The Restoration of Southern Railway Caboose X201 Photos and information © Jeremy Cole | Sourced from SRHA website | This document was created by NCRails.com – 29 MAR 2020 | All Rights Reserved.

Source links provided throughout article.

The Move to Calera

Jeremy Cole acquired Southern caboose X201 from the City of Selma, AL. He moved this caboose to the Heart of Dixie Railroad and

is working to restore it to road condition. Jeremy has agreed to keep us updated on his progress.

On June 21, he had his new caboose moved from its old home at the depot in Selma, AL to the Heart of Dixie Railroad Museum at

Calera, AL. Here the caboose will be restored to its original "Yellow Belly" local caboose paint.

Loading at Selma, AL on the way to Calera, AL

Unloading at Calera

Update 1: Cleaning and Window Repair: September 18, 2002

Well, the X201 restoration project is slow going to say the least. I began the restoration with a good pressure cleaning of the interior

and exterior just to get a

feel of what I had to work

with. Most of the grime

that had accumulated on

X201 over the past

several years was

removed in this process.

What I discovered was

that the car body was not

in too bad of a condition.

The interior was in

excellent condition. It had

been cleaned and painted

by the previous owners.

One of the first things I

had to do, just to

weatherproof the

caboose was to replace

the window where the

previous owners had

installed an air

conditioning unit. I

removed the aluminum frame and had a piece of Plexiglas cut to fit. Replacing the old weather-stripping was a little tricky but it all

went back together smoothly with the help of a little Vaseline. I sealed the corners where the old weather-stripping didn't quite

mesh with black silicone. The Plexiglas replacement is only temporary as it will "fog" quickly in the direct sunlight. All the caboose

windows will be replaced with FRA glazing or an approved equal (Lexan MR10) later in the restoration.

Update 2: Priming the Roof: December 20, 2002 I removed the Solar Panels from the roof. I am in the

process of gathering technical data on the panels and the battery charger. I have a contact person from the old ARCO Solar, Inc., the

company that manufactured the solar panel system. I chose to disassemble this system and rebuild it in my shop at home over the

coming winter. I had to remove everything from the roof anyway to prep it for paint.

Work is progressing slowly on X201 due to all the rain we've been having. I have been concentrating on the roof, since it was the

main part of the caboose needing immediate attention. As you can tell in the photo, the original paint had worn away and the entire

roof was nothing but surface rust. I felt I should secure the roof for the coming winter.

I coated the roof with a rust converter called OSPHO. It changes the iron oxide into an iron phosphate and supposedly ends the

rusting process. Then, to be on the safe side, I coated the roof with a Rust Penetrating Primer from ICI (Glidden/Devoe) Paints. I

rolled the flat surfaces and painted all of the ribs and rivets with a brush to be sure I got a good thick coat on them. You don't realize

the number of rivets in a steel bodied caboose until you try to paint them all with a brush! I believe the roof should hold up fine until

summer when I plan on applying the Safety Red topcoat.

As described in a previous update, I replaced another window in the caboose. The existing one was leaking and a soft wet spot was

detected in the wooden flooring along with some rust stains appearing on the inside wall below the window. So, I figured I had

better nip that problem in the bud quickly.

Update 3: More Priming and Testing the Brakes: May 20, 2003

Well, I've learned that the restoration process is a lot slower than I expected. It seems like I work on X201 every spare minute I have

but don't have much to show for it. Since the last update, I have begun the long, tedious process of sanding and priming all of the

surface rust spots that have accumulated on X201. Overall, the caboose body is in good shape. The existing coat of paint from 1979

has held up pretty well so I decided against sandblasting the cab. I used a wire brush attachment for a pneumatic die grinder on the

rough spots and then came back over them with a pneumatic dual action sander. I sanded down to bare steel before applying the

primer.

The primer I used was a red ICI

(Glidden/Devoe) brand, Alkyd Metal

Primer. Since using the red primer, I

was advised that a gray primer

would work better on the portions

of the caboose that will be painted

yellow. This will reduce the number

of coats of Safety Yellow topcoat

that will be required to cover the

primer. The primer was applied

with a brush to get a thick coat. I

will lightly sand the brush strokes

before adding the topcoat.

On the interior, I installed the air

gage. I had planned to use one of

the two green-faced Salem air

gages, native to Southern

equipment that I have collected over

the years. But, I ran across a black-

faced Westinghouse air gage at a

flea market for $8.00. It was missing

the glass lens but I had one

cut at the local glass

company for $3.00.

This particular style of

gage was also used on

Southern cabs and the

bracket on my locker

matched this gage. This

was the only piece

missing from X201

besides the EXTREMELY

rare lamp that was

mounted over the

conductor's table.

Also, since the last update, I charged X201's air

reservoir and tested the brakes. Besides some

leaky angle-cocks, the air system functioned

perfectly, even after sitting for 15 years! I'd

like to thank Mark Walker, owner of Southern

X461, and John Cudd, owner of Southern

X445, for their continued advice and

assistance in the restoration of X201.

Update 4: Even More priming and Solar Panels: November 7, 2003

The progress of X201's restoration continues to be slow. In what little free time I've had over the past few months, I have been

priming the exterior of the caboose, preparing it for a fresh coat of paint, hopefully in the Spring of '04. In the last update, the

photos showed the spot priming on some of the lightly rusted parts of the body. After the spot priming, I decided to get one good

thick coat on the entire body. The photo below shows where I am so far.

I have also primed the handrails and brake wheel supports at each end of the caboose. I have not gotten to the grab irons or steps

yet.

I removed and cleaned the solar panels from the roof. After some extensive research, I found a contact at Hutton Solar who was

involved in installing the solar energy systems to the SR cabs back in 1979. He sent me some specific information and technical data

on the charging system. The panels were rated at 20.5 volts when they were new. I tested X201's solar panels with a voltmeter

after cleaning them. One panel put out 18 volts and the other put out 13 volts. According to Hutton Solar, these numbers are

acceptable and should be sufficient to charge the batteries for the marker lights.

Update 5: Priming the End and Restoring the Windows: March 26, 2004

Well things are looking up for X201 finally. After several months of building a house and getting moved in, I am beginning to direct

my attention back to X201. I finished caulking all of the seams in the roof panels to ensure against leaks and corrosion. Surface rust

has begun to bleed back through the Rust Penetrating Primer from ICI (Glidden/Devoe) that was applied in late 2002. So, I plan to

coat again with the same red ICI (Glidden/Devoe) Alkyd Metal Primer that I have used on the majority of the car body. It seems to be

holding up really well.

I removed the "porthole" windows on the ends of the cab and sanded the end wall and door. The original red paint actually looked

pretty good after the outer layer of dead paint was removed. Due to several nicks in the paint from possible road debris during

X201's service with the SR, I decided to go ahead and prime this area as well. I plan to buff the aluminum "porthole" window frames,

replace the bolts with stainless hex-head bolts, and replace the glass with Safety-plate sheet glass.

Upcoming work: swapping trucks

I plan to swap the friction journal trucks

with a set of Barber-Bettendorf leaf

spring type caboose trucks with roller

bearings. For history's sake, the SR

equipped the local "yellow-belly" cabs

like X201 with used friction journal

trucks upon their manufacture by Gantt

Mfg. The "road" cabooses (X315 and

higher) received the BB roller bearing

trucks mentioned above. I will be

swapping the trucks with another SR

bay window "road" caboose (X458)

owned by the Heart of Dixie Railroad

Museum. This will probably happen in

April. I will document the swap with

photos which will be posted here in the

future

< The stripped end of X201

The Removed Porthole Window Close-Up

The Disassembled Porthole Window

The Primed End of X201

The Finished Porthole Window

Update 6: July 8th, 2004

Removing Trucks

Brake Repairs Swapping Trucks

Bettendorf swing hanger caboose truck Brochure

Since the last update, the X201 has had a complete mechanical overhaul - brakes and trucks.

As you may or may not realize, all (at least I believe this to be true) local "yellow-belly" cabooses in the X200 series were equipped

with older, previously used friction bearing trucks, since they normally saw only yard service or short-trip road service on local

trains.

The friction bearing trucks were in fair shape considering their age (40's era) and the wheelsets had plenty of tread and flange left.

All the journal brass was in place and in good condition as well. However, since X201 is going to be returned to service, I chose to

sacrifice a bit of originality for a more modern, less maintenance set-up. I wanted to swap the friction bearing trucks for a pair

of Barber-Bettendorf swing action trucks by Standard Car Truck Co. that were built especially for cabooses. This is the truck that all

of the Southern's modern era road cabooses received and used until their retirement.

Southern caboose X458, owned by and stored at the Heart of Dixie Railroad Museum, was the candidate for the swap. The Museum

graciously agreed to let me have the roller trucks since they agreed the more modern set-up would better suit their train operations.

(I truly appreciate the generosity of the Museum and plan to make a donation.) The roller trucks appeared in decent shape.

Before making the swap, I used a pair of old car jacks to lift one end of X458 and remove one truck.

With a backhoe, I disassembled the first truck to inspect for stress cracks, worn wear plates, and other common truck problems. I

found that many of the wear plates on the truck transom were loose or missing due to broken welds.

I also found several stress cracks in corners of the transom.

I imagine that most of these problems were caused by slack action at the end of the train and the bolster slamming against the

transom repeatedly. With the help of my father-in-law, the cracks were burned out using a torch until only good steel remained,

and then filled with E70 weld.

Burning out the stress cracks

The Final Wear Plate

In a particular note of interest, an examination of the roller trucks from X458 proved that one of the trucks had seen service under at

least two different cars. I found stencils on the bolster reading X458. Under the X458 stencil, a second stencil reading X604 can be

detected. What happened to caboose X604? Was it scrapped, was it wrecked? I plan to re-stencil both trucks to read X201 since they

have found a new home.

Since the last update, the X201 has had a complete mechanical overhaul - brakes and trucks. The old brake valves still functioned

after 15 years of static display, but since X201 is scheduled to go back in service at the Heart of Dixie Railroad Museum, I thought it

best to refresh the brake system to ensure compliance with FRA standards.

In April, I was able to obtain and install new service and emergency valves for the ABD brake.

After installing new angle cock valves on the train line and new emergency dump valves on the platforms of the caboose, I had a "car

knocker" or car-man with a local Class 1 railroad perform the single car test. X201 passed with flying colors.

Since the last update, the X201 has had a complete mechanical overhaul - brakes and trucks. The truck was then temporarily

reassembled because the date with the crane was fast approaching. Using the services of Steel City Cranes, I made the swap on May

12. As you can tell in the photo, X201 looked rather different with her new wheels!

Due to the different suspension design, X201 now sits about 2" closer to the rails. After making the swap, X201 was raised with jacks

and placed on cribbing in order to rebuild the other set of trucks. I am currently in the process of repairing the stress cracks in the

other truck. In the meantime, a local shop is fabricating new shims for the swing hanger pins in both trucks.

As soon as the shims are finished and the cracks are repaired, this truck will go back under X201. I will have to make one final raise to

install the swing hanger shims in the first truck, add fresh brake shoes, and replace the center pin with a new one. Then X201 will be

ready for service, at least from a mechanical standpoint.

In a particular note of interest, an examination of the roller trucks from X458 proved that one of the trucks had seen service under at

least two different cars. I found stencils on the bolster reading X458. Under the X458 stencil, a second stencil reading X604 can be

detected. What happened to caboose X604? Was it scrapped, was it wrecked? I plan to re-stencil both trucks to read X201 since they

have found a new home.

http://www.srha.net/documents/BarberCabooseTruckPamphlet.pdf

Update 7: Painting the Trucks, and Window Repair: February 5th, 2005

Since the last update, X201 has seen steady progress, but no drastic changes or improvements. Just more of the same....priming,

replacing windows, etc.

I sprayed the trucks and wheels with the OSPHO rust converter mentioned in a previous update. I did this to stabilize the serious

surface rust on the truck side frames. This left the wheels and side frames a white color. As seen in the photo, I have begun

spraying the trucks with cheap flat black paint. I am not concerned about the looks of the trucks. I'm sure they will accumulate dirt,

grime, and some light oxidation soon anyway due to normal wear and tear when the caboose is returned to operation.

Also pictured is another window replacement. I am having pretty good luck with the Plexiglas. The first piece was installed over 2

and a half years ago and surprisingly has no sign of "fog". So, I have been using the same acrylic Plexiglas from the same company on

the rest of the windows.

Notice the beginnings of some serious rust underneath the window frame. I grinded and sanded this rust and applied the standard

primer and one quick spray of the topcoat before reinstalling the window.

I have begun to apply a coat of brown primer on the roof, over the white rust inhibitor primer. Since the roof is highly exposed to the

elements, I don't think you I can have too many coats on it. Also, I believe the red will match better if the entire car has the same

color primer. I have priced the paint for the topcoat.

It looks like I will be able to purchase Dupont Imron "Fire Protection Red" and "Safety Yellow" for just under $50.00 per

gallon. Those are the colors specified for the caboose on the original shop drawings from the Southern Railway. Hopefully, the next

update will feature some "Fire Protection Red" being applied!

Update 8: Painting the Yellow Bellies: June 4th, 2005

The restoration process is progressing nicely now. X201's "Yellow-bellies" have received their fresh yellow paint. The last bit of work

included stripping the caulk/sealer from around the frames of the bay windows. After masking the frames and glass, the primer was

roughed-up with 120 grit sandpaper. After blowing the dust and wiping with a tack cloth, the bay windows were ready to paint.

I chose an Alkyd Enamel Bright Yellow paint by PPG Commercial Performance Coatings. The part number was ALK-FP801 in a factory

pack. This is the same product as the PPG Tec-Star 200. I also used a Tec-Star 201 hardener. I chose this paint combination for three

reasons. 1. Compatibility with the Alkyd Metal Primer used on X201. 2. Proven performance of this paint on Southern X445 owned

by John Cudd. X445 has been painted for approximately 6 years and still looks like new. 3. Price - $56.34 per gallon including the

hardener. Some of the paints I researched were going to cost in the neighborhood of $150-$250 per gallon. I had originally hoped to

use DuPont Imron or DuPont Centari. The Imron would not work chemically with the primer used on X201. The Centari (automobile

paint) was going to cost approximately $250 per gallon.

I'd like to thank Denver Moss, friend and fellow volunteer at the Heart of Dixie RR Museum, for applying the paint. Denver provided

the equipment and the know-how and did an outstanding job. Three coats of yellow were applied to each bay window, using a total

of 1.5 gallons of paint (+ thinner). The finish is deep, rich, and glossy. As you will see in the photos, there are two dents/creases

along one of the bay windows. I debated filling these with Bondo or putty, but decided that they gave the car some character. No

telling what sort of incident resulted in these marks! Next comes the red....

Painting the Yellow Belly

Completed Yellow Belly paint

Update 9: Preparing for the lettering: January 18th, 2006

Things are slowly coming together for X201. All of the original markings have been sanded and ready to be primed for the red paint. I

recently used a heat gun and a razor blade to remove the ACI labels, Consolidated Stencils, and Wheel Inspection decals. The

remaining glue was sanded away with a D/A sander.

I then used the D/A sander to smooth out the painted "SOUTHERN" letters and "X201"

numbers. The paint used for the letters and numbers was more of a paint-coated

"tape" than just brushed or sprayed on paint. I wanted to have this area as slick and

smooth as possible since I plan to use vinyl decals for the new letters and numbers. I

used a grinder to smooth the welds between the body panels in the location where the

numbers and letters will be applied.

As for the vinyl decals, I had Reidler Decal in Harrisburg, Pennsylvania produce the correct lettering on quality 3M decal paper.

Reidler is a company that produces logos and lettering in vinyl for freight cars and other uses in the railroad industry. I measured the

details of the individual letters and numbers on the caboose and drew them in an AutoCAD file. I them emailed the CAD files to

Reidler who produced the final product. I am very pleased with the quality and appearance of the decals. I will post more comments

about the decals after they are applied. The next step is to sandblast and prime the platforms and steps.

Update 10: More Body Prep and Test Run: July 31st, 2006

Project X201 is still dragging on. I'm trying to fight discouragement as I keep finding more body-prep chores that need to be done. I

know it will pay off in the end. On May 6, X201 went for a trial run on the end of a Calera and Shelby RR excursion train. I wanted to

test the mechanical repairs before moving forward with painting the car, in case there was a problem that required major repairs. As

expected, the brake system worked perfectly and the truck repairs seemed to be adequate as the ride was nice and smooth;

although I hear from retired conductors that a caboose ride at 15 mph is quite different than at 50+ mph.

I have recently sand-blasted the platforms and steps and re-primed the handrails. The car is ready to receive the top coat now.

I have also begun work on the interior paint job. I had initially planned to leave the inside the light gray color that it was when I

obtained ownership. The Old Depot Museum had painted the interior, but had used a gray that was way too light. The paint almost

appeared to be white. I wanted something closer to the SR gray. I chose the Rustoleum brand Smoke Gray from Lowe's and decided

to go with that. I looked for SR paint codes for caboose interiors but came up blank. I compared the Smoke Gray to the interior of a

derelict cab at NS Norris Yard in Birmingham, and it was reasonably close. I have completed about half of the interior painting so far.

Hopefully the next update will include some red paint!

Update 11: Painting: August 9th, 2006

Finally some definitive progress. X201 is now in the Calera & Shelby RR shop receiving paint. I began by washing the caboose with a

liquid detergent and scrubbing mold and grime from the primer. It was amazing how much dirt came off that I hadn’t noticed

building up. After the caboose was shopped, I masked all the windows and then masked the yellow belly, since it had been painted

previously.

Next, I sprayed all the steps and handrails with the same PPG Alkyd Enamel Yellow that was used on the bay windows. It took two

heavy coats to cover the brown primer.

About a week later, I was able to mask the steps and handrails so that I could apply the red.

I inspected the yellow paint on the bay windows after washing the car. I was disappointed in that the tops of the yellow bellies had

faded very slightly in just one year of application. Therefore, I began to rethink the type of red paint I wanted to use for caboose

body. Again, budget constraints are preventing me from using a professional system like a Dupont Imron or something of that

nature. I had hoped to use the original SR color “DuPont Fire Protection Red”, but I have been told by Dupont that this is now simply

“Saftey Red”.

I contacted a Sherwin Williams Industrial Coatings Rep from the Birmingham area and had him come out and look at the caboose. He

recommended a paint that Sherwin Williams currently sells to Norfolk Southern paint shops for their rolling stock. This product is

called SherCryl HPA Gloss, an acrylic paint with performance properties similar to a two-part epoxy, or a urethane paint. He also

recommended I use a clear coat, Sher-Clear 1K, on top of the red and also on top of the existing yellow that would enhance the UV

protection and in turn prevent fading as much as possible.

With this combination he estimated 10-12 years, maybe longer with minimal fading. The rep also recommended that I roll the paint,

instead of using a sprayer. I have applied one to two coats of red to the entire caboose. I believe one more coat will finish it out. The

following picture shows X201 with one coat of red on one side.

I decided to spray the intricate places and roll the flat smooth panels. I sprayed the roof ribs and all the rivets across and along the

length of the roof. As you will recall from previous updates, I have already brushed two different primers on these rivets. I swore I

would NOT do that again. The next photo shows the brake valves and air tank. I also sprayed the remaining handrails and brake

wheel supports, as well as the bay window braces and area under the bay windows.

Update 12: Finishing the Painting: January 12th, 2007

Well, the paint job is now complete and the overall restoration is nearing completion!

On September 5, 2006, X201 emerged from the shop with 4 coats of Sherwin Williams Sher-cryl HPA “Safety Red” paint and one coat

of Sher-clear 1K clear coat. The yellow-belly masking was removed leaving a striking contrast between the yellow bay window and

the red car body.

On September 16, I began to apply the lettering and miscellaneous car markings. The consolidated stencil, wheel inspection decal

and end-of-car numbers were applied.

X201 was returned to revenue service on September 23, 2006. As seen in the roster photo below, the correct SR numbering and

lettering has been applied. The original lettering reproduced very carefully. I sketched and measured the individual letters and

numbers to the nearest 1/8”. In 1:1 scale, I drew the numbers and letters using AutoCAD software. The CAD file was emailed to

Reidler Decal Corp. in St. Clair, Pennsylvania. Reidler specializes in graphics for the railroad industry. I ran across their ad in a

railroad publication and gave them a shot.

I felt comfortable with Reidler since they produce railcar graphics, logos, misc. car markings, etc for railcars day in and day out. The

decals were printed on 3M Railcal, a very fine, amazingly thin vinyl. The letters and numbers were cut perfectly; almost too perfect

since the original lettering was some sort of paint “tape” that SR slapped on the car body in rough fashion. I made the mistake of

applying the lettering on a windy day, which I will never do again. I ruined the “U” on one side and had to break into my spare set to

complete the job.

A note about decal costs, etc. The total cost of the lettering, consolidated stencils, and wheel inspection logos was $337.65. This

included the set-up fee and the decals themselves. Each individual decal becomes less expensive as the quantity

increases. Therefore I was able to order an extra pair of each decal at a fraction of the cost of the initial set.

My thinking was that if I kept the extra decals in a climate controlled closet, they would be good the next time around (although I’m

now minus a “U”!). If anyone out there is restoring a SR caboose, I would highly recommend Reidler for the lettering since they

have the SR caboose lettering on file now. The only thing necessary would be to measure and sketch the other numbers – 3, 4, 5, 6,

7, 8, and 9. I would be happy to assist anyone with that.

I also have the design and CAD file for the correct “ACI” label, or bar-code, unique to X201. Due to the intricate details of the ACI

label, this decal was priced to me at $218 per pair, so I have placed that purchase on hold to see how my budget goes on the

remainder of the project.

Moving to the interior…..The entire interior has been repainted with Rustoleum Smoke Gray, which is very close to the gray color

used by the SR for caboose interiors. This part of the project was not hard, just time consuming. You come to appreciate all the

uneven surfaces, conduits, rivets, corners, etc. that are present after the third day of painting. I’d like to thank my buddy T.C.

Vickery for his help in painting the interior. I’d have given up about half-way if not for Tommy.

The marker light lenses have been installed. I ordered new lenses from the McDermott Corporation in Chicago, the producer of the

original marker lenses on the SR cabs. A pair of lenses was just over $50…..ouch!

The next photo shows the first interior stencils have been applied over each door and each large bay window. I verified the correct

font height by measuring the stencils in a couple of derelict SR cabs at NS’s Norris Yard in Birmingham. Also, I was able to sand

through the paint and find X201’s original stenciling over the door.

The new “X201” stencil was created from the same CAD file mentioned above, but scaled to the correct 2” font. I had this cut in

vinyl at the local graphics shop, removed the characters and used the remaining outline as a stencil. Thanks to fellow museum

member and friend Jeff Murphree for this idea. The stencil cost was $4.80.

The last photo for this update shows X201 on

October 14 bringing up the rear of the day’s

“Pumpkin Patch Express” excursion at the

Heart of Dixie RR Museum. The L&N

Historical Society Special took the siding for

the regularly scheduled Pumpkin Patch train

to pass. The Special was part of the events of

the L&N H.S. Convention held in Birmingham

last month.

Remaining work for next update:

Complete interior stenciling

Exterior stenciling ( 2” COMP SHOES, BLT

GANTT MFG 9-71, and Safety slogan above

steps)

Solar panel and marker light refurbishment

Update 13 Part 1: Adding the warning labels: May 31st, 2007

Well, the project is nearing completion. Since the last update, I have added miscellaneous exterior and interior lettering.

I inspected several surviving cabs in storage at NS' Norris Yard in Birmingham and reviewed hundreds of old SR caboose

photos, studying the correct font and character height.

After gathering the lettering data, I decided to have the miscellaneous exterior lettering created on vinyl decals at a local

graphic design shop. (See previous updates for information on the large SOUTHERN and X201 lettering.) I located three

font designs on various websites that are almost identical to the original font created by the SR stencil machines. I

purchased the closest font in true text format from one of the font websites.

I will be happy to provide that information but decided against sharing it here due to copyright issues. The graphic

design folks were able to print the correct text based on my measurements and original text height measured from the

ragged cabooses at Norris Yard.

The exterior decals include the unique Safety Slogans over the steps and on the inside of the doors. These slogans were

repainted/changed frequently as X201 had three different slogans partially visible in layers over the steps. I chose my

favorite of the three and went with it. I believe SR painted the same slogan over the steps and on the doors, but I chose

to use two different slogans for variety's sake. I decided to have the interior safety slogan made as a stencil with the

correct font from a reputable stencil manufacturer's website.

Other new exterior lettering includes the brake shoe specification and the builder info, both in the correct size and font.

Interior stenciling includes various 1" stencils and ¾" stencils. I used the 1" stencil machine at the Heart of Dixie Museum

for the 1" stencils. In keeping with my goal of being as authentic as possible, I had to locate a ¾" stencil machine for the

remaining interior stencils. I would like to thank the Tennessee Valley RR Museum shops in Chattanooga for letting me

borrow their ¾" stencil machine for a couple of hours to complete the lettering portion of the project.

Update 13 Part 2: Restoring the Solar Panels: May 31st, 2007

I have also restored the solar charging system unique to SR local cabooses. The only electrical appliances on the local cabooses were

the two marker lights. These were powered by solar energy as opposed to the axle generator systems installed on the road

cabooses. This is due in part to a local seeing mostly yard service and not much time on the road at speeds great enough to generate

much electricity for battery charging. Below are some before and after photos of the solar panels and battery bank.

In order to make the system operational again, I first had to test the

charging system. In 2003, I traced down the original

manufacturer/vendor of the solar charging system. I actually spoke with

a gentleman who worked for ARCO Solar on the SR caboose project in

1979 when the local cabs were retrofitted with marker lights.

Mr. Locke forwarded me the original specifications for the ASI 16-2000

solar panels used on the caboose which included the panel’s rated

voltages and current. After a thorough cleaning, I was able to test the

panels with a volt-meter and found that both panels still produced

slightly less than the original rated voltage - 17 volts on one panel and

14 volts on the other.

The solar panels were originally covered with transparent plastic covers,

to keep water and dirt away from the panels. After much deliberation

and budget analysis, I finally decided not to fabricate new plastic panel

covers – pricing was in the neighborhood of $300 - $600 depending on

the vendor. I was shocked at the price of the plastic and the fabricating

work done for the covers.

I studied several photos of SR cabooses and found that in the early 80’s,

the covers began to disappear from the cabooses in the photos. In some

late 80’s photographs, many cabooses did not even have covers. It

appeared that the railroad also decided not to replace the worn and discolored covers with new ones and just let the panels

withstand the elements. I have tried to seal the banded edge of my panels with silicone to help make them water resistant. I hope to

keep them sealed, and plan to clean them regularly, so that the covers will not be needed. If bad comes to worse, I can buy one new

waterproof solar panel that will outperform the two existing panels. The cost for one new panel is approximately the same as the

cost of two new plastic covers.

To the best of my understanding, ARCO Solar has changed hands

a few times since 1979 and has been rolled into what is now

Hutton Solar. I was able to purchase a new charge controller

which was smaller and better suited to the elements. I

purchased an ASC 12/8 by Specialty Concepts, Inc. from Hutton

Solar for $45. I’d like to thank Ms. Donna Vega at Hutton Solar

for her patience in answering many questions and for drawing a

wiring diagram needed for the restoration. As for the battery, I

used a typical 12V size 24 deep cycle marine battery. The system

was put in service on April 20, 2007. The operating marker lights

really add some authenticity to the caboose, especially when in

service on the Calera and Shelby RR excursions at the Heart of

Dixie RR Museum.

Update 14: Final Update: April 18th, 2009

Overall, X201 has fared well since the restoration was “finished”. At some point I had to draw the line and say the

restoration was complete. Now, something harder than the restoration has begun: maintenance. X201 sees weekly

service on the Calera & Shelby Railroad (C&S) at the Heart of Dixie RR Museum in Calera, AL.

Regular use has led to the typical wear and tear, mainly just paint damage around the platform, grab irons, coupler area,

etc. That is expected and actually gives the caboose some character as a working railcar, not just a museum piece. I

have also had to replace brake shoes, air hoses, and air hose restraint cables.

I have been fortunate to find every single piece of original equipment to furnish the car’s interior. X201 has an Igloo

water bottle stamped “SOU RY”, the original Westinghouse air gage, and the original Aladdin kerosene lamp. The final

and most recent addition to the caboose interior was the Motorola Handie-Talkie portable radio that fits into the special

wall bracket. The wall bracket has been there all along, but has been empty.

I have searched the web and eBay for years trying to locate one until the head of the museum car department, Jeff

Murphree, located one. This radio, also stamped “SOU RY CO.” was found in a boxcar at the Heart of Dixie museum

along with other long-forgotten-about memorabilia. Thanks to Jeff for locating this piece and offering it to me for use in

the caboose – where it belongs!

Toward the end of the 2008 C&S

operating season, I noticed some

“cancer” popping up along the roofline

of X201 where the roof panels wrap

over and are riveted to the top of the

car body. Further investigation

revealed a poor job of cleaning and

priming in that area. Over the winter I

began grinding and sanding the rust

down to sound metal and priming. As

soon as the weather cooperates, I will

repaint the affected area with top coat

and clear coat.

END – This document was created by NCRails.com – 29 MAR 2020. All Rights Reserved.