Mike's Workshop Notebook

Reading 2100 Restoration

In 1945, the powerful Reading T-1 4-8-4 “Northerns” were built in the Reading Company’s own shops — a remarkable example of in-house engineering at the very end of the steam era. These locomotives were heavy, fast, and purpose-built for mainline passenger and freight service, representing some of the most refined steam technology of their time. One of them, Reading 2100, is currently undergoing restoration in Cleveland, Ohio under the care of the American Steam Railroad Preservation Association. The project is as ambitious as the locomotive itself — a full mechanical and cosmetic revival of a 4-8-4 mainline engine. Besides lots of grinding, painting and unsticking of rusted bolts, here are some of the other 2100 projects I had the privilege to work on.

Photos

Lapping Tool
One of the more specialized tools I worked on was a washout plug lapping tool. The boiler has roughly twenty-one inspection ports in four different sizes, so several tools were required — this being one of the set. After machining, each tool was hardened to improve durability.. The working face is then charged with abrasive compound, starting with a coarser grit and progressing through increasingly finer grades. With the compound applied, the tool is inserted into the inspection port and rotated slowly under light, even pressure. The goal is controlled material removal — just enough to polish the seating surface and eliminate minor nicks, corrosion pitting, and groove marks. A properly lapped surface ensures the washout plug seats cleanly and seals reliably under boiler pressure.
Pawl
Another small but surprisingly intricate component I worked on was the oil valve pawl — the part that positively indexes and holds the oil valve in position during operation. I began with a 3D-printed prototype, which proved to be a smart move. The print quickly revealed a non-concentricity issue with the handle's bore, that would have created binding and uneven engagement if the pawl had been machined directly. Catching that early saved a fair bit of frustration. The final part required careful milling of both the handle and the pawl itself. The pawl alone demanded four separate setups on the mill. Each face required slightly different cuts. The rectangular pawl body and the pawl shaft had to remain precisely aligned with the bore in the handle to ensure smooth operation. A Small part — but a satisfying one to get right.
Pawl
After all the careful setups, indicating, and incremental cuts, everything came together just the way it should. The pawl engages cleanly, the shaft runs true in the handle bore, and the action feels crisp and positive without any binding. A very nice fit indeed.
Pawl
The geometry worked out just right — no tight spots, no hesitation, and no tendency to cock or bind. The alignment between the pawl shaft and the handle bore paid off, allowing the part to travel freely while still maintaining positive engagement. An inserted spring will provide the preload, holding the pawl firmly against the quadrant. That spring tension ensures consistent indexing and a reliable, repeatable positioning.
Pawl
Making the new gasket for the water heater was one of those jobs that quietly demands your full attention and a bit of courage. The material was extremely expensive, so there was no margin for error. If a bolt hole landed even slightly off, or the fill tube opening didn’t align perfectly, there wouldn’t be an easy redo. I used the remains of the old gasket along with the heater cover itself as templates. Each hole location was carefully measured and transferred, then checked again before committing to a cut. The material was also fairly brittle, so it needed solid backing underneath and gentle, controlled cuts to prevent cracking or chipping at the edges. This effort unfolded over two Saturdays — steady progress, careful layout, deliberate cutting and patience.
washout plug gasket
I also cut a new set of copper gaskets for the washout plugs — about a dozen in total. They were cut from 0.125" copper plate on the waterjet. At first, everything was going smoothly. But as the center circle began to separate, the waterjet pressure would tip the loose slug upward. When that happened, the jet could deflect back toward the nozzle, soaking the abrasive stream and clogging the nozzle. Cutting would cease. Small tabs were added to hold the center piece in place during the cutting cycle. That kept everything stable, prevented lift, and allowed the jet to complete the profile cleanly. Once off the table, the center slug was removed and each gasket was hand-finished with a file to clean the tab remnants. (Ignore the 1.5" locomotive brake parts, they were also jetted that day.)
washout plug gasket
Following the same approach as before, a new batch of gaskets was cut from both 1/16" and 1/8" copper sheet. Copper is a great choice here—it’s soft enough to conform to minor surface irregularities, yet durable enough to hold up well in service.

The copper plate in the back is fresh off the waterjet, essentially in its as-cut condition. From there, the individual gaskets are separated from the sheet, the center openings removed, and the small tabs left by the cutting process filed flush. The finished gaskets can be seen in the foreground.

These will be used in several key areas on the boiler, including the safety valves, stay bolt caps, and various washout plugs.