Canadian Hopper Number Two: Operation Life Saver...
by Lee Wright

click on images for larger view

The first hopper was so much fun I thought that number two should be in order. I had already welded together the tank so that was a head start on number two.

Back in 1999 Model railroader had a picture of an HO Canadian National hopper. This was a one of a kind paint job on a 100 ton covered hopper used to haul agricultural chemicals. The paint job caught my eye, so I decided that someday I would build a car like that and give it that paint job.

The car is pained on one side like a roll of life savers using seven different colors of paint. It is an eye catching paint job. Although the car is not quite finished for lack of a few bolts and nuts, the following photos will show some of the construction procedures.

Picture number one shows some of the bolster parts laid out before welding. The bolster side plates were cut from 1/8" material so that in welding to the car bottom, I would not burn through the side of the plates. The holes in the plates will be for the brake lines to run through at a later time.

All the parts will now be clamped to the sheer plate or floor of the car.
The sheer plate is made from 3/16" thick material. Included is: the center frame or coupler pocket and cover, the bolsters, bolster ends and end braces and truck center bearing. The blue painters tape will help me keep the parts lined up on center as they are clamped into position.

The photo below shows the welding completed and the parts primed.
Note the safety chain brackets welded to the coupler cover plate.
Also this is a good view of the bolster truck bearing and pin. The long pin is used to guide the car onto the trucks, but the car sets on the bearing and is not attached in any way with bolts and such.

The next photo shows the welding complete on both ends. Note the tie bars welded across the frame rails. These will be removed later after the tank is welded on.

Building he Hopper bottoms: This was a new technique on this car, more parts to cut and more welding, but much better results.

I started by using the same blue prints. This time, rather than trying to saw and bend several parts at the same time, I cut all the individual part on the sheer and then welded them together using the hole strips and plug weld system.

By making the welding strips, punching holes in them to weld in, I eliminated the necessity of welding along the seam between the parts. This procedure keeps the parts from warping.

Finally the hoppers are attached to the bottom of the car using 6-32 button head cap screws. The bottom of the frame rail is tapped for this attachment.

Hopper is much too big and heavy to handle at this point. Hoist is used to pick up and turn it over. The cargo strap and be centered on the car and one person can turn the car over. Later when car is put on it's trucks, it will remain there for the rest of the build.

At this point I will jump ahead and show a few pictures of the car although it is not finished at this point.

Stay tuned for more on the build. I will show details of the tank hatches, bottom gates and walkway.


Lee