In my layout room, I would just have a picture on the wall 😉
@Mark Boyce posted:In my layout room, I would just have a picture on the wall 😉
That's a good plan and I totally appreciate its advantages. 
I put my blast furnaces on the divider backdrop because I lack the space (and skill) to do them justice.
Panhandle 1 had a version of the Open Hearth that was just a 3D backdrop. Let's just say it was my practice run at that type of building. 
George
Updated 3/6/2022:
Today we managed to cut the access hole per the plan.
More when I know it. 
George
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Updated 3/14/2022:
The "Cinder Pot Express", Weirton Steel Alco S-2 #203, joins the roster at Weirton Steel on my PRR Panhandle Division. This Lionel Legacy-equipped switcher is the former Chicago & Northwestern #1031. Christine Braden executed the transformation wonderfully. Isn't she a beauty? No. 203 joins stablemates 207 and 208. As assigned on the prototype, #203 will haul slag pots from the mill to Standard Slag and back.
More when I know it.
George
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It looks like the stock paint job to me!
George, the green switcher, that’s a Wow, it’s beautiful and I bet with Legacy command it crawls around your beautiful layout. Your layout has come a long way. I’m into the smaller switchers. So, does Christine Braden do work for others? Thanks for posting the beautiful pictures. Happy Railroading Everyone
Christine does such a great job! I have a couple I want her to paint, but need to get good photographs of what I want first.
@leapinlarry posted:George, the green switcher, that’s a Wow, it’s beautiful and I bet with Legacy command it crawls around your beautiful layout. Your layout has come a long way. I’m into the smaller switchers. So, does Christine Braden do work for others? Thanks for posting the beautiful pictures. Happy Railroading Everyone
I haven't run it too much yet, but I will get to that.
As for the layout, there is still a lot of it to be built. Only about 40% of the bench work is complete. For the moment, I have been concentrating on some of the larger Weirton Steel buildings and that area. Because of the relative narrowness of my basement, I am having to coordinate the construction. I can't just build all the bench work, followed by all the track and then the scenery. Access is the driving factor here, that can't be added later. I must carefully stage the materials and construction process; that means sections are getting done, but the total progress is slower than I would like. I can run trains, but only along the bridge and the long back wall of the layout and into the Staging Area.
Absolutely, Christine Braden does work for others. That's how I heard about her. She's looking for work.
George
You guys will like this photo - Weirton Steel Alcos 200, 202, and 201 in pretty much new condition. This would be 1945.
George
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Updated 3/17/2022:
- Cleared off the 30” x 6’ table in the train room. Previously, this held Vinylbed and track, which has since gone into some long plastic bins under the bridge. Now that it’s clear, it will be used for the Open Hearth base and subsequent work.
- Drilled and fastened all the corner and “L” brackets in place to secure the position of the Open Hearth on the benchwork. Also fastened 2 rolling casters on the bottom. First photo shows one of the backstops for the base of the Open Hearth.
This shows the hole for the casters. When the mill base is right-side up, they will sit in this hole. Why does this base have casters, you might ask? Well, because it measures 37" x 72" and will weigh an estimated 35+ lbs. If it needs to be moved it will be rolled to the edge of the layout and then lifted off by 2 people.
Here's a shot of all the backstops and the rear edge of the base.
- I also evaluated some Arduino potentiometer code sent to me by a friend; I expect to use several potentiometers in the operation of the mill. I sent him back some questions.
More when I know it.
George
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The rolling is a slick idea. Things are heavy when you have to hold them out in front of you. Our geometry teacher in high school would have you hold a book out in front of you if he caught you sleeping in class. It was palm up while you stood there and then he set the book on your hand haha
I can't wait to see the Arduino stuff!
@BillYo414 posted:I can't wait to see the Arduino stuff!
Yeah, me neither! 
I think programming the mill's operations is going to be a real fun project.
George
Updated 4/2/2022:
Haven't posted in a while, but we have been making some progress:
- The Open Hearth build is still underway, but the delay in obtaining all the Plastruct components I need is starting to have a large negative impact. All roof trusses are done, but columns (in particular) are waiting on parts.
- The wooden base of the mill has been cut as well as the board which will hold the electrical components. Both have been screwed together.
- Design of the transfer ladles is complete. We had a trial version 3D printed and adjusted the size upward a bit.
- I have spent the last 2 weeks or so figuring out how the Open Hearth's software will operate the mill. I have written a design document as well as started to layout the pin assignments. It's looking more and more likely that the Arduino UNO will not have enough I/O pins. I will probably have to go to the Arduino MEGA.
- I have also been learning the C programming language and working with the Arduino sample code and components. Just today I wrote code to successfully read the values of 3 potentiometers that will be used to set the mill's options.
- A great deal of time has been spent researching and ordering the Arduino and associated electrical components (12VDC relays, jumpers, buttons, potentiometers, etc.).
- A Fast Clock set of timings has been created.
More when I know it.
George
Good planning
Updated 4/11/2022:
- Still waiting on my Plastruct order to get straightened out.
- Got my C program to accept input from 3 potentiometers. Setting these at startup will control the mode of operation, time compression, and smoke density over the operating period.
- Designed the dials used by the potentiometers, but wasn't happy with them. So I redid the dials, changing the number of options and making their appearance a little simpler and more consistent. Doing so meant I had to refactor the software (such an innocent sounding software engineering term for "slicing and dicing" code ).
- Also got my program to lock out a button once it has been pressed.
- After getting some good advice, I placed the order for an MP3 player. I also ordered speakers, relays, an Arduino MEGA 2560, and a few assorted electrical odds and ends.
Inching along. Just inching, but moving nonetheless.
More when I know it.
George
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Updated 4/13/2022:
Some toys arrived today! We've got an 8-relay board, Arduino MEGA 2560, a holder for it (and breadboards), speakers, and a 32GB SD card.
More when I know it.
George
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I've been quietly following your thread on the Arduino sounds. That is going to add so much depth to the scene!
@BillYo414 posted:I've been quietly following your thread on the Arduino sounds. That is going to add so much depth to the scene!
Thank you. I have big plans, but still need to pull them off.
George
Updated 4/21/2022:
- My Plastruct order arrived last week and I picked it up. It's been sorted and labeled for the parts of the mill.
- After reviewing the number of pins needed for all the relays and other components, I decided to use the Arduino MEGA 2560 processor board (70 I/O pins). That was ordered and arrived. I tested it out the other day.
- Taking into account what I learned about 12VDC relays, I re-ordered two 8-relay boards (5VDC).
- Writing the C code for the Open Hearth simulation is proceeding well. We're probably about 40% done.
- Some of the additional components - MP3 player, speakers, jumpers, connectors, 5VDC power supply, crimping tool - are starting to arrive.
More when I know it.
George
That's exciting news!! Sounds like you have some momentum now!
Updated 4/26/2022:
On Saturday, I attended my division's Model Train Jamboree. It was an awesome event. I learned a great deal from both the clinics and from talking to 2 electricians who are members of the division. In fact, based upon what I heard from them, I am changing directions on the wiring of the Panhandle. Originally, I was pursuing the use of IDC (insulation displacement connectors) or "suitcase" connectors for bus / track feeder connections. From what I've learned, this is not a good solution. I am going to a more expensive, but reliable terminal block approach. This is what I'm looking at:
- 12 gauge bus wires (red & black)
- Terminal block with jumpers to the feeders
- 16 gauge GarGraves pigtails as feeders
I've also learned about something called "No-Ox" which should eliminate track cleaning and improve track electrical conductivity. I am going to give that a try as well. I think there was a thread on this forum about it awhile back.
More when I know it.
George
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I was also planning to use terminal blocks. I'm glad to hear I was barking up the right tree.
I remember the thread about track cleaners. Where does a person come across the No-Ox?
Great work going on here! I can't wait to see how the mills turn out! For the "No-Ox" I know you can get that from Midwest Model Railroad's website!
Man, that open hearth is gonna sound really cool. Ok George, gonna make u laugh - You need orange smoke for the open hearth stacks.
Tom
@TomSuperO posted:Man, that open hearth is gonna sound really cool. Ok George, gonna make u laugh - You need orange smoke for the open hearth stacks.
Tom
Oh my God, you are right! But even I am not going to that extreme. We are definitely not duplicating the toxic effects and graphite particulates of that era. 
You have to draw the line somewhere.
George
How about smoke that smells "orangey"?
Chuck
@PRR1950 posted:How about smoke that smells "orangey"?
Chuck
Hi Chuck!
Trust me, you don't want that type of smoke. The photo is taken right across the river from Weirton.
I don't think I will ever forget the smell of that HCl - palm oil mix used to keep coil ends from rusting.
George
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George,
Is that you?
Dave
That's it George - Orange Citrus smoke. We'll make a fortune.
They blew up the BOP; can't get any more graphite. How bout a couple of penciles.
It's amazing how all those smells stay with you, embedded in your smell memory. Pig fat, sulfur dioxide, red hot steel, HCl, all unique - you never forget em. yuck
Tom
George.....it was good to see you at York.....it was also funny to say out loud....."I've got to get this smokestack picture to George", and, at that very instant we realized that we were standing next to each other!
Peter
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@Putnam Division posted:George.....it was good to see you at York.....it was also funny to say out loud....."I've got to get this smokestack picture to George", and, at that very instant we realized that we were standing next to each other!
Peter
It was funny! And so very kind of you to think of me. Making and having friendships is one of the very significant by-products of this hobby. Thanks!
And you know what? While that stack isn't appropriate for Weirton Steel, it is a good fit for Federal Paperboard in Steubenville, OH. That stack was brick.
Thanks again, Peter!!! 
George
Eureka George. You're right. Looks like the federal paperboard stack. Paint it white and you're good to go.
Updated 5/8/2022:
I know it won't seem like a big deal to the electronics gurus around here, but today I made my first two Dupont connector crimps! And best of all, they deliver actually power!
George
I might have spoken too soon. While the power is correct, the female housings are not gripping the pins on the relay board well. I adjusted one of them and it's OK, but what a total PITA these are. 
This is going to take some more fiddling.
George
It’s always something
@Mark Boyce posted:It’s always something
It is. This looks simple, but... Companies that mass produce Dupont jumpers have specialized equipment. For the rest of us, it's a struggle. I did get one working and I think I know what to do. We'll see tomorrow if can produce 3 more good ones. That's all I really need.
Are you familiar with these Mark? I understand JST connectors are a possible replacement, but I know even less about them and their ease of assembly.
George
I occasionally fought with them, but it's been 20 years ago. I found them to be a bear.
Updated 5/10/2022:
Serious progress today!!!
- Resolved some mounting issues with the Arduino in the Open Hearth. Ordered some spacers, mounting feet, and extra jumpers.
- Also made a power cable for the relay board using a USB cable - it works! I decide to mate pre-made Dupont connectors to the cable (twist wires, electrical tape, heat shrink).
- Fired up one of the relays on the board using a test snippet of Arduino code - it works!
The pieces are starting to come together!
More when I know it.
George
