Where to start?

When the excitement of our purchase of #4 had worn off, many of us within AIRS were left with the daunting question- where do we start? The engine had been left in a wild state of disarray, having been taken apart and moved by no fewer than three individuals over a thirty year span. And while we had a pretty good idea of what we had when we bought #4, a full inventory would be needed to figure out what was missing from our locomotive. The Hoosier Valley Railroad Museum donated enough pallet racks for us to organize, consolidate, and store many of the palletized parts that had taken up precious floor space up until this point. While this happened, volunteers took inventory of everything we had. Unsurprisingly, there were a few freight and passenger car parts that had found their way into the mix; these were separated and marked for us to rehome later.

An assortment of parts that make up #4.

Then organized, inventoried, and shelved.

We estimate that #4 is about 80-85% complete as we have it. Most of what we’re missing are the engine’s appliances, such as headlights, dynamo, air compressor, brake stands, and more. Additionally, we are also missing the wooden tender frame, which rotted away long before AIRS acquired #4. Most of these items are replaceable, so their absence has not disqualified our engine from our plans for operation. On the other hand, in our inventory we also found a number of parts which were freshly machined and rebuilt by Dave Miner when he owned the #4 and was restoring it at the Fort Madison, Farmington, and Western Railroad. Many of these fresh parts were rebuilt and stored until we found them, which will save us much time and money later! Included were brand new pistons, piston rods, piston rings, valves and valve rods, and much more. Added to the rebuilt axle boxes, turned axles, and the new crank pins and tires already in place, the rebuild of #4’s chassis is already well underway from the work done prior to AIRS.

The rest of #4 laid up in storage

One of AIRS’ primary concerns has been cleaning and inspecting the #4s boiler to identify what repairs will be needed to bring it into compliance with federal regulations for safe operation. To this end, over two thousand ultrasonic thickness measurements will have to be taken to calculate our form 4, and identify any thin or heavily corroded areas that will need attention. We’ve already made decent progress in this area, having already noted several items to be added to the list of boiler repairs. Once our inspections have been completed we will be able to elaborate on the true extent of the boiler repairs.

Taking ultrasonic thickness measurements on the boiler barrel.

Removing the remains of the old smokebox baffles to facilitate inspection of the front tube sheet.

Further investigation of the tender tank has led us to determine that the best course of action will be to replace it entirely. The bottom is almost non-existent, as does the top show serious corrosion. The sides are not far behind- the Indiana Northern cut out and replaced the entire   middle at some point in the past, and even those repairs are worn thin. While this project is still some time away in the future, we are trying to stay ahead of the curve. Designs are being drawn up to have a new tank pre-fabricated in kit form and riveted together by AIRS volunteers when the time comes.

#4’s tender tank. Note that a faint “Indiana Northern Railway” can still be seen after decades of sitting outdoors. Plans call for the construction of a a new tank using components from the original.

Additionally, our Chief Mechanical Officers and Board have decided to move forward on what will be our first major project of the restoration. Every locomotive needs a cab, and that includes #4. The cab will be a very visible component of the engine which we will use to show our progress and give insight to how #4 will appear once returned to operation. The work necessary, while extensive, is not unmanageable or uncommon for most locomotives. Only a minor amount of metalwork has been identified- replacement of the rain gutters on the cab roof, patching small sections of the bottom of the rear cab wall, and replacing the angle iron brackets at the cab floor that allow the cab to be bolted down. From there the cab can be media blasted to bare metal and painted with primer, the wood lining remade with new lumber, and then it can be painted over in the appropriate shade of Baldwin green. When we’re done the cab will look just as fresh and green as it did when #4 left Baldwin nearly 110 years ago!

#4’s cab sitting in Aledo. The cab will be the focus of AIRS’ latest fundraising and project effort.

To have all of this done we have anticipated a total project cost of $6,000. This will ensure that it is turn-key and ready to install when the rest of the engine is ready. While not the most significant or largest project ahead of us, it is still a necessary milestone.

Only with your help will we be able to meet this goal- we are running a fundraiser through customink to sell our first T-shirts to support this project. Consider supporting the restoration of #4’s cab by purchasing an AIRS shirt through our Customink fundraiser, or by making a direct donation through our website. Please be sure that any donations made to the cab are marked as such in the “more information” section of the donation portal. Thanks!

Want to support the restoration of the Indiana Northern #4’s cab, and get a cool shirt? Get yours today at our Customink fundrasier

We’re already  looking forward to bringing you the next update from AIRS. Until then be sure to follow us on Facebook and our Youtube channel for more!