Restoration of PRR 5809 class EP22.

The Philadelphia Chapter of the PRRT&HS expresses its sincere appreciation to Bennett Levin

for granting his permission to publish the restoration process of PRR 5809 on our website.

PRR 5809 as of Sunday 8/20/00 some photographs are large for detail.
	Engineman's side nose showing recreated ventilation louver detail.
	Roof detail showing the two different styles of induction Train phone uprights used on EP-22's.  The different types of brackets were necessary to clear the winterization hatches on these units.
	Bodymen apply and sand filler on the repaired nose section.
	Bodymen apply and sand filler on the repaired nose section.
	Machinist E.B. Levin applies "Batten Straps" to car body.
	Machinist A.G. Hillman uses a "plumb bob" to "double check" porthole  location from blueprint dimensions to actual photograph location.
	Machinist A.G. Hillman uses a "plumb bob" to "double check" porthole  location from blueprint dimensions to actual photograph location.
	Work table note EMD blueprints and detail photographs of the Union  Pacific E-9's.
	Levin and Hillman use a beam compass torch guide to burn portholes in  the 3/16" steel plate car body.
	A.G. Hillman removes fire protection from the engine room area.  Note sandbox opening to the left of porthole with door missing.
	View through porthole showing #2 engine protector and water pump.
	Car body engineman's side showing application of portholes.
	Car body engineman's side showing application of portholes.
	Detail of nose showing application of new steel and body filler.
	Shutter batten strip showing renewal of broken fasteners.
	Detail of two piece induction Trainphone upright made necessary by the  winterization hatch.
	Detail of two piece induction trainphone upright made necessary by the  winterization hatch.
	Detail of two piece induction trainphone upright made necessary by the winterization hatch.
	Machinist G. S.  Kusner finish grinds a patch applied to girder plate belt.
	Application of 5/16-18 Pan Head Phillips machine screws to car body    access doors.  The finished project will require the drilling and hand tapping  of over 700 individual holes.  Each tap hole requires a pilot drill, tap drill, clearance drill, and tapping operation.  Over 2800 operations will be  necessary to restore the distinctive screw patterns to the car body.
	Application of 5/16-18 Pan Head Phillips machine screws to car body    access doors.  The finished project will require the drilling and hand tapping of over 700 individual holes.  Each tap hole requires a pilot drill, tap drill, clearance drill, and tapping operation.  Over 2800 operations will be necessary to restore the distinctive screw patterns to the car body.
	Car body porthole and fastener work taking place.
	New door to conceal the 27 pin MU receptacle.  Originally the PRR nose MU connections flanked the headlight behind concealed doors. These were later moved to an exposed connection below the headlight and above the anti-climber.  It would have been possible to recreate the original headlight level doors, but the height of the MU receptacle would hamper operation with road freight diesels.  The design of this application was copied from the Union Pacific Railroad's E-9 locomotives.
	Machinist Hillman begins to fit the 1" tube that will make up the induction Trainphone loop.
	Detail of Trainphone loop.  This is prior to the application of the machined clamps that hold the tube to the upright.
	Detail of Trainphone loop.  This is prior to the application of the machined clamps that hold the tube to the upright.
	Detail of Trainphone loop.  This is prior to the application of the machined clamps that hold the tube to the upright.
	Detail of Trainphone loop.  This is prior to the application of the machined clamps that hold the tube to the upright.
	Where we left it on Sunday August 20, 2000!!!
More Photos from August 30, 2000