Join the Railroaders Memorial Museum and FMW Solutions to recap the colorful history of Pennsylvania Railroad steam locomotive No. 1361 and explore the engineering and restoration challenges in taking on the rebuild of the Spirit of Altoona. You can support the project by making a donation here.

The restoration of K4 1361 is a thirty-year undertaking that has seen multiple project managers, with considerable work completed. However, there is still much to be done. The latest boiler studies revealed some of the following:

(1) Some of the rivets used in the boiler were of the incorrect steel.
(2) The repair and subsequent re-repair of the main dome course needed further inspection.
(3) Some firebox repairs were completed with improperly sized materials. FMW Solutions has undertaken ultrasonic testing to further assess the boiler’s integrity. It was determined that the firebox area would require some of the project's most substantial repairs.

The square, Belpaire-style firebox with which K4 1361 was built was a key feature of PRR steam locomotives. The Pennsy designed the K4s with the ability to swap components between 400 different locomotive designs. FMW undertook both traditional and computational engineering analysis of the boiler in addition to building a 3D CAD model. Through modifying material thickness and staybolt size, FMW has engineered a solution that will preserve the original Belpaire boiler and return the locomotive to operation. Much of the firebox will be replaced with new steel—resulting in a safer and sturdier locomotive to last.

For a summary of our initial inspection and engineering report for the locomotive, click here.

CHATTANOOGA, TN – FMW Solutions, a railroad mechanical, engineering, contracting, and consulting firm, has hired railroad veterans Katie Slider as Senior Operations Manager and Roy Wullich as Manager of Operations and Finance.

“Our firm has over 60 active projects between our machine shop, engineering department, heritage work, and diesel locomotive repair efforts,” explained Davidson Ward, President of FMW Solutions. “Katie and Roy will bring valuable organizational support to not only our 30-plus employees around the country but our diverse group of clients as well. We’re humbled to have these accomplished rail industry professionals aboard.”

An award-winning Norfolk Southern employee, Katie Slider’s 24-year career saw her administer equipment planning, operating best practices, end-of-train devices, and car maintenance with senior leadership, mechanical departments, business analysts, and fleet managers. Katie also helped lead Norfolk Southern’s 21st Century Steam Program between 2011 and 2015. Her role at FMW will oversee client onboarding, project management, internal procedures, and the firm’s expanding machine shop in Soddy-Daisy, Tennessee.

With over 40 years in accounting and finance, including 20 years in rail operations, passenger car management, and historic preservation, Roy has held various senior management positions at several international companies including Intel, KPMG, and Price Waterhouse. Roy’s service in rail preservation includes leadership and advisory positions with Canadian Pacific, Railroad Passenger Car Alliance, Tom E. Dailey Foundation, Nashville Steam Preservation Society, and service with the New Kent County Sheriff’s Department.

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ABOUT FMW SOLUTIONS

FMW Solutions and its subsidiary National Rail Consulting Group offer a suite of professional services for the railroad industry, including mechanical and engineering design, diesel locomotive servicing and repair, rail operations, strategic planning support, marketing, public relations, safety compliance administration, training, and alternative fuel technology research and development. FMW is also an accomplished rail preservation resource, with expertise in the restoration and operation of historic equipment. For more on FMW Solutions, to request a quote, or proposal, or to explore opportunities for your railroad operation, email us, or call (423) 425-9753.

CHATTANOOGA, TN (March 27th, 2023) – Railroad contracting, engineering, and mechanical services firm FMW Solutions has received its ASME “S Stamp” and NBIC “R Stamp” Certifications. These two certifications enable the firm to complete the new fabrication and repair to “Code” regulated pressure vessels, including steam locomotives operating at theme parks and historic traction engines. FMW is now under contract to assist a steam heritage railroad and a steam traction engine owner with code work, utilizing these new certifications to aid those clients in operating and restoring their historic boilers.

“FMW’s earning of the R and S Stamp certifications allows us to expand our quality boiler repair work beyond just FRA-regulated locomotives,” explained Shane Meador, FMW Vice President – Mechanical. “This development allows our firm to continue providing one-stop, in-house solutions to our heritage customers, utilizing our team of mechanical engineers, welders, fabricators, and machinists to champion craftsmanship in the 21st Century.”

First on the list of “Code” work for FMW is the provision of on-call steam locomotive mechanical, inspection, and repair work to a steam heritage operation in New England. The state-regulated railroad is home to three operational steam locomotives that it operates throughout the tourist season.

In addition to our work in New England, FMW is also assisting with the overhaul of a Nichols & Shepard steam traction engine. While the engineering survey is underway for the boiler, it is envisioned that a new boiler will need to be fabricated for the vintage traction engine. FMW will complete the fabrication of this new boiler at its Soddy-Daisy, Tennessee, machine and fabrication shop.

FMW Solutions and its subsidiary National Rail Consulting Group offer a suite of professional services for the railroad industry, including mechanical and engineering design, diesel locomotive servicing and repair, rail operations, strategic planning support, marketing, public relations, safety compliance administration, training, and alternative fuel technology research and development. FMW is also an accomplished rail preservation resource, with expertise in the restoration and operation of historic equipment. For more on FMW Solutions, to request a quote, proposal, or to explore opportunities for your railroad operation, email us, or call (423) 425-9753.

Pere Marquette steam locomotive No. 1225 is undergoing some of the most extensive mechanical restoration work in over 70 years. Visit with leadership from the Steam Railroading Institute and FMW Solutions - Railroad Contractor Services to learn about the in-depth process of renewing the running gear of one of Central Michigan's beloved railroad attractions.

OWOSSO, MI - The Steam Railroading Institute (SRI) has retained FMW Solutions to perform critical wheel and running gear work on Pere Marquette steam locomotive No. 1225. Underwritten by recent grants and generous donations, the work will see 1225 lifted, and its 30-tons of drivers, axles, and wheel assemblies removed and rebuilt by FMW. This will be the most extensive running gear work performed on the locomotive since before it was retired in 1951.

“This project is all about sustainability,” shared Steve Wasiura, Superintendent of Facilities & Railroad Operations for SRI. “1225 has been a reliable performer throughout its excursion career, and this work will keep it running for decades more. At FMW, we found partners who share our passion for preservation while understanding what it takes to keep steam-era railroading alive in 2022 and beyond. We are thrilled to be working with them!”

“1225 has emerged as an icon in our industry and one of the few large mainline steam engines with a regular operating schedule, which puts a unique kind of demand on a machine that’s 80 years old,” stated Shane Meador, Vice President of Mechanical for FMW Solutions. “We’re looking forward to assisting SRI in getting thousands of miles more out of this machine.”

1225 joins the lineup of over a half dozen steam locomotives in the United States for which FMW has performed work or is currently under contract, including the restoration of United States Sugar Corporation No. 148; Former Atlantic Coast Line No. 1504 for the United States Sugar Corporation, Pennsylvania Railroad No. 1361 at the Altoona Railroaders Memorial Museum; Nashville, Chattanooga, & St. Louis No. 576; Western Maryland Scenic Railroad No. 1309, among others. FMW is also responsible for the marketing, operations, and passenger car restoration for Sugar Express.

The Steam Railroading Institute is a non-profit, volunteer-driven educational organization dedicated to preserving steam era equipment and the skills needed to maintain and operate it. In addition to Pere Marquette 1225, SRI also operates a growing fleet of historic passenger equipment and is restoring another steam locomotive, Chicago & Northwestern 175, to operation. Visit michigansteamtrain.com for more information on how you can help keep steam railroading alive for future generations.

FMW Solutions and its subsidiary National Rail Consulting Group offer a suite of professional services for the railroad industry, including mechanical and engineering design, diesel locomotive servicing and repair, rail operations, strategic planning support, marketing, public relations, safety compliance administration, training, and alternative fuel technology research and development. FMW is also an accomplished rail preservation resource, with expertise in the restoration and operation of historic equipment. For more on FMW Solutions, to request a quote, proposal, or to explore opportunities for your railroad operation, visit fmwsolutions.com, email info@fwmsolutions.com, or call (423) 425-9753.

Restoring, renovating, and rebuilding vintage railroad passenger equipment is the next step for a steam-powered excursion line in Florida. Learn how we helped create a first-class tourist train – and the customer experience to go along with it.

Written By Kelly Lynch, Director of Special Project and Railroad Preservation Consultant

As the restoration of United States Sugar steam locomotive No. 148 crossed the finish line in April of 2020, the conversation immediately pivoted to what the 1920s steam locomotive could pull behind it. While Florida had previously been home to several steam-powered tourist trains operating on the general railroad system, the South Central Florida region hadn’t seen any steam or first-class trains in decades – a far cry from an area that had once hosted the prominent trains of Atlantic Coast Line, Seaboard Air Line Railroad, and Illinois Central.

Operating as the Sugar Express, the steam excursion operation was conceived to welcome passengers on trips through the cane fields and communities of the Lake Okeechobee area throughout the year. This meant that any passenger car acquired, rebuilt, or restored had to not only provide guests with a comfortable and enjoyable trip in accommodations that were complimentary with the heritage of 148 but also withstand Florida summers and extreme weather events.

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An obvious first choice was to lease Georgia 300, a privately-owned heavyweight observation car built in 1930 and kept in Orange Park, Florida. A resplendent Pullman Standard car, Georgia is best known for hosting three different United States Presidents on various Whistle Stop tours from 1992-1999 and as a result, carries a Presidential seal on display inside. With comfortable bedrooms, a kitchen, dining room, and lounge, the car was utilized on Sugar Express’ first Toys-for-Tots train in 2020 and is now on lease for the 2022 season. Georgia proudly displays a custom, lighted drumhead with the logo we developed for the operation.

With Georgia as a benchmark for a first-class car, we pivoted to equipment that could supply an abundance of passenger car seats. We approached the United Railway Historical Society of New Jersey (URHS) regarding three high-capacity coaches from the Great Northern and Union Pacific that had been in storage but left in various states of repair by a lessee. Trading off their ability to carry 80 passengers each, the cars were “fixer-uppers” originally built in the 1950s and last saw major work in the 1990s – but it was equipment that we could completely restore to our standards. At present, the cars are being gutted and rebuilt from the frame up, from the trucks to the upholstery, with major work focused on the HVAC and electrical systems.

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“These cars were left in a very complicated situation and after so many years, they’ve finally gotten the happy ending they deserve. We’re grateful to have had FMW Solutions and Sugar Express as partners and the funds from this sale have already been contributed to important preservation efforts for us,” said Kevin Phalon, President, URHS. “We look forward to working with FMW on future rail preservation projects in New Jersey.”

There was a lot of discussion amid U.S. Sugar and the Sugar Express on an open-air or open window car – something that would allow passengers to enjoy the Florida weather and connect to the rural countryside, but also take in the sights and sounds of the 148 at speed. Discussions on acquiring traditional observation cars or converting a coach into an open-air car (akin to the Lookout Mountain) ensued. 

Ultimately, we decided to follow the practice of other excursion operators and determined a baggage car would fit the bill. As Amtrak had just spun off dozens of cars from its heritage fleet a few years earlier, a former Santa Fe baggage car had made its way to the non-profit Nashville Steam. Now fully restored, the baggage car, now known as the Miami Locks, is on a long-term lease to Sugar Express.

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With an open-air baggage car, a beautiful observation car, and three coaches in the mix, the passenger train needed at least one more amenity – a dining or lounge car and Sugar Express Operations Manager Scott Ogle found a good fit: Former Pennslyvania Railroad William Penn. Originally constructed in the early 1950s as a parlor car, Amtrak converted it to a galley/lounge car, and the car was acquired in mid-summer of 2021.

The car was shipped 1,300 miles from St. Louis to Clewiston, Florida, and after some brake and running gear work, and additional adjustments to the generator and the interior, the car was placed into service as the Palmdale.

One of the most visible signs of progress on any passenger car is the paint scheme. One of these coaches, no. 1002, had been named the Lake Okeechobee and was the first car to appear in the new Sugar Express paint scheme.

Over a period of several weeks, we explored several different paint schemes and options for the growing passenger car fleet. Next to the steam engine itself, the appearance of the passenger train was critical, and an opportunity to create a matched train set was not only compelling but historically appropriate. 

Internally, early designs explored matching Georgia’s handsome blue and grey appearance, while others contemplated the Atlantic Coast Line’s striking purple or green passenger train looks. Through research, we ultimately felt that Illinois Central’s pre-war City of Miami passenger train paint scheme was one of the most striking – and also complemented the existing palette of colors used on the South Central Sugar Express’ diesel fleet.  The City of Miami was fitting –it was once a famous, all-Pullman year-round passenger train that ran through the area.

Using the restored Bamboo Grove (the Miami’s sole surviving observation tavern-lounge-observation car on static display in Ormond Beach, Florida) as a template, and after consulting the Pullman and EMD archives, shades of green, yellow and red were ultimately chosen, making only minor deviations to accommodate the client’s preferences (a shade brighter yellow, a slightly lighter green) and the vendor’s ability to reference the original colors in paint (for the passenger coaches) and vinyl (for the Miami Locks.) 

FMW employed the same process used on Brightline’s new passenger trains and determined that a vinyl wrap on a historic passenger car was not only cost-effective but a worthwhile experiment, and while it required additional surface prep work, the results were indistinguishable from the traditional pain used on the other equipment.

Amid this ongoing work, plans to market and operate the first official passenger excursion for the Sugar Express were taking shape. Upon the arrival of the Palmdale and Georgia, and the completion of Miami Locks, we started work on creating the Lake Placid Limited – a first-class, all-day trip from Clewiston to Lake Placid.

The year of work spent building the Sugar Express fleet was not in vain – tickets for the inaugural trip sold out in 14 minutes, and the journey ultimately welcomed passengers from around Florida and six different states. 

To round out the experience, we designed historically inspired tickets and a timetable for passenger souvenirs, hired a local caterer to produce a bountiful breakfast buffet, and our onboard train crew wore appropriate period uniforms. To quote one passenger, “when we were greeted at the door by a fully uniformed conductor in 87 degrees, we were impressed. We knew we were in for a treat.”

“Each one of these passenger cars came to us at different stages of mechanical usefulness, and different challenges as a result. It’s been gratifying to work side by side with Sugar Express and Scott Ogle. We learned the ins and outs of these together and came up with practical, affordable solutions, that will support the passenger experience onboard these trains,” explained Drew Reynolds, Project Manager for FMW Solutions, who manages the fleet for Sugar Express. “A customer’s experience can be marred by the presentation of a train, not to mention any number of mechanical issues. We want our clients and their guests to have the best experience possible, even if components of the train set are 50 or 100 years old.”

For guidance or help on your railroad passenger car restoration or rebuild project, or to request a proposal or quote, visit fmwsolutions.com, email info@fwmsolutions.com, or call (423) 425-9753.

FMW Solutions and its affiliate National Rail Consulting Group offer a suite of professional services for the railroad industry, including mechanical and engineering design, diesel locomotive servicing and repair, rail operations, strategic planning support, marketing, public relations, safety compliance administration, training, and alternative fuel technology research and development. FMW is also an accomplished rail preservation resource, with expertise in the restoration and operation of historic equipment. 

Vice President of Mechanical Shane Meador walks us through the condition of Pennsylvania Railroad steam locomotive no. 1361's frame at the Railroaders Memorial Museum in Altoona, Pennsylvania. Learn what we've discovered about the frame’s current condition and our expectations for future work on the Spirit of Altoona.

To learn more about the project or to support the museum with donations or memberships, visit www.railroadcity.org/1361. Vintage and historic footage courtesy of the Railroaders Memorial Museum.

To learn more about our work on the K4, click here.

HISTORY

For the past 30 years, the K4-type locomotive has been disassembled, partially restored, but unfinished. In 2019, FMW Solutions performed a comprehensive inspection of No. 1361, including a full review of all past work performed, and a full engineering study of the integrity and repairability of the locomotive boiler. This six-month process included engineering calculations and reporting, 3D modeling, non-destructive spectrometer, radiograph, and ultrasonic thickness tests, rivet material review, visual inspections, and consultation with the Federal Railroad Administration (FRA).

FMW has determined that much of the boiler’s firebox will need to be replaced with new steel. FMW’s findings and repair procedures have been reviewed and accepted by the FRA. The repairs will allow the original Belpaire boiler design to be preserved while being brought up to contemporary safety standards. Projections indicate the restoration, which will include repair of the boiler, appliances, frame, spring and brake rigging, drivers and running gear, and test runs will cost in excess of $2 million dollars.

Initial fundraising efforts are being led by railroad preservation advocates Bennett Levin and former Norfolk Southern and Amtrak CEO Wick Moorman. Among other rail preservation efforts, FMW is currently assisting with the rebuilding of Nashville, Chattanooga, & St. Louis steam locomotive No. 576; recently completed the restoration of U.S. Sugar No. 148, and is undertaking the relocation and eventual rebuilding of Atlantic Coast Line No. 1504. For more on FMW Solutions, to request a quote, or to explore opportunities for your railroad operation, visit fmwsolutions.com.

How do you begin to rebuild The Spirit of Altoona?

Join Wolf Fengler, Vice President of Engineering for FMW Solutions, on a tour of the boiler and Belpaire firebox of Pennsylvania Railroad steam locomotive no. 1361 at the Railroaders Memorial Museum in Altoona, Pennsylvania. Learn what we've discovered about the locomotive’s current condition and our process to assess past work on this historic machine.

To learn more about the project or to support the museum with donations or memberships, visit www.railroadcity.org/1361. Vintage and historic footage courtesy of the Railroaders Memorial Museum.

To learn more about our work on the K4, click here.

ST. LOUIS, MO (July 14th) - A historic Wabash Railroad turntable has been rescued from obscurity and will be preserved as part of a planned steam-driven tourist railroad in South Central Florida.

MetroLink, a light rail system serving the greater St. Louis region, had sought a new home for the historic structure for over 25 years. As MetroLink cleared the area for redevelopment, the turntable’s fate was uncertain. Earlier this year, representatives from FMW Solutions LLC, an industry contractor with expertise in rail preservation and logistics, approached MetroLink with several options to save the structure.

Since February, FMW has worked with MetroLink to clear the site and turntable, removing and salvaging structural components and wood, and even managed to save two newborn kittens that were living in the turntable pit. Nicknamed “Link” and “Wabash,” the kittens were turned over for adoption at the local humane society.

The 90-foot long, 62-ton turntable will make a thousand-mile journey from St. Louis to Clewiston, Florida, where plans call for it to ultimately be restored and used as part of the Sugar Express, a regional tourist train operation in the Lake Okeechobee region.

“The installation of this turntable will be an important step toward our future goal of offering public excursions on the Sugar Express, where passengers will be able to see South Florida farming operations firsthand aboard an historic steam locomotive-driven railroad,” said Scott Ogle, General Manager of the Sugar Express. “We appreciate the staff at FMW Solutions for helping to relocate the turntable as we make plans for its installation near Clewiston.”

Built in 1917 by the American Bridge Company, the turntable was used to orient locomotives at the railroad’s facility at Vanteveter Avenue roundhouse and almost exclusively served the line’s storied steam and diesel passenger locomotives throughout its history. In the ensuing years, the roundhouse was demolished and the property was absorbed by Norfolk & Western, and later owned by Norfolk Southern until 1989 when the adjoining railroad line was deemed secondary and later sold to Bi-State Development as it began construction of MetroLink. 

For more information on Sugar Express, visit sugarexpress.com. For more information on the Metropolitan Saint Louis Transit Agency, metrostlouis.org.

FMW Solutions and its subsidiary National Rail Consulting Group offer a suite of professional services for the railroad industry, including mechanical and engineering design, diesel locomotive servicing and repair, rail operations, strategic planning support, marketing, public relations, safety compliance administration, training, and alternative fuel technology research and development. FMW is also an accomplished rail preservation resource, with expertise in the restoration and operation of historic equipment.

ALTOONA PA (June 25th)  - The Railroaders Memorial Museum (RMM) announced this week that it has named FMW Solutions LLC as its strategic partner in the restoration of Pennsylvania Railroad K4s-class steam locomotive No. 1361. Working with the board and staff at RMM, and a team of qualified volunteers, FMW Solutions will oversee the day-to-day restoration efforts of the museum’s national icon and assist in strategic planning for the eventual operation of the attraction.

“FMW Solutions brings a remarkable set of skills and talents to this project,” said Joseph DeFrancesco, Executive Director of the RMM. "Their portfolio and professional approach is exactly what we need for this endeavor and their highly credentialed team has a successful track record that speaks for itself.”

“The legacy of the Pennsylvania Railroad, the K4, and the industrious identity of Altoona makes this extremely special to us,” said Davidson Ward, President of FMW Solutions. "Our team is prepared to assist RMM turn a new page in this project. Our hope is to make the locomotive a viable ambassador for Altoona and the Commonwealth for years to come.”

For the past 30 years, the K4 has been disassembled, partially restored, but unfinished. In 2019, FMW Solutions performed a comprehensive inspection of No. 1361, including a full review of all past work performed, and a full engineering study of the integrity and repairability of the locomotive boiler. This six-month process included engineering calculations and reporting, 3D modeling, non-destructive spectrometer, radiograph, and ultrasonic thickness tests, rivet material review, visual inspections, and consultation with the Federal Railroad Administration (FRA). 

FMW has determined that much of the boiler’s firebox will need to be replaced with new steel. FMW’s findings and repair procedures have been reviewed and accepted by the FRA. The repairs will allow the original Belpaire boiler design to be preserved while being brought up to contemporary safety standards.

FMW Solutions undertook both traditional computational engineering analyses of the boiler as well as built a 3D CAD model of the boiler. The 3D studies also employed finite element analysis of key boiler components.

“Paired with our board of directors, staff, skilled volunteers, government agencies, and donors, this partnership will return The Spirit of Altoona to the high iron once again and create educational and economic development opportunities while fulfilling the museum’s goal to preserve America’s rail heritage through the Altoona railroading experience,” DeFrancesco added.

Projections indicate the restoration, which will include repair of the boiler, appliances, frame, spring and brake rigging, drivers and running gear, and test runs will cost in excess of $2 million dollars. Initial fundraising efforts are being led by railroad preservation advocates Bennett Levin and former Norfolk Southern and Amtrak CEO Wick Moorman. To learn more about the project or to support the museum with donations or memberships, visit railroadcity.org/1361.

Among other rail preservation efforts, FMW is currently assisting with the rebuilding of Nashville, Chattanooga, & St. Louis steam locomotive No. 576; recently completed the restoration of U.S. Sugar No. 148; and is undertaking the relocation and eventual rebuilding of Atlantic Coast Line No. 1504. For more on FMW Solutions, to request a quote, or to explore opportunities for your railroad operation, visit fmwsolutions.com, email info@fwmsolutions.com, or call (423) 425-9753.

FMW Solutions and its subsidiary National Rail Consulting Group offer a suite of professional services for the railroad industry, including mechanical and engineering design, diesel locomotive servicing and repair, rail operations, strategic planning support, marketing, public relations, safety compliance administration, training, and alternative fuel technology research and development. FMW is also an accomplished rail preservation resource, with expertise in the restoration and operation of historic equipment.