East Broad Top Railroad

Rebuild of Side-Dump Hopper #802 by FEBT

During the fall of 2004, Hurricane Ivan traveled through the Aughwick Valley causing some damage to the operating and out-of-service portions of the East Broad Top right-of-way. After closing for a weekend for bad weather and damaged track, EBT crews had to use a standard 3-bay hopper by dumping its load onto the track and shoveling it to one side to repair the fill. After this incident, it was clear that having an operational side-dump hopper would be an important asset.
This project was begun in November 2004. Hopper 802 is one of ten cars in the original Pressed Steel Car Co. 2-bay hoppers from 1913. Four of these were later reconfigured to dump their loads to the side instead of straight down onto the track. Only one other EBT side-dump car exists, #800 in Mt. Union. Used into the 1970's, #802 has sat for over two decades on track #4 near the south end of the yard, its steel too corroded to be used any longer.
Since this is a rebuild, and not a restoration, bolts have been used to assemble the car instead of rivets to save time. The side sheets were the only ones deemed repairable on the car, and work started with the documentation and removal of all the interior hopper and slope sheets and doors. The interior was stripped down to the frame, which was examined and found to be in very good shape. Rust was abated and painted. All the air lines were removed and replaced and the triple valve and cylinder were rebuilt as needed. Additional fittings were added for the operation of air tampers on MW trains. New steel plates on the end of the draft gear replaced the original corroded sheets.
New sheets, cut with modern lasers from CADD models were ordered to match the original, but were heavier for longer life. This car with its side dump hoppers is much more complex in its construction than the standard three bay EBT hoppers and required more than fifteen separate sheets. Some of the sheets weigh several hundred pounds and were lifted into position by the hands of many dedicated FEBT volunteers. Spare EBT door latches were rebuilt from EBT inventory and installed on the car. Most sheets were primed and painted prior to installation. All of the repaired metal components on the car were rust abated and painted.
The last sheet of steel went into the car in early 2006. Installation of the doors and additional hardware will probably be done before swapping the car to its original trucks will occur in 2006. This original group of ten cars was built with archbar trucks. #802 currently sits on cast Vulcan trucks which do not fit.
During the FEBT's mid-July 2006 work session, one archbar truck belonging to hopper 802 was removed from another car and was prepared for maintenance.
The first truck's suspension bolster and pivot was rebuilt due to casting damage both inside and out, the bearings and brake rigging were gone over during winter 06-07 and it was primed. Two of the dump doors were rebuilt, fitted and painted during the fall weather. During the spring of 2007 the first truck was installed after the car's bolster pivot was replaced due to rust and age. Two wooden stone plows were rebuilt and the third door was fitted. A second arch bar truck has been located and it's rebuild was started, mainly needing the same work as the first. The fourth door is currently being worked on and the second end's bolster pivot must also be replaced. Completion of the project is expected for late fall 2007 if there are no more surprises.
During the September 2007 work session the second archbar truck was installed under hopper 802.
The second truck was installed in November 2007 with the side bearings setup and all the brake rigging hooked up and tested for the final time as well as having all the brasses removed and inspected.
During January 2008, the second truck had the journal boxes repacked and oiled. The final miscellaneous suppport brackets were welded on and several minor clean up things were taken care of. The hopper is operational right now but will require some painting once the weather warms up, to truly say it's finished.
The total time it took was: 3 years and one month (however there was a six month period that no work was done on it due to priority on other projects). It can be said that a five man crew working 40 hours per week did it in ten to twelve weeks.

New hopper sheets are being riveted into place and
grinding is being done on a corner of the frame.
The slope sheets on the B end of the car have been removed
revealing the inside. Notice the small rail used for horizontal bracing.

A later photo of the B end shows one slope sheet
installed and red primer on the frame.
A coat of paint is applied to the inside and the doors of hopper 802.

The archbar truck on the B end of the car was previously installed.
Here the other end of the car is jacked up to remove the Vulcan truck and
install the second archbar truck.
Hopper 802 sits on the escape track with just a few minor things to take
care of being it can be turned over back to the EBT.