conveyor belt. Here the ore was heated and blended with additives such as limestone and other ore fines brought in through the harbour at Michipicoten to upgrade the ore for the Algoma Steel blast furnaces at Sault Ste. Marie. In 1998 however, the Algoma Ore operations around Wawa were shut down, with the steel mill sourcing taconite ores from south of the border, and the sinter plant was eventually torn down. Absolutely nothing in the above photo save for the rocky terrain itself still exists today.

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AC scale test car 10302. Wawa, winter 1980-81. Photographer unknown. Chris vanderHeide collection.

This scale test car photographed at Wawa was converted from one of the first steel hopper cars rostered by the Algoma Central. These cars were built by the Pressed Steel Car Company in 1900-1901, meaning this car was somewhere around its 80th birthday when photographed in the winter of 1980-81. Amazingly this car actually still exists today; it’s preserved at the Canadian Railway Museum in Delson, Quebec.

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AC hopper 6056 (ex-ONT). Wawa, winter 1980-81. Photographer unknown. Chris vanderHeide collection.

From the oldest to the newest. Built in 1971 by National Steel Car for the Ontario Northland Railway, these are actually older than the 8201-8500 series rapid-discharge cars acquired new in 1974-75, but these 30 cars acquired secondhand from the ONR in 1978 were the last hoppers acquired by the Algoma Central Railway before they were absorbed by the Wisconsin Central in 1995. For several years they kept their old Ontario Northland numbers with the reporting marks re-stencilled “AC”, but around 1986 these cars were renumbered into a proper AC number series, AC 8600-8629. A check of the UMLER (computerized equipment register) shows that many of these cars are actually still in service, making them the last surviving hopper cars in AC markings.

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Wawa, winter 1980-81. Photographer unknown. Chris vanderHeide collection.

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Wawa, winter 1980-81. Photographer unknown. Chris vanderHeide collection.

Express freight shed at Wawa. Front and back sides. This is pure gold for being able to model this structure. While much larger, some similarities in construction can be seen between the Wawa shed and the smaller shed at Hawk Junction, seen in the previous post.

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And finally, on the frozen shores of Lake Superior at Michipicoten harbour. This photo is taken from the modern dock at Michipicoten, which was built as a coal dock in 1929 (and extended in size several times over the years) to replace the original ore dock. From the 1920s to the 1960s, this was a port to bring in coal to fuel northern Ontario paper mills and also for CNR locomotive coal for northern terminals. In 1939 when the sinter plant was constructed at Wawa, an ore unloading bridge was added to tranship ore from rail to ship. It’s too bad there were no slides that showed the opposite direction, looking towards the old facilities on the coal dock – a video I have from the late 1980s shows that some remnants of the old steel work was abandoned but actually still standing at this time. By the 1980s all of the previous operations at Michipicoten had been abandoned but the dock continued to see significant traffic. Self-unloading ships depositing huge stockpiles of limestone, coke and other ore fines on the dock, and these were loaded into hoppers using large front-end loaders and shipped as required to Wawa to support the operations of the sinter plant there.

The old rotting wooden dock visible in the above photo is the remains of the original commercial dock, abandoned some time in the late 1950s or early 1960s

Stripathon! or, An Evening with my Good Friend Alcohol…

No, no, no. Not that kind of alcohol, and not that kind of stripping.

I spent some time tonight disassembling and stripping the paint off of some Walthers hopper kits to prepare them for detailing.

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Yesterday these dozen cars were in such varied paint schemes as Conrail, FEC, William Bros./Blue Circle Cement, and even WC/AC. It’s interesting how underneath the paint the cars were also cast in varying colours of plastic.

A bath of 90% rubbing alcohol from the drugstore attacked the paint and lettering quite nicely – in less than five minutes the lettering was literally floating off of the yellow cars. Most of the paint came off quite easily by scrubbing with an old tootbrush, although it took a little elbow grease to get most of the paint out of the corners.

AC 8201-8500 series hoppers – Part 3: End platform grating

Here’s a good view of what the end of one of these cars looks like:

http://rrpicturearchives.net/showPicture.aspx?id=1251473

While the stock Walthers model basically just has some generic raised-tread pattern on the end, you can see that the pattern of walkway grating is quite distinctive, and I wanted to capture this.

The following wreck photo also highlights quite clearly how the grating is open, and would be see-through:

http://algomacentral.railfan.net/images/AlgoCenRy/AC_Mile_5_wrk-5_5-14-1980.jpg

If I were only doing one of these cars, I might consider completely cutting away the end platforms and rebuilding them from scratch to have the open grating, however for the sheer volume of these cars that I need, I’ve decided this would be far too much time and effort to be worth it.

I do however wish to at least replicate the tread pattern, which is a big difference from the model. To this end, after disassembling the cars and removing the handrail pieces, I filed the top surface of the end platforms smooth to remove the existing tread texture.

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End platform filed smooth.

I cut the new walkways out of etched brass walkway/grating material. The walkways are a rectangular “Apex” tread pattern. I’ve been using etched brass material from Details Associates. I just used a regular pair of scissors to cut the thin brass sheet.

There’s two parts to the walkway tread on these cars. There’s the grating on the open area of the platform, and an extra bit of grating leading to the end ladder. The platform grating is cut out of the etched material in a rectangle 2.5 by 10.75 scale feet in size. The cut piece should all be whole rectangles, with the “grain” following the width of the car.

The walkway to the end ladder grabs is oriented perpendicular to the platform grating. With the sizing of the rectangles in the Details Associates etching, I cut a strip from the etched sheet 3 rectangles wide; this is perfectly the size to fit between the platform grating and the car body. I then cut these into approx. 1.75 scale foot pieces.

With all the piece cut, I attached them to the prepared underframe pieces using CA adhesive. Very carefully, trying not to glue my fingers to themselves or the car, I used a toothpick to spread the CA across the bottom surface of the grating, and then applied the grating material to the car. For the smaller pieces I used a pair of curved tweezers to move them into position.

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Several finished platforms, with one just filed smooth in the middle.

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Completed walkway/platform grating with the underframe and body fitted together, showing how the walkway accesses the end ladder.

This is the current point I’m at with these cars (well, the 9 I’m [semi-]actively working on). 5 cars now have the grating complete (I just finished a few of them up tonight) and another 4 have the platforms filed and prepared (and actually have for quite some time now).

After I finish this current batch of cars, (I’m hoping to try to bring these 9 all the way through to completion now) I’ve got another 50 or so of these Walthers cars waiting for the same treatment at some point!

AC 8201-8500 series hoppers – Part 2: Interior and Top Chord

So in my previous post, I introduced this project and the prototype for these cars, 300 cars built by NSC to an Ortner design in 1974-75. Walthers makes an HO model of the Ortner design, which makes a convenient start to this project. Of course there are some details, both major and minor, that differ between the Walthers model and the AC prototype cars.

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Stock Walthers model without the hokey included aggregate load.

The biggest change that needs to happen is that the AC cars have tubular V-bracing between the bays, not the solid bulkheads that the model has. This takes a little bit of work, but is not difficult, and you’ll agree this makes a huge difference in appearance.

If you only want to do minimum changes or detailing to turn the Walthers car into a reasonably accurate AC car, this is the change to make. Also, since the insides of the cars were unpainted steel, this change can be done on a factory painted car while completely preserving the factory lettering, as the inside of the car should be masked and repainted a rusty colour.

The first step is the easiest, just take out the removeable bulkhead pieces and throw them away. (Or, toss them in the scrapbox. A good model railroader is a pack rat; you never know when that oddball useless leftover part now can be repurposed for something completely unintended later. Or at the very least chopped up into smaller pieces or used as part of a steel scrap load or junkyard scene.) Then I fill the holes left behind with modeling putty. Most of the cars I’ve been working on so far I’ve filled the holes using either Tamiya or Squadron putties. Other modelers also recommend Bondo putty from the automotive department, and I’ll probably try that in the future. Canadian Tire is a lot more convenient than the local hobby shops that are an hour+ away.

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Several cars in progress.

Once the body putty has had a day to cure, I file it down even with the inside surface of the sides and sand it smooth with progressively finer sandpapers. Once again the automotive aisle at Canadian Tire is rather handy here as a source for 1000+ grit finishing/polishing sandpapers to get a nice smooth interior side.

Smoothing out the bottom of the bays is a bit more tricky with the angled geometries, so I just did the best I could. A sanding stick from the hobby shop gets a good start here.

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I used a sanding stick like this one on the inside of the bays.

Now, before I move on to installing the interior bracing, I finish cleaning up the top of the car body. (Or this part can really be done first.) The AC cars have an overhanging lip over the top of the car end that the model doesn’t have. I modeled this simply using an HO scale 2″x6″ styrene strip across the top of the end. First, however, two little angle pieces need to be carved off the top of the corners on the model and filed flush with the top of the end, as indicated in the below photo marked with arrows:

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Remove corner detail on top surface at points indicated to allow 2×6 header to be installed.

Once this detail is removed and smoothed down, the end cap is installed. I simply cut a piece of styrene 2×6 to length and cement it to the top of the edge. Once the end cap has been installed and the cement has set, I file down the angled top chord on the model flush all the way around with the top of the 2×6 end cap.

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End cap installed. End handgrabs are partially installed on this car.

Once the sides are finished, the interior bracing can be installed.

I made the braces from .040″ brass rod/wire. The rod is cut to length (approx. 1.20″) and I file one end off at an acute angle so that it rests properly against the side. Test fit this several times before glueing in place.

I drilled a small hole right next the the centre sill of the car between the bays to accept the bottom end of the brace. Then I simply use a drop of CA glue to secure both ends of the brace.

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Interior bracing.