Saturday, March 10, 2018

Bottineau Grain Train

Station sign Bottineau

In the summer of 1991 I took a trip to North Dakota with my brother, sister, mom and stepfather to visit my grandparents at their home in the quiet town of Bottineau. We caught the county fair, played at the lake, visited the family farm and played lots of card and dice games. Even thinking back to the pre-internet world that probably sounds boring, but my grandparents were a fun couple who loved to laugh and dote on their grandkids.

After our vacation concluded and we were about to leave, I chose to stick around and hang out with my grandparents for another week. I had graduated high school and didn't have anything pressing to do that next week, so why not? I'm really glad I was able to spend that time with my grandparents and get to know them as a young adult about to start college.

Anyway, there wasn't a whole lot going on during the lazy days so I chose to grab my sketch book and draw. I was going to be starting on a degree in fine arts in a few weeks so I was determined to draw what I could around town.

Like many small towns in North Dakota, Bottineau is home to a grain elevator complex situated alongside a railroad branchline. It wasn't long before I was drawn to the facility and began to study it. I took in the cylindrical and prismatic structures, the piping and wires connecting the various buildings, the contrast of the older sheet metal clad wooden elevator and the modern slipformed concrete silos and head house. Some things I can still remember clearly: the coolness of the shadows against the radiant concrete in the high sun and the ripples and waves in the slipformed walls when the evening sun set the buildings afire with red light.

And then one morning a train arrived.



Two geep thirty-eight types pulled fifty-two empties into town followed by a caboose. The train rolled into town quickly, then paused and started off again. The crew cut the crossings and tied the train down in four cuts, then stashed the power behind the depot. Before I knew what was going on the crew hopped in a taxi for a ride back to Minot.

In Texas I was used to the trains near my house flying by on the main, or coal trains struggling up the hill, or when things would get congested holding off crossings waiting for a light to get into town. The trains I'd see in Saginaw seemed static as we'd fly over the yards on the freeway. Even the jobs working the elevators and mills seemed to always be at lunch. I certainly hadn't seen anything like this.

ILSX 1366 and BN 454511

There wasn't much down time before the elevator crew fired up the old SW1 and started spotting cars in cuts of three at the barley house and at the durum house. As each car was loaded the switcher shoved them down the storage track, filling it up and eventually having to cut the crossings. Throughout the day and into the next the process repeated until the loaded train was set up in four cuts ready to be put back together and air tested.

I missed the train getting put back together, but I did see the caboose roll away behind the train and disappear into the twilight as the crew dragged it through the fields of grain down to Rugby to rejoin the main line.

It occurred to me that this process repeated itself over and over again. There was no time to rest, not for the rail crews that brought the empties in or took the loads out, not for the drivers bringing tractors, pickups, wagons and semi-trailers full of grain to the elevators, and certainly not for the switch crew at the elevator, who now had given up their switch engine duties to join in the effort to refill those silos.

Trucks lined the streets waiting for their turn through the head house. Fans and motors and machines made a constant droning sound around the complex. Clouds of grain dust floated in the air tinging everything with gold. The town was filled with that warm scent of cut summer grass.

21 years after the merger and still seeing Big Sky Blue

I had sketched and I had photographed and I had taken notes. I had a record of the locomotives, the railcars and the caboose that came to town and left. As many times as this process must have happened in towns across the midwest every day it seemed really insignificant. But those are the things nobody ever seems to take down, and soon they fade away as if they never happened. Two small town elevators combine into one complex. One town thrives and one fades away. Whatever would happen I wanted a record of that week.

Besides pre-merger hoppers, BN was grabbing every retired co-op car they could

It wasn't long before I began to make models based on those photos and notes and sketches. I soon became aware that exact models simply weren't available for most of the cars. And by exact, I mean as far as I knew there were rib side three bay hoppers and there were cylindrical shaped three bay hoppers. I could tell there were differences between many of them - some "missing" ribs in key places, some with high or low sides, some with a barrel shaped body and others almost completely cylindrical like a tank - but I didn't know how the differences broke down into capacity or manufacturer. But over time two things happened: I learned who made which car and manufacturers like Accurail, Intermountain and Model Die Casting brought out models to supplement the Athearn Pullman Standard and ACF hoppers that made up my first attempts at this train.

I took a crack at the caboose using a factory painted Athearn model. I eventually realized the Athearn model is too short, that it's a flawed model of a Rock Island caboose and not much of a match for the BN caboose I saw. Eventually I bought an Atlas caboose. Much better!

Atlas caboose modified with one of my 3D printed cupolas

Same thing with the locomotives. I bought two Athearn GP38-2s, one in BN green and one in Conrail blue. I fired up my airbrush and coated everything with a cloud of mud colored dust. It was brutal. Those locomotives eventually got stripped and repainted, then again stripped and cut up to become a pair of Mopac GP38-2s I still need to finish... I found a shell at a train show that looked pretty much how I remembered the ex-Conrail geep, so I bought it and found a drive for it. I picked up an Atlas GP38 decorated for BN later on.


Time for some updated photos!

Over the years I've replaced nearly every car I originally bought to make a model of this train. Some of them have been repurposed into models for this train and some for other subjects. More manufacturers have produced even more models, so I'm able to dial in the models closer and closer to the real thing. I even became a manufacturer myself of sorts when I worked up parts to model the caboose more accurately. I've covered some of the cars modeled in my blog previously, here, here and here.

To this day, nearly twenty-seven years later, this train remains a work in progress. I'll probably never finish modeling it. But by pursuing it, I keep it alive. I keep that summer alive. Making big bets at the card table in my grandma's house doesn't seem that far away.

My brother and I, both of us are engineers now

Now that I've been an engineer for some time, I can relate so much to that crew that tore into town, cut that train up and flew back to Minot in the cab. How many times have I done the same thing itching to get out of the seat and make it home for some time with the wife and girls before they go to sleep? Yes, you still have to dot all the I's and cross all the T's and do it safely, but an experienced and motivated railroader can do it quickly.

The older I get the less I rush like that. There's too much you can miss if you do. You end up doing it twice or more unless you take your time and move with purpose. You only learn that the closer you get to finishing something, when you can finally see your mistakes, missteps and oversights.

Who knows? Maybe one day I'll eventually get it right.

Friday, March 2, 2018

GE Kitbashes

I have a soft spot for GE locomotives if it isn't already clear. This comes from operating them for a living. The Dash 9s and GEVOs I run every day are powerful, responsive and reliable. It wasn't always that way, though. I don't think anyone disputes the bad reputation GE's Universal series and to a lesser extent the Dash 7 series earned. But once GE started listening to customers report problems, especially as they became involved in solving these problems, things started to turn around.

Real life kitbash: AC4400C4M AC four motor conversion from C44-9W ATSF 608

A big change in railroading was effective dynamic braking. As long as there was an occupied caboose at the rear of the train, train handling meant keeping the slack stretched to avoid throwing your conductor and brakeman out of their seats. To accomplish this the engineer would make a minimum reduction and drag the train over hogbacks and shallow valleys. As dynamic braking technology improved the timing couldn't have been better. New crew consist labor agreements and legislation made cabooses go away for most Class I trains. This freed up the engineer to control the slack without dragging brakes, something the railroads were very interested in because of the massive fuel savings potential, greater average speed, and a lower risk of sticking brakes, flat spots, hotboxes and other problems with the train.

Dynamic brakes had previously been more of a mountain grade feature to augment air braking on long downhill runs than a tool you'd use to control speed on flatter terrain. By themselves they weren't enough to keep heavy trains under control. But through the 70s and 80s the technology was developed to increase their effectiveness and to lower the minimum speed they were effective. With these new capabilities engineers were able to transition between throttle and dynamic braking frequently.

Back when dynamic brakes were used primarily on long descending grades, there weren't many scenarios where the diesel engine would be running hot and demanding cooling from the radiators at the same time the dynamic brakes were dissipating braking force in the form of releasing heat energy through the resistor grids. Therefore it made sense to locate the resistor grids near the radiator where you already had a large fan and intake grilles. But once the ability to transition frequently between throttle and dynamic braking was available, the diesel engine didn't have time to cool while the resistor grids kept the radiator hot. This led to relocating the dynamic brake resistor grids and cooling fans ahead of the diesel engine, first seen on Burlington Northern's second order of B30-7A cabless booster units and C36-7s delivered to Missouri Pacific and Norfolk & Western.

As the use of dynamic brakes moved outside the realm of mountain grades, they became more powerful and more cost-effective to use. Along with the adoption of computer control systems of the diesel engine and electrical systems, design elements of the locomotive had to change to hold up under the new normal extreme operating conditions. These improvements in part led to the Dash 8 series, the wildly successful Dash 9 series and finally to today's Evolution series.

GE wasn't alone in innovation. EMD also computerized their engine and electrical systems around the same time. Like GE, EMD took a new approach with the dynamic brakes on their 50 series locomotives and again with the 80 and 90 series, relocating and improving them each time.

When GE unveiled a new locomotive series it looked like each new design was nothing more than the old Universal series locomotive under layers of bolted on parts. Let's face it: aesthetics were never part of GE's design philosophy when it came to locomotives. Form follows function period. Compare this to General Motors' Electro-Motive Division, where styling was part of the identity of the company from the Corvette to the Cadillac. Look at the homely hodgepodge of a locomotive, the GE B39-8 demonstrator. Compare this to the sleek and aerodynamic EMD GP60 demonstrator, its direct competitor. If looks matter, it's not even a fair fight. But when it came to achieving fuel efficiency, higher horsepower and putting that horsepower to the rail, GE won.

EMD 7 GP60 Demonstrator

ATSF 7402 GE B39-8 Demonstrator

As a modeler it always looked to me like GE simply kitbashed their latest design using parts from previous models. The basic Universal series locomotive had a distinctive cab with a rounded roof, a snub nose and a plain long hood with a rounded roof contour echoing the lines of the cab. This plain hood was punctuated with the occasional grille and a large radiator at the rear. The improved Dash 7 series was just like the Universal series, but with the largest of the large U33 radiators extending out over the walkway. As production carried on Dash 7s had the dynamic brake housing separated from the radiator and moved to a "bump" in the auxiliary cab roof. This bump carried through to the early Dash 8 series and was incorporated into a boxy hood between the operator cab and the engine compartment. U33 radiators were changed out for larger angled Dash 8 radiators.

The Dash 9 series saw the end of the four axle diesel, the standard cab, and the simple angled fuel tank with reservoirs at each end. But with that end came the adoption of large outside coil spring trucks and optional AC traction technology. In the midst of all that was the old Universal series hood covering the engine compartment. Everything else had changed, but that hood was still there (though angled instead of rounded). That feature finally went away with the Evolution Series, along with the Dash 8 radiator, but still around were the comfort cab, the Dash 8 auxiliary cab, the big trucks and the Dash 9 fuel tank.

The apparent modular nature of GE locomotives makes them ideal modeling subjects, especially with so many nicely detailed and great running models from Atlas. The U23B drive and body shell can be combined with the U33C drive and shell to build a U33B, U36B or a U23C. Before Atlas released the B23-7 and B30-7 models, I cut down a C30-7 shell into a B23-7. I had enough trouble with the Bachmann drive -- in particular the trucks -- that I stopped work on the model. The release of the Atlas B23-7 model finally stuck a fork in this project. But the concept was proven, that with enough slicing and dicing the raw materials were there in the Atlas shell parts to build a variety of models.

GE B23-7 from Atlas C30-7 long hood and nose, Atlas U23B cab and Bachmann B23-7 frame and sill

Of course 3D printing has opened up an entirely new set of possibilities using modular components to either cut into the Atlas shell or even replace entire parts. I mentioned building a model of a late C36-7 in my Norfolk & Western clasp truck blog. At the time I didn't address the stacked horizontal radiator intake grilles because there was no good source of the grilles. I couldn't figure out how to scratchbuild them or where I might get something reasonably close to cut in. Besides, the model is painted black. Who can even tell? I finished the model in January 2014 and moved on.

GE C36-7 as NW 8534 from Atlas C30-7, Smokey Valley and Hi-Tech Details parts

A couple years later it occurred to me I could use the translucent nature of 3D printed acrylic parts to model the see-through nature of the corrugated screen grilles on GE locomotives. I drew up some replacement panels for the area under the radiators on the Atlas model and printed them. I painted them lightly with a dirty brown color, just enough to tint the grilles, then I masked the grilles front and back and painted the rest of the parts the black body color. Installed on the model they look great. If you hold the model up to a light you can see the light come through the grilles. Of course the large metal weight mounted to the frame blocks most of the light, but as a concept it's solid.

NW C36-7 radiator parts available from my Shapeways store



Since then I've designed other hood parts, fuel tanks, air reservoirs, cabs and frames. I'm even working on a body kit for Burlington Northern B30-7A booster units. Where will this end? Who knows? But I'm pretty far from the end right now. There are a lot of models and variations to cover -- and kitbash -- yet.