Powell 3-Chime Steam Whistle: The "Almost" Repair... 

I always enjoy your videos, and thank you for for passing on your craft skills. By watching your videos I can tell that you are a true gentleman.

Hey Keith, great video. Nice to see you use the adjustable wrenches in the correct direction. I've watched all the other guys use them in reverse and drives me crazy.

Good choice. Safety first. Rescue the old whistle if at all possible. Thanks.

Keith I congratulate and admire you for your Safety First decision. I love those miniature Crescent wrenches. Regards

We can all see how safety will be your first consideration Keith, and most will be hoping to see you either cast a new valve body or machine one from the solid. I can't wait to hear the tone of that whistle, should you make a successful repair, all the best, Rob

Hi Mr. Tucker. Steam can do an amazing amount of work when harnessed but can be A killer if left to it's own devices. My father was an electrician for 40 year's. Didn't want his son's going into such A dangerous trade so my brother and myself became steam engineer's. No danger in that!! Good luck!

Just watching this it occurs to me that with all the machining tools you have at your disposal, you could build a whistle. That would be a fun project to build I'm sure. It would also be a thrill to watch. I know my online persona doesn't reflect it. I am a relatively huge steam nut. I've always found a great fascination with old machinery. So much so that I've built several small model engines and even gone so far as to ride the Daylight Express which is one of the largest steam engines still in serviceable condition. Though I think they run it only about once a year it is an amazing experience that I highly recommend. The point is that those deep trotted whistles have a warmth to them and I'm sure you could just build one. While the maths would be a little more complex than you may be used to there are online resources to help with that. I got at least 30 results from simply googling it. Anyway, it's just an idea. So far I love the videos and I hope to keep seeing them.

Hi Keith, Right decision, after all it's a good thing it's a bad whistle valve, we'll get an interesting series on casting and machining, isn't your channel about restoration, above all...? lol Don't forget to include lots of details! That decision made the whole bunch of us very happy. Take care, Pierre

That whistle would look good on the train! I hope Kevin lets you go ahead with the casting rebuild for the valve! Nice "Almost repair" Keith! Hope it becomes a future casting/machining video! Jeff

I too hope that at some point you can get the Whistle valve rebuilt or replaced. Good luck with that and thank you for sharing.

That steam whistle certainly has seen much better days. You could cast a new body in bronze but it would be a significant effort to design the casting. Great videos.

I would definitely make a replacement base for that whistle a lot stronger and larger so it doesn't break again.

Hope to see the whistle get repaired, but I agree with you safety has to come first.

Hey Keith, sorry to see the loaner whistle was not repairable, but good to be safe and not risk it. Fun watching you install the whistle there at the end, good camera work.

Hi Keith From a distance it looks like the valve body could be unscrewed from the whisle itself - if not you may be able to MAKE it as a two-part jig - the whisle itself and the valve itself. It looks like it could have a very ear-gentle sound with these 3 tones making a chord deeper than the existing one on the locomotive today. ... and it would be a very nice project too - right ;-))

i\m glad you decided not to risk that whistle failing again. plenty of antiques can be enjoyed without them being powered. i would say i have moderate understanding of steam engines since i build one every few years, but any time i see a component over 50 years old working i'm very cautious of how the old metal will handle the pressure/age/heat.

Quite right. Safety first. The expansive quality of steam (250X) also makes it ideal for fire fighting. When injected into a super heated space of uncontrolled fire, you have instant fire knock down. The technique is taught on board ship to the fire teams. Fire and steam can be a most helpful friends, but when uncontrolled are fearsome! Cheers.

WOW Hope you can make the repair sometime soon!

Keith, I was hoping you would think 'Casting Project!!!' It would be great to hear that old whistle working safely again and not becoming a missile into space. Do you have any drawings to go along with it so we all could build one? It would make a great safety warning for when one of the machines at work start turning. Right now we just yell 'CLEAR' and away it goes.

thanks for the video

Yep, i could imagine if the engine had just got up steam, plenty of fuel on the fire, and that whistle came off, apart from the danger of the projectile, you would have steam pouring out of the hole, and would have to put the fire out quickly for fear of boiling dry But then i noticed you have a second valve on that stack. Good call though

That would be a complex casting with the passages and machining. Might be worth it to see if anyone else needs one.

Keith, A wise decision! Steam is nasty stuff! As you know, water boils at a higher temperature when under pressure. Thus the boiler is full of super-heated water that has not yet turned to steam. Once the pressure vessel is breached, the pressure is lowered and that super-heated water instantly turns to steam! That's when boilers blow up and all kinds of nasty things happen. I've read in my vintage locomotive magazines about engineers getting scalded because the water level got below the crown plate (the sight glass wasn't working properly). The crown plate sagged enough from the heat of the firebox and bolts snapped breaching the boiler. The super-heated water turned to steam, blowing the door off the firebox, blowing the fire into the cab and the steam "cooking" the engineer and fireman. They were luck to survive! Operating a steam locomotive in poor repair is akin to sitting on boxes of dynamite with a lighted match. Sorry for the ramble. I'm sure that guy with the 3-D printer can come up with a form for a valve body that you can cast and machine. Sorry the other whistle didn't work, but you are very wise to err on the side of caution! Have a good one! Dave

The new valve body project would be a real treat to watch.

hello Mr. Rucker, i just saw this and loved powell 3 chime. its funny that you mention the buckeye whistle i just bought one from Ebay. it looks like the rocker arm is broke right off. i could probably buy a new valve. what would the valve assembly be called? any specific terms? thank you.

To maintain historical integrity and originality it could be possible to use the original material melted to make new one.. might have to add a little more because of material losses but the idea of a 3D print molding and casting would be so nice for this.

i know valves are normally made from bronze, but could that vlve be made from brass and have de zinced?

Keith, I sure do enjoy your videos. Being an old time welder and have I done a lot of brazing in my time I was wondering. I saw the cracks you showed us in the video that are through the threads and the body I think. Maybe you could grind the cracks with a small rotary stone or burr half way through the body on the inside of the thread bore.Then grind the cracks out from the outside of the valve body to the new braze deposit and then braze the crack back up to the surface giving you 100% new metal. Then remachine the valve body threads in the lathe probably in a 4 jaw chuck if it can be chucked. Just a suggestion since you would have 100% new braze material which would be as good as the parent metal. Of course safety is always first and that is the main concern. Thanks for your videos I'm learning, Jeff

keith i hope one day you go and rebuild that valve and make it safe to use. i would really like to see that.

Have you looked into repairing the whistle? Five years has gone by.

Such a pity. Hopefully you'll get the go ahead to cast a new piece, it would be a shame not to get to use it anymore. IMO, it was hit whilst on the locomotive it last came from. I've seen one being sheared off many years ago as a kid. It was quite a shocking experience. Luckily nobody was hurt as the piece just bent over to the side but you can imagine the sound and the shock of the moment. It's actually one of my most vivid recollections of my childhood.

Keith, What is the PSI of the steam in your locomotive?

I just saw that this video is at least 5 years old. Did the whistle get off the back burner?

A would love ta see the video on when u redo the steam whistle and hear how it sounds when it's done

That is what happened to 819’s whistle when in fact, it was on the return trip to pine bluff from St. Louis in 1990 when the whistle close to the stack blew off southbound and then find the whistle and call in a diesel helper for the remainder of the trip home in pine bluff

I'm curious. Can't you cut the valve clean off and thread the bow or actually solder a nut and thread that? The whistle i think can be reused.

Just won a 3 chime whistle at a auction. Have not found a name on it just some short numbers 2 to 3 digits. Hooked it up to air and it blows well. The problem is it looks like someone shot it with a black powder ball round twice both in the same chime towards the top one made a dent about the size of a quarter the second round was just below the first about 1 1/2 inches it also made a dent about the size of a quarter this dent also has a small crack in the brass. Can any one tell me how to remove dents in a brass whistle and what would be the best way to repair the crack in the bell? I will get some pictures but I am not sure how to get them up to view.

That’s a magnificent piece of treasury. Too bad you can’t just machine a new one like that one.

not familiar with that whistle but does the valve body not unscrew from the whistle if so you could replace it maybe?

I hope you get to cast a new valve body. I like see restorations that look undo-able but just take a little more know how.

Wise choice.

Too bad the valve body was in such bad shape. Looks like a good project for the future....Does your cast iron foundry vendor work with brass?

We’re you ever able to fix it?

With your skills, you could design a new whistle. There are some formulas to determine the size of the chamber to make a note (organs and wind chimes). Since having a lower note sounds advantageous, that might be the direction to go.

I hope you get the OK and find time to recreate that new valve. I have little doubt the lower pitch is more suitable for Y'alls needs,,, what with the children... My grandson holds his little ears at far less decibels, sometimes to my surprise! Thanks for this video Keith! :o] O,,,

The valve is separate from the rest of that whistle; it threads into the bottom of the bowl (strait, not tapered threads). You could take it out, get a 1 1/2" or 1 1/4" whistle valve, and machine an adapter to go between the two.

Lost wax casting works for a one-off . . . at a price?

I agree with safety first. Once you get permission to take it apart, I'm wondering if machining the valve out of solid brass would be stronger and safer than casting a new one.

Yeah 💪you do have man 👨 size 💪🔧 tools ⚒️ thumbs up 👍 I liked them tool sir ☝️😄

Hi Keith, one idea, can you make a whistle of stainless steal? Here in Aruba I saw one in the Oil Refinery...works on steam. It was just the size you have there broken.......I think that thing was about 25 years old when I saw it......that was in seventees and it's still there and working. I don't recall it had three chimes......but they use it everyday. Hugs big daddy....love from Aruba! Vale!

Ahhhhh come in repair it it's a beast

I would like to repair my powel 3 chime whistle but am not sure where to start. can you help, mainly need to where to start. i have a parts photo.. thanks. Aden

That's to bad. If I was in Georgia I'd loan you guys my 6 chime. Made in 2013 it's a cast valve/bowl and welded chimes. Only been mounted to an engine once.

Hello Keith - Long time subscriber of your videos, watching this video of you using those heavy crescent wrenches you don't you look into buying a few aluminum crescent wrenches, less strain on your wrists - I have a invested in a few and they do come 24 inches in length .

Good afternoon from St John Parish, Louisiana 14 Dec 20.

These Powell whistles were often built with defects. It doesn't surprise me that something is damaged on it. The vale should be removable, and you shoud be able to put a different external valve on it. Also if you want a source of new whistles, a frind of mine makes new ones in that size from scratch. Look up Rizzoli Locomotive Works.

could you cast a new one?

If you've got the ability to sand cast, I'd say go for it. Some time on a 3D printer and pouring brass has got to be cheaper than a giant block of brass and a CNC machine.

So close , but like you said safety is first concern.

Keith Cut that valve off and braze a hex on that bowl ,after turning the bowl bottom true. Make a heavy fat brass/bronze hex and braze it on. Carefull not to warp it. Send me that thing I will do it!!

Hope you get to rebuild it be a shame not too. great video anyhow.

Keith, PLEASE try to repair/replace that whistle valve body as an extremely interesting "project." It looks so simple, but we know better.

maybe you could get some billet material and cnc machine a new valve, expensive but history is priceless.

Come on Keith, don't give up yet. Recast that valve body! Remember the little engine that could. :-)

It'd be awesome if you could repair that by recasting the valve body.

c'mon keith you know you can do it...;)

Valve itself , reminds me of older gas shutoff valves, converted.

I wonder if Kevin Wood knew Albert Keyser in Pensacola who was building a scale model of the General at Kennesaw in the '80s. Albert even made parts for the engine that were missing. I lost track of his engine, about finished when his health deteriorated.

Shame about the valve body. I wonder if Powell's valves for whistles that size all had the same threads?

Neveda and northern baldwin 4-6-0 engine #40 also was known for Powell 3 chime steam whistle it sounds like a ghost train

Can you cast a new valve body out of brass and machine it to fit? It would be really neat to hear that operate.

Have you thought about taking the valve out of it and putting an external valve underneath it? It would reduce the chance of it coming off.

You can always adapt an air nipple onto it and blow it using compressed air. A lot safer and entertaining. Did that to mine and it works great.

Good choice in not using the whistle. I have heard of a steam tractor blowing up somewhere in the States that killed people.

Bummer...

Any chance you could message me the dimensions of this hard to find whistle?

Get that forge fired up lad :)

Can't see why another can be machined from a solid block most done on a lathe and a little milling? rainy day work Keith

THE VALVE IS REPLACEABLE. IT IS THREADED UP INTO THE WHISTLE. THIS IS UNIQUE TO POWELL WHISTLES.

MCMASTER & CARR - STEAM VALVE REPLACEMENT ??

You guys can still repair it all you need to do is make a new valve and bottom pice. Not that hard or expensive

calling all youtubers get together and restore that whistle

almost :-(

the only thing worse than shrapnel is HOT shrapnel...looks like something for museum display only. sorry you lost all yer stuff. the only thing left in my truck usually is sonic wrappers and I don't want my door or window jimmied over that.

Keith, you may like the sound of this whistle of the stern wheeler Sprague. en.wikipedia.org/wiki/Sprague_(towboat) steamboats.org/whistle-calliope/sprague-steam-whistle.html

ONE CAN BE MADE FROM A SIMPLE GLOBE VALVE OF THE CORRECT SIZE ALTHOUGH THE THREAD IS NOT A STD. NPT. YOU WILL PROBABLY HAVE TO TURN OFF THE FLATS ON THE TOP OF THE VALVE. THREAD A NIPPLE IN THE BOTTOM FIRST, CENTER AND THREAD TO THE PROPER DIMENSION.

If that part comes off? Why not just make a new part, and yes make a 3D part, or give it to our buddy Adam Booth.

. Fix the darn thing! that's what A shop is for! and that's what a shop foreman is all about !!!...I mean you could send that thing to India just the part that needs to be replaced and they could pour a new one out of a sand casting!!! Don't give up so easily on authentic real stuff. After all that's what a shop for Mand does!!! if you can't do the work then send it somewhere else and let them cast a new bottom, or just machine it out of a solid block! amen amen and amen or is someone trying to get that whistle on their fireplace mantel? The bottom doesn't have to be the same !you can remanufactured our use a piece of cast-iron fitting or whatever to make it work

+Keith Rucker if you want to watch a video of my 6 chime being blown check out my videos on my channel. Also there's a video of me giving details about it's fittings etc.

Keith, here is a snippit of video my friend Stephen Syfrett made of me running the train the day we ran that Powell whistle on the Vulcan just folks can here what it sounds like. ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-PkCjtpE1A4k.html I had heard Powells were kinda notoriously hideous sounding but this one isn't too bad....

Here's someone's vid with the Powell in it, if you wanna hear. ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-PkCjtpE1A4k.html

Keith, What about just buying a new valve? Lunkenhiemer still makes quick acting globe valves. valves.lunkenheimercvc.com/category/bronze-valves. I could not tell from the video but it looks like the top of the valve is a male thread? Rick

Good for you. Don't be stupid and kill someone.

Recast the valve

I'll give ya $200 for that nasty old thing.

shame that keith

Couldn't you build a replacement valve out of brass? Would look sharp and be a nice project to watch...but: right decision.

. Don't give up so easily on authentic real stuff. After all that's what I shop for Mand does if you can't do the work then send it somewhere else and let them cast a new bottom or just machine it out of a solid block amen amen and amen or is someone trying to get that whistle on their fireplace mantel? The bottom doesn't have to be the same you can remanufactured our use a piece of cast-iron fitting or whatever to make it work

If you can't fix it send it to me and I'll fix it

I was disappointed that you put it back together. Please tag it as dangerous so no one in the future tries to use it.