Method and cast components for cold formed center sill rail car modification programs and railcars formed thereby

A method of modification of a railcar comprising the steps of:

• providing an existing railcar;
• removing an upper portion of the existing railcar including all existing railcar side walls, all existing railcar end walls and all existing railcar top chord sections;
• cutting and splicing a center sill of the existing railcar to a desired length to form a spliced center sill which includes using a splice casting having a center section with the same profile as the exterior of the center sill with two end sections that telescope into the interior of spliced center sill sections;
• forming an upper railcar body having top chord sections and a pair of end walls and side walls coupled to the top chord structure;
• forming an underframe construction including the spliced center sill running the length of the car and bolsters configured to be above truck assemblies and coupled to the center sill;
• and
• coupling the upper body to the underframe.

A method of modification of a gondola railcar comprising the steps of:

• providing an existing double tub floor gondola railcar;
• removing an upper portion of the existing railcar including any existing railcar side walls, any existing railcar end walls and any existing railcar top chord sections;
• cutting and splicing a center sill of the existing railcar to a desired length to form a spliced center sill which includes using at least one of i) a splice casting having a center section with the same profile as the exterior of the center sill with two end sections that telescope into the interior of spliced center sill sections and ii) a cast transition casting between the spliced center sill and a draft arm;
• forming an upper railcar body having top chord sections and a pair of end walls and side walls coupled to the top chord structure;
• forming an underframe construction including the spliced center sill running the length of the car and bolsters configured to be above truck assemblies and coupled to the center sill;
• and
• coupling the upper body to the underframe.