Category Archives: DSS&A Sleeper DULUTH

Follow the restoration of the DSS&A DULUTH sleeping car.

Duluth, South Shore & Atlantic DULUTH Sleeping Car Restoration 2022 Progress Report

Mid-Continent Railway Museum Posted on by

Introduction

Good progress continued to be made on the DULUTH project in 2022 thanks to a crew of volunteers, hired help, contractors (for stripping, stained glass, brass polishing and woodworking) and many donors. A total of $29,650 in donations was received this past year, with the largest amount coming from the Emery Rail Heritage Trust grant ($15,000).

Stripping off the old varnish and paint finishes on the interior woodwork and vestibules was completed this year, while demolition and removal work continued. In addition to the work on the car, a big push was made this year to purchase and line up materials and restoring parts needed for completing the car. We are now starting to see new parts and pieces going back onto the car.

The main emphasis inside the car continues to be working on restoring the 10-section sleeping compartment that is the middle of the car. In this portion of the car new wiring has begun to be installed for both the berth lights as well as the annunciator system. In addition, new headlining panels were made and several of them were installed in the sleeping compartment.

On the exterior of the car much of the old siding has been removed and we have installed a small section of new siding. In addition, removal of the old roofing is complete while the clerestory side framing removal continues. The upper and lower roof boards are in very good condition, only needing a few localized repairs.

Work on the DULUTH will resume in 2023 with a concentration in the sleeping compartment.

Photos and additional information on the progress made during 2022 on the DULUTH Project follows.

View of the sleeping compartment showing the results from stripping down the woodwork.
View in the sleeping compartment showing one of the headliner panels being painted in the original green color.

Planning

  • Updated 3-year restoration plan
  • Updated the list of the sleeping compartment work tasks and sequence of activities
  • Obtained proposals for reproducing additional wood parts for the car
  • Developing and submitting grant requests for 2023

Design Work

    • Measured and designed the (4) vestibule doors and end windows
    • Acquired samples of the curved upper drip rails (the end drops)
    • Measured and finalized the design for the (3) missing interior doors
    • Designed the upper and lower roof drip edge moldings
    View of the vestibule end window opening that was uncovered so new window frames can be built and reinstalled.
    One of many drawings made during the year. This drawing was developed for reproducing the upper roof drip rail.

    Disassembly Work

    • Removed the balance of the old roofing material from the roof
    • Removed the clerestory wall coverings and roofing on the east side
    • Removed the original lower car siding of the entire car
    • Removed arched window trim (exterior) and battens
    • Removed the intermediate window stops
    • Exposed the framing in the NE end vestibule window opening to expose the original window frame
    • Removed the (4) vestibule doors from the car
    • Removed the hardware off of the (4) vestibule doors
    • Removed the seat cushions from the sleeping compartment and put them into storage
    Volunteers removed the old roofing material off of the roof deck and collected samples of the roof drips rails.
    Volunteers removed the original car siding off the car. Exposed is the car framing which is in very good condition.
    Volunteers in the process of removing the arched window trim, battens and the intermediate window stops.
    Volunteers in the process of removing the arched window trim, battens and the intermediate window stops.
    Two of the vestibule doors that were removed for a pattern.
    Vestibule door hardware that will be restored.

    Stripping

    • Stripped the old finish off of the end vestibules (interior), Women’s room and north aisle. This completes stripping of all of the old finish off of the entire interior of the car.
    • Stripped the paint off of the entire letter board
    • Stripped the paint off of the arched window frames
    • Stripped the old finish off of the headliner trim pieces
    • Removed straps and hinges from upper berth racks
    • Stripped the old finish off of the upper berth racks
    • Removed all of the inner window frames (25) and sent them out for stripping
    • Sent out the berth headboards for stripping
    • Sanded the lower sides of the car (exterior) to remove the old glue off of the wood framing
    A view of the aisle, on the north end of the car. This area was stripped of its old finish in 2022.
    The transom panel above the north door. This area was stripped of its old finish in 2022.
    The letter board in the process of being stripped and sanded.
    The letter board in the process of being stripped and sanded.
    The removable berth headboards staged for delivery to the firm that will strip and refinish them.

    Restoration Work

    Installation and Painting

    • Repaired (7) of the lower roof carlines
    • Cut, fit and glued new car siding on the west side of the car (north end). The section of siding consisted of approximately four feet of the car side.
    • Installed a new vestibule ceiling panel in the SE corner of the car
    • Cleaned, primer and painted the iron work (truss rods, queen posts, etc.) under the car
    New siding that was applied to DULUTH.
    A new ceiling panel installed in the vestibule.

    Materials

    • Ordered replacement specialty wood parts for (window trim, veneer panel, etc.)
    • Test fit the berth divider trim piece in the sleeping compartment
    • Received specialty wood parts made including the clearstory window frames, trim, battens, veneer panels, berth divider trim pieces, etc.
    • Sent out a vestibule door and other wood samples to woodworking shop for replicating the new parts (2023 delivery).
    • Purchased poplar material for the upper and lower drip rails
    • Milled the new upper (inner) and lower drip rail stock
    One of the volunteers test fitting the berth partition trim piece.
    Sample parts from the DULUTH (to the left) and new custom made wood parts made for the DULUTH. Parts include clerestory windows, berth partition trim pieces, window battens and window post trim.
    Custom-made interior trim pieces complete with marquetry to match the original design.
    A complete set of custom made clerestory windows made for the DULUTH. Once complete these frames will be fitted with stained glass.
    New lower roof drip rail (L) based on a sample piece (R) acquired from the car. Volunteers milled the trip rail set at the Fox Valley Technical College.

    Parts and Hardware

    • Cleaned and polished brass hardware for the sleeping compartment of the car. Presently 99% of the berth and sleeping compartment hardware has been obtained, reconditioned and restored.
    • Restored (4) toilet room roof vents for the DULUTH
    • Fabricated a new stack cover for the Baker heater
    • Restored and polished the (20) berth dampers
    • Stained and varnished the wood plunger blocks for the berths
    • Fabricated (6) new steel berth cushion support straps
    • Made replica berth curtain rod end supports (12) and curtain rods (6)
    • Restored the berth ladder for the car
    • Cleaned and polished coach lamps and associated parts (in process)
    • Acquired one of the overhead entryway oil lamps for the car
    • Stripped the paint off of the vestibule door hardware
    • Stripped the brass window catches (100) needed for the car
    • Sent out the wooden berth racks (10) and the (8) headboards for finishing (in process)
    A sampling of the brass window and interior hardware that was cleaned and polished during the year.
    The brass headboard hinges that were cleaned and polished.
    An original toilet room roof vent that was restored.
    Cleaned and polished brass parts for oil coach lamps.
    Wood blocks restored for the upper berth dampers.

    Wiring

    • For safety and reliability purposes the entire car is being rewired. This includes the wiring for all of the interior car lighting as well as the low voltage annunciator system.
    • Removed wall trim around the berth lights to access the wiring
    • Removed all of the existing wiring in the sleeping compartment
    • Installed new wiring for the sleeping compartment berth lamps (Qty. 20). (In process)
    • Installed new wiring for the sleeping compartment annunciator buttons (in process)
    Volunteer installing new wiring for the berth lights in the sleeping compartment.
    Volunteer installing the new wiring for the sleeping compartment annunciator buttons.
    Sleeping compartment annunciator buttons.

    Stained Glass

    • New stained glass material (sheets) from Kokomo Glass were received for the lower arched and oval windows
    • Took receipt of the new stained glass that was cut to size for the lower arched windows
    • Temporarily fit two new pieces of stained glass in the arched window frames
    • Provided the stained glass shop with oval window frames so the new stained glass can be made to fit into the oval windows (2023 delivery)
    A piece of the old stained glass (the large piece) with a sample of the new stained glass (small piece).
    A view of the new stained glass installed in the sleeping compartment of the DULUTH.

    Headliners

    • Cut the plywood to size for the headliners
    • Cut the canvas to size and glued the canvas to the sleeping compartment headliners
    • Painted the only remaining (original) headliner (#10) in the sleeping compartment
    • Painted the new headliner panels (#1-9). (in process)
    • Installed the headliner panels in the car. (in process 4 of 9 installed)
    The new headlining panel being installed in the car.
    One of the completed headlining panels installed in the sleeping compartment.

    Fundraising

    • $29,650.65 in donations were received in 2022. The largest donation came from the Emery Rail Heritage Trust grant ($15,000).
    • The “Giving Tuesday Fundraising Challenge” was met by successfully matching the $1200 challenge, in turn raising a total of $2400 for the DULUTH project.

    Expenses

    Contract work$25,937.62
    Labor$6,945.83
    Supplies$2,456.00
    Freight$187.34
    Total Expenses for 2022$35, 526.79

    Volunteers

    • In 2022 over (20) MCRM volunteers logged (555) man hours of time on the DULUTH project.

    Publicity and Events

    • A film crew from TRAINS magazine was on hand in the Duluth to perform a Trains LIVE video production. The crew filmed inside and outside the car while commentator Bob Lettenberger discussed the history of the car and the restoration process.
    • The DULUTH was opened up for tours in MCRM’s Car Shop during MCRM’s annual Vintage Rail Car Tours.
    • The DULUTH project was featured in the September 26th edition of the Baraboo Newspaper.
    The Trains Magazine crew video taping inside the DULUTH.
    A tour being conducted in the DULUTH.

    William Buhrmaster

    MCRM Restoration Department

    December 22, 2022

    DULUTH Fundraising Status

    Mid-Continent Railway Museum Posted on by
    Created using the Donation Thermometer plugin https://wordpress.org/plugins/donation-thermometer/.$75,000‘Thanks$67,823‘Thanks90% Other Donors ($39,573) SLHTS ($1,250) Dailey Foundation ($3,000)Emery Trust ($24,000)

    A $75,000 fundraising effort is presently underway to allow major material acquisition and some labor cost for the DULUTH to allow its restoration to move forward. This post will be updated regularly to show progress toward reaching that goal.

    To help Mid-Continent restore the DULUTH to its former glory, please consider making a donation to the DSS&A Sleeper DULUTH Fund. Donating is tax-deductible and easy to do. You can make your donation via mail or donate online using the Donate button.

    DONATE

    Be sure to write in “DSS&A Sleeper DULUTH Fund” on the printable donation form or check memo line if sending a donation by mail. Credit/debit card donations can also be accepted via phone at 608-522-4261 or 800-930-1385 by speaking to our staff during administrative office hours Monday-Friday.

    The fundraising total shown is as of December 29, 2022. The fundraiser began in May 2019. Total excludes monies raised through separate fundraisers, such as the Buy-A-Berth campaign and Matching Your Funds matching fund drive.

    DULUTH Sleeping Car Receives $15,000 Grant

    Mid-Continent Railway Museum Posted on by

    We are very pleased to announce that Mid-Continent Railway Museum has received a $15,000 grant from the John H. Emery Rail Heritage Trust (ERHT) for use on Mid-Continent’s Duluth South Shore & Atlantic sleeping car “DULUTH”.

    The DULUTH was built in 1902 by the Barney & Smith Car Company. The 10-section sleeping car operated daily on the DSS&A’s passenger train between Sault Ste. Marie, MI and Duluth, MN until 1934. After the car was taken out of service it was sold to a private resident of Laurium, MI and it spent the next 81 years as a summer cabin on the shore of Lake Superior. In 2015 the car was donated to MCRM and in 2016 the DULUTH was moved to the MCRM, where restoration work began to return the car to its original configuration and operating condition. For additional historical information, see the DULUTH’s Roster Page.

    Much work has been done to date to restore the car. To date, volunteers and employees have dedicated a combined 3,200+ hours working on the DULUTH. This 2022 grant from the ERHT will enable MCRM to focus on the sleeping compartment, making new stained glass windows and performing some exterior work. Once this phase is completed, restoration of the car’s other interior sections, seat upholstery, carpeting and the exterior restoration will take place as separate phases of the whole project.

    This is the second grant the John H. Emery Rail Heritage Trust has awarded to the DULUTH project. The Trust previously awarded $9,000 for the DULUTH in 2018 and has supported other museum projects as well, including the C&NW #1385 steam locomotive and the museum’s DL&W #595 coach car. Mid-Continent Railway Museum sincerely thanks the John H. Emery Rail Heritage Trust for their most generous grant.

    About the John H. Emery Rail Heritage Trust:

    The John H. Emery Rail Heritage Trust was created by John Emery, a native of Chicago, and a lover of the classic passenger trains of America. The Trust was founded as a way to support Mr. Emery’s interests in the passenger trains of the 1920s through the 1950s. The Trust operates as a tax-exempt 501(c)(3) foundation

    Volunteer Kathy removes decorated trim pieces from the DULUTH sleeping car’s arched windows. William Buhrmaster photo.
    Volunteer Nancy removes trim pieces from the DULUTH sleeping car’s windows. William Buhrmaster photo.
    Stu pulles wires for the berth lamps in the DULUTH’s sleeping compartment. February 20, 2022. William Buhrmaster photo.
    March 17, 2022 progress photo showing stripping the interior finish off the DULUTH sleeping car’s walls. Stripping of the entire interior is 90% complete. William Buhrmaster photo.
    Progress photo taken March 17, 2022 showing stripping of the DULUTH sleeping car’s interior woodwork. William Buhrmaster photo.

    Duluth, South Shore & Atlantic DULUTH Sleeping Car Restoration 2021 Progress Report

    Mid-Continent Railway Museum Posted on by

    Very good progress was made on the DULUTH project in 2021 thanks to a great crew of volunteers, contractors and hired help. The primary focus was to work on restoring the 10-section sleeping compartment but a lot of other areas and parts of the car were also worked on during the year. The most noticeable progress on the car has to be the interior woodwork that has been stripped of its 120 year old varnish and shellac. What has reappeared is beautiful mahogany and marquetry throughout the car. Another significant milestone for 2021 was the upper sleeping berths and lower berth seat ends, as they were completed and delivered to the museum. This included six replicated upper berths and four restored (original) upper berths. The berths are absolutely beautiful and we look forward to the day when they are reinstalled in the car. Underneath the car significant progress was made the air and hand brakes. As of the end of the year we now have functioning air brakes and the hand brake system is 95% complete.

    Photos and additional information on the progress made on the DULUTH Project during 2021 follows.

    Berths

    View of the sleeping compartment showing the woodwork that has been stripped during 2021
    • Completed the construction and finishing (staining/varnishing) of the (6) new upper berths
    • Completed the construction and finishing (staining/varnishing) (6) new lower berth seat ends
    • Applied final finish (stain/varnish) to the (4) original upper berths
    • Delivered all of the completed berths, seat ends, seat cushion frames to the museum
    • One of the original upper berths after being restored and following fresh coats of stain and varnish.
    • Another of the original upper berths after being restored and following fresh coats of stain and varnish.
    • A crate containing (5) of the upper completed berths being loaded in Michigan.
    • A crate containing (5) of the upper completed berths being unloaded at Mid-Continent.
    • (3) of the (6) new lower berth seat ends getting ready to be loaded and shipped to MCRM

    Interior

    • All of the old finish (shellac) has been removed from the existing woodwork in the sleeping compartment, men’s smoking room and the women’s toilet room. This work was performed by hired help due to the extensive scope of this work and the large number of work hours required.
    • All of the clerestory windows were removed from the car. New windows are being made as the railroad revised the design of these windows and eliminated the original stained glass.
    • Sent out 100+ pieces of interior trim and wood parts to be chemically stripped
    • (12) sets of new seat cushion frames were made. Each set includes a head rest, seat back and seat bottom
    • (12) sets of seat cushion support frames and seat back top rails were made
    • (12) pairs of seat cushion support blocks were made and finished
    • Test fit the revised berth partition overlay piece (prototype)
    • Material was purchased for reproducing the headliners in the car
    • Interior woodwork in the process of being stripped inside the DULUTH.
    • Interior woodwork in the process of being stripped inside the DULUTH.
    A portion of the end door after being stripped.
    • Mirror frame in the process of being replicated. Original frame (top) and replicated marquetry for a new frame (bottom).
    • New bottom seat cushion supports.
    • Test fitting the berth partition trim piece in the sleeping compartment with the aid of a laser frames and the seat cushion frames.
    • Taking delivery of the replicated oval window.

    Men’s Smoking Room

    • Volunteers have further developed the drawings for the missing Smoking Room and Men’s Toilet walls
    • Removed the deteriorated headlining panel along the east wall.
    • Ordered a replacement wall panel (for above the three windows) that had significant water damage
    • The east wall of the smoking room showing the headliner and upper wall panel removed.
    • The west wall of the car across from the smoking room showing the stripping in process.

    Exterior

    • Continued to remove the roof material (rolled asphalt and tar) off of the car. The roof is presently approximately 75% stripped and the majority of the wood on the roof deck appears to be in very good condition
    • (9) new oval window frames (mahogany) were made
    • (25) new outer window frames (mahogany) were made
    • 160 feet of new poplar window sills have been made for the car at an area technical college
    • We have started to remove some of the deteriorated wood siding and trim from the car
    • New replica oval window frames.
    • New lower sash window frames.
    • The cross-section of the original window sill.
    • Making the new window sills at an area Technical College.
    • View of the lower roofing being removed.
    • The upper roof deck after the roofing material has been removed.

    Air and Hand Brakes

    • Completed the fabrication and installation of all of the air brake cylinder levers and rods
    • Tested the functionality of the air brakes
    • Finalized the hand brake system design
    • Completed the installation of all of the hand brake levers, rods , supports and guides under the car
    • Remaining work on the hand brakes involves installing the hand brake levers (handles), stems and support bracket in each vestibule
    • Two of the new brake cylinder levers that were made. The steel levers are 1 inch thick and 36 inches long.
    • The bottom side of the Duluth showing the air cylinder with the new levers, rods and hangers installed.
    • Volunteers installing some of the hand brake brackets.
    • View of the air brakes being tested on the DULUTH.

    Parts and Hardware

    • Cleaned, restored and delivered over 400 pieces of berth and sleeping compartment hardware
    • Presently 95% of the berth and sleeping compartment hardware has been obtained, reconditioned and restored
    • Cleaned and restored the hardware and rollers for the (25) window shades
    • Secured a Baker heater for the car. The original one had been previously removed from the car
    • Restored Berth Pulley mechanism.
    • Restored and polished window shade hardware.
    • Boxes containing over (400) pieces of restored berth hardware.
    • Baker Car Heater acquired for use in the DULUTH. Awaiting restoration.

    Planning

    • Updated the list of the sleeping compartment work tasks and sequence of activities
    • Obtained a proposal for reproducing additional wood parts for the car
    • Updated the three year restoration plan
    • Developing 2022+ grant requests

    Fundraising

    • A total of $35,185.12 was donated (plus $1,000 pledge) to the DULUTH Project during Nov. 1, 2020-Oct. 31, 2021 fiscal year.
    • The DULUTH Sleeping Car “Matching Your Funds Drive” campaign kicked off in 2Q 2021 and met its goal in the 4Q of 2021 by raising a total of $30,000
    • The “Giving Tuesday Fundraising Challenge” held on November 30, 2021 raised a total of $2,200 

    Financial

    • A total of $41,851.79 was expended on the project during the Nov. 1, 2020-Oct. 31, 2021 fiscal year. This is a combination of labor, contractor and material costs.
    • In 2021 Volunteers logged (418) man hours of time on the DULUTH project.

    Report by
    William Buhrmaster
    MCRM Restoration Department
    January 8, 2022

    This report is also available as a PDF.

    2021-DULUTH-Progress-ReportDownload

    Giving Tuesday Matching Funds Available for DULUTH

    Mid-Continent Railway Museum Posted on by

    A donor has made a pledge for this Giving Tuesday (Nov. 30, 2021) to match up to $1,100 of donations received today for the DSS&A DULUTH sleeping car restoration. Show your support for the DULUTH project by helping Mid-Continent take advantage of this generous match offer and make a donation today! All donations are tax-deductible.

    Donations can be made through our Facebook page for maximum giving effect – meaning Facebook does not charge Mid-Continent any transaction fees for donations received through their platform.

    Don’t have Facebook? You can also donate to the DULUTH project via PayPal (accepts all major credit/debit cards).

    Donate

    Note: Donations made via PayPal are not reflected on the Facebook donation progress meter.