For $35 they plasma cut out the area for a horn, cut a hardy hole, and welded the base to the rail. I need to talk with the welding/fab shop that did most of the work as to how they did it. The old rail was in there for like 15 years. Rail is a lot like that, the first train over it and you'd swear it's gonna need changing out again in a week. I can't remember how long it lasted tho :/ seems like it was still in there when the story was being told (years).once the stuff had a chance to work harden, the wear almost stopped. Put them in and the wear rate the first day was. So along came some high carbon, high manganese steel plates, cheap as dirt, no special heat treatment was done to it so it was easy to drill etc. They'd wear out inģ months and have to shut it down and replace it. The crusher foreman told me a story about how they used to buy very expensive heat treat treated (quenched and tempered) steel plates (armor?) for the insides of the rock crushers. I had an "annunciator" track circuit hooked to a siren so the guys in the crusher plant (all wearing ear plugs ) would know the ore train was approaching. ) So, keep the bit cutting! :) (high carbon plus medium(?) manganese steel) The rail is looking for any excuse to work harden. :) Using Co HSS (M42?) drill bits, 8 holes per drill bit if drilled dry, 40 holes if it was kept sprayed down mith "WD-Dummy" or oiled. That was a signalman's job drilling 3/8" holes through the web of the rail. Even WD-40 will help the drill bit while drilling rail. If it's hacksaw cut it won't drill like mild steel but will still drill nice. Is that end friction saw cut or torch cut? If so, need to figure out a way to get under the hard part.
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