Recreating the Kalakala in 3D (IMAGE INTENSE THREAD)

[Steve Rosenow]

A long time ago, I had been fortunate to take part in a collaborative design attempt to make ferries usable for Microsoft Flight Simulator. In the process of doing so, I created a model of the Kalakala for the simulator. It was basic, with a rudimentary recreation of the Kalakala's passenger decks and a crude rendition of its car deck.

Limitations kept a lot of detail out.

At the time I finished up work on that model (which unfortunately never got publicly released due to upload size limit restrictions on all of the major Flight Simulator-related add-on sites), it was the most accurate model of the Kalakala recreated in 3D up to that point. Technical limitations within Flight Simulator, as well as my modeling skills and available photo library (provided by Evergreenfleet.com), meant the model had some inaccuracies. A bare-bones version of the model, compiled when I had just wrapped up most of the superstructure, was uploaded to the SketchUp 3D warehouse, and then left alone in an incomplete state.

Two months ago, I was contacted by an architecture company out of Portland, Oregon, and they expressed interest in using that model. Their goal was to create an information display wall for the components of the Kalakala that the City of Kirkland purchased, when it was sadly demolished a couple years ago. 

Providing the bare-bones model, plus a later version which I had added a lot of details to in the process of making it FS-ready, had me thinking it was time to revisit the ol' girl and give her the memorial (and restoration) she never got.

Over the course of the last two months, I have been painstakingly working to recreate the Kalakala in every detail possible, right down to the features patrons saw in their day-to-day crossings on the famed vessel in her prime. In doing so, I have completely overhauled the model I worked on for Flight Simulator (and rendering it incompatible due to the detail additions), and as of now, I have what may be the most highly detailed, virtually-accurate model of the Kalakala to ever be compiled using 3D modeling software.

It has not been an easy task. When complete, the model will be released as part of a download using the Unreal game engine, to take virtual tours of the ill-fated 'Flying Bird."

The following photos (and there are a lot, please bear with me), show the progress of working to make this the most accurate model available. I have completely overhauled the existing model, and there's now a ton of detail.

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

In this photo, I've completed overhauling the superstructure. It was a ton of work to get right, especially when it came to the number of window openings. Unlike the earlier model I created, this model is accurate even down to the framing and number of window openings.

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

Adding the details in the main passenger cabin deck. This was an arduous task as it involved a lot of research, including stumbling on new photos of the vessel taken in the months before its demolition. I've completely modeled the bathrooms (both men's and women's), and are accurate as much as possible based upon what limited information is available.

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

I've now added the transverse I-beam floor members which ran the entire length of the vessel. 

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

This was rendered just after I had finished overhauling the promenade deck bulwarks, and added the revised flying bridge deck structure. 

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

A preliminary render of the starboard side of the promenade deck, just aft of the aft staircase. Note the absence of window frames and the window glass, and two bulkheads which would later form the room in which the Double Horseshoe Cafe was situated.

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

Completing the basic structure for the Flying Bridge deck and Officer's Quarters. The 'skin' of the model is based on 1/4" thick structural steel thickness, and the entire vessel is modeled just as if you were actually building it to actual shipbuilding techniques. Note that I've also added the windows.

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

A preliminary render at around 75% completion. I've now added the car deck porthole openings, and revised the rescue boat openings to suit new photographic evidence I found on Flickr.

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

A couple renders at car deck level, showing the structural framing details. The car deck's framing is accurate to within 98% of the actual vessel's number of framing members. Some were omitted due to lack of adequate reference material, and revised to 'fill those voids' so to speak.

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

By the time these renders were completed, the Kalakala's upper decks above the car deck are within 90% completion. Work then moved up to the promenade deck/palm court/ Double Horseshoe cafe area.

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

A render from the roof, above the Double Horseshoe Cafe area.

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

Filling in the framing details (based upon limited available details), as well as revising the interior of the pilothouse. 

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

A render from within the pilothouse itself. 

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

A render from the forward end of the promenade deck, looking up towards the pilothouse.

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

The model approaches 95% completion as I added interior lighting to the vessel. Light fixtures are modeled as accurately as possible, and recreate light just as the real fixtures did aboard the actual ferry. 

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

Looking aft in the Palm Court. I've chosen to model the Kalakala as it would've likely appeared immediately after Washington State took over ownership, but before the benches were installed around the upper deck balustrades.

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

The Double Horseshoe Cafe, showing the lunch counter as it looked in the original Flight Simulator model (as I used the Flight Simulator model as a template in which to improve, and overhaul as needed). Details at this point are sparse, and used the original textures.

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

A render looking forward in the main cabin deck, from the starboard side of the vessel immediately aft of the aft staircase. I've now added specular highlight mapping to the flooring and all interior surfaces. Even the 'virtual paint' has the same sheen and appearance as the real world vessel would.

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

A symmetrical rendering looking aft, situated at the entrance to the upper deck.

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr



Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr



The lunch counter has now been substantially revised based upon photos taken of the actual counterpart late in the Kalakala's WSF career, as well as a perusal of some Asahel Curtis photos taken in the 1940s. I determined that through those photos, the basic structure never really changed despite a near-20 year gap. I've chosen to model the lunch counter with the inner ring of stools present, as well.

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

A render showing the kitchen area, or 'galley' aboard the Kalakala. A few of Asahel Curtis' photos exist which show a limited view inside this, however I never really knew what this area looked like until I stumbled upon a rather obscure site that had photos taken in 2002 of the same room. Apparently, a ghost hunting crew went aboard the Kalakala in 2002, and documented their experience quite well. Through that documentation, I was able to accurately model this feature to within 95% of accuracy to the real-world counterpart in a structural sense. Since the room's equipment and facility arrangement was not known (and likely won't ever be), I had to model the equipment with 'creative license' applied.

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

The Double Horseshoe Lunch counter has been revised even further, with the addition of soda taps (again, with creative license since it is not known how the actual counter's facilities were laid out), and napkin holders, salt and pepper shakers, as well as creamer and sugar containers for coffee. It is here, where the model now sits. I am still in the process of updating the lunch counter details even further, with the addition of an Art Deco-inspired display case (based upon an Asahel Curtis photo) as well as misc. details throughout the inner ring.

Also note, that I've now added the two sliding doors on the aft bulkhead, modeled to the real-world counterpart.

Stay tuned, folks. There's lots more to come.

[Kahloke]

Wow!  That's impressive, as are your Sketchup modeling skills.  Well done.

[Steve Rosenow]

Jan 21, 2018 7:09:36 GMT -8 Kahloke said:

Wow!  That's impressive, as are your Sketchup modeling skills.  Well done.

Thank you! 

[Steve Rosenow]

The Kalakala's Double Horseshoe Cafe is now complete. I've added a pair of Bunn commercial coffee brewers, two vintage cash register setups which were based off an Asahel Curtis photo, plus four Bain Marie soup warmer stations (two each side).

I've also added racks for coffee cups, two soda fountain cup racks, and tidied up things a bit.

Now that the details in the superstructure are largely complete, I'm now moving down below decks to add the engine and propulsion arrangements.

Overhauling the Kalakala in 3D by Steven Rosenow, on Flickr

[Steve Rosenow]

Modeling the Kalakala to be as detailed as possible has been a thorough adventure. It has not been easy, especially when details aren't readily available.

In the pursuit of the most accurate model available, I've scoured tons of photos, videos, and whatever else I could find.

Modeling the Kalakala's massive 10-cylinder, three-thousand-horsepower diesel engine has not been the easiest of those jobs. Only a small handful of photos exist of the original engine, plus two of an identical engine that was used for a power plant in Logan, UT.

Thirteen roughly-identical engines, each ranging from six to ten cylinders, were built by Busch-Sulzer Diesel. Of those thirteen, only one was outfitted for marine use (installed in the Kalakala) and of all of those, only a small handful of literature and photos exist. It is what makes modeling this engine so difficult. Having said that, I'm trying to model it as close to what I have available, to match that reference material for the most accurate 3D immersion possible.

Modeling the Kalakala is coming to a close soon, and as I write this, I am about 98% complete.

Overhauling the Kalakala in 3D - modeling the Kalakala's massive 10-cylinder engine by Steven Rosenow, on Flickr

Overhauling the Kalakala in 3D - modeling the Kalakala's massive 10-cylinder engine by Steven Rosenow, on Flickr

Overhauling the Kalakala in 3D - modeling the Kalakala's massive 10-cylinder engine by Steven Rosenow, on Flickr

[mybidness459]

Hey Steve, Although I am not a Kalakala lover, I do Appreciate the work you are doing.
Awesome Job!!!

[Steve Rosenow]

After making my last post in this thread, I generously received a ton of reference material (some not seen) of the Kalakala. Special thanks go to EGFleet for contributing to this effort.

That reference material helped out immensely with the construction of the main engine details, and refining the model for greater accuracy.

Shortly, I'll be overhauling the hull of the model to accomodate the engine, and adding in some details such as bilge tanks, water pumps, and the watertight door assemblies. It's interesting to note that the Kalakala used watertight door assemblies that were virtually identical to the type and size of the units used aboard the famed Titanic. However, unlike the rack-and-pinion gears which operated the Titanic's WTD assemblies, the Kalakala's appear to be a worm gear-driven type.


Overhauling the Kalakala in 3D - modeling the Kalakala's massive 10-cylinder engine by Steven Rosenow, on Flickr


Overhauling the Kalakala in 3D - modeling the Kalakala's massive 10-cylinder engine by Steven Rosenow, on Flickr


Overhauling the Kalakala in 3D - modeling the Kalakala's massive 10-cylinder engine by Steven Rosenow, on Flickr

[Steve Rosenow]

Getting things ready for the final blend of the engine to the rest of the vessel. In doing so, I had to completely revise the hull based upon the framing plan arrangements of the Peralta (which weren't modified when it was converted to the Kalakala, with the exception of shaving the beam down from 68 feet to 55 feet).

The last in this series shows the engine finally installed in the hull, with basic engine room details already complete. The engine room details will be modeled as accurate as possible given technical and research limitations.


Modeling the Kalakala in 3D - Hull improvements by Steven Rosenow, on Flickr

Modeling the Kalakala in 3D - Hull improvements by Steven Rosenow, on Flickr

Modeling the Kalakala in 3D - Hull improvements by Steven Rosenow, on Flickr

[Steve Rosenow]

Since the last post, I've made significant progress in the engine room of the 3D recreation of the M.V. Kalakala, and I've modeled that particular area within roughly 80% of real-world accuracy.

In the process of modeling that part of the vessel, I've spent a great percentage of time studying every available photograph that I've been provided for reference.

Modeling the Kalakala in 3D - Engine Room Details by Steven Rosenow, on Flickr

Modeling the Kalakala in 3D - Engine Room Details by Steven Rosenow, on Flickr

Note the Art Deco styling on the engine room telegraph. I've also applied this styling to the telegraph in the bridge (as I believe they were identical units). Additionally, the installation of the vessel's power management center was a huge headache. Over 50 hours was spent modeling this particular feature due to research limitations.

Modeling the Kalakala in 3D - Engine Room Details by Steven Rosenow, on Flickr

This area, on the port side of the engine room, was of particular difficulty. The available research data suggest that this area was home to two large freshwater tanks, and a series of pumps drawing water from a series of pipes leading up from under the engine room floor plating. The research materials I have (provided by EGFleet) suggest that an area similar to this sits behind the power management center.

[Steve Rosenow]

Sometimes, a couple steps forward equals a few steps back. In this case, a few steps back meant overhauling some key features of the engine room.

Over the course of the last several days (since my last post) I've taken the liberty of revising the engine room's cooling details, most notably the bilge pumps and engine freshwater cooling system.

Since I was having trouble with the accuracy of the pump arrangement, I decided to ask a few marine engineers with some expertise. Through their generosity, I was able to identify the type of pumps used as well as their drive motors. They were kind in assisting me to the correct type of General Electric motor, which on the Kalakala was a 2HP motor running 1750RPM. Each motor was coupled to a DeLaval centrifugal pump of the split-case, single stage design.

Since this render, I've also added a few new details, such as the cooling water lines on the engine block, as well as a few revisions to the accuracy of the ladder works inside the engine room.

Compare with the above rendering.

Modeling the Kalakala in 3D - Engine Room Details by Steven Rosenow, on Flickr

[Steve Rosenow]

It's been a few days since I've posted anything regarding the model, and I've made some progress.

When I say that modeling this has not been easy, I don't say that very lightly. Even with the impressive amount of reference material made available to me by the generosity of Evergreenfleet.com, I still have to utilize a fair bit of 'creative license' because the reference material only covers so much.

Then again, some newfound reference material came up in a big way, and that was through the resources of Archive.org, where some impressive magazine archives (featuring some articles on the Kalalaka's engine and radar installation), have been a big help.

Initially, I had not intended on modeling the auxiliary engine, and leaving that bulkhead sealed off by way of an immovable watertight door. However, since both engines were not identical (and the latter, a smaller engine of different type and design), I decided to go for it. Even with the amount of creative license I need, I feel I can say that I can come to within roughly 80% of accuracy with both engine rooms. If only the original blueprints to the build had survived, or some schematics and exact layouts existed.

Modeling the Kalakala in 3D - Main Engine room by Steven Rosenow, on Flickr

The main engine room approaches 95% completion. The cooling system has been modeled to within 85% of accuracy based upon the fact that the Kalakala used a freshwater engine cooling system, and I've modeled it based off of known system schematics and a bit of creative license. I've also installed the turbo blower and turbo blower motor housing.


Modeling the Kalakala in 3D - Engine Room overview by Steven Rosenow, on Flickr

An overview of both engine rooms as they currently stand. The bow is to the right in this view, and the main engine room is the one on the left. Additionally, I've also modeled the spaces for the Tap Room and Shower Room (although they'll likely remain blank or modeled with a fair bit of creative license, as no known photos exist of how they were configured) 

In this view, you can also see the exhaust system, specifically the exhaust boiler which heated water for use throughout the ship.

The exhaust boiler was situated on Bulkhead No. 4, dead center to the bulkhead itself, and at an elevation of six feet above the engine room floor plating. It then extended up into the car deck's engine room casing, at which point a single 18-inch diameter pipe of 1/4" thickness, extended out of the boiler. At that point, a flange mounted elbow directed the flow upwards and into the exhaust pipe, which extended up into the exhaust casing that ran through both passenger decks. The exhaust pipe of the Kalakala then exited the vessel on the exhaust funnel's port side. (which hasn't been modeled yet)
.


I've also modeled the engine exhaust (and its insulation wrap) on the auxiliary engine.

Modeling the Kalakala in 3D - Auxiliary Engine by Steven Rosenow, on Flickr

The Kalakala's auxiliary engine, which powered the vessel's electrical systems, lighting, and air starting and maneuvering engines. Unlike the massive two-cycle, trunk piston-design 10-cylinder engine which powered the Kalakala's propulsion, the auxiliary engine was a smaller four-cycle diesel engine of conventional build. Situated on the forward end (seen below, right of center), was a 400kW, 480-volt generator with a chain-driven exciter on the outboard bearing.

Both engines were manufactured using the same bed plate dimensions, which boosted the keel strength and overall strength of the engine itself.

[Steve Rosenow]

Things progressed fairly well on the model today. In fact, this week I expect to be *mostly* complete with the details of both engine rooms. 

Today, I completed the principle exhaust systems of both the main and auxiliary engines. That includes the exhaust gas boiler assembly and uptake draft piping that led upwards to the exhaust funnel just forward of the Double Horseshoe cafe.

The exhaust gas piping out of the main engine is modeled directly off of details seen in a 1932 issue of Pacific Marine Review ()which was a shipbuilding and shipping industry trade magazine for the Pacific coast of the United States). That 1932 issue extensively covered the type of engine used in both the ferries Kalakala and Chippewa (which used Busch-Sulzer engines of identical configuration), and the Willapa, which used an 8-cylinder version of the engines used in the former. 

After this render was completed, I managed to complete the freshwater cooling system for the main engine, and I'll be installing a clone in the auxiliary engine room (based upon creative license and the fact both engines used their own cooling system, plus the fact that the Kalakala used a freshwater cooling system in general).

When the engine rooms are complete, I'll be tidying up the loose ends and making fine detail adjustments throughout the Kalakala (adding fire extinguishers on the car and passenger decks, plus other details needed).

From there, it could reach beta release as early as next week.



Modeling the Kalakala in 3D - Engine Room Overview #2 by Steven Rosenow, on Flickr

[Steve Rosenow]

Modeling the auxiliary engine in the Kalakala has been a tough task due to the lack of available reference material. Having said that, I've come to an accuracy percentage within roughly 90% of the real vessel's auxiliary engine room, based upon what limited reference I have been provided.

Areas in which I am admittedly stumped on, are the exhaust systems in the auxiliary engine room, and the areas in the reference photos I've been provided, that are out of the frame. It is presumed to be an empty space (at least from what I see) so at the risk of losing accuracy to a great deal of unnecessary 'creative license', I have chosen not to model the 'unseen' areas.

In this render, I chose to 'hide' all areas outside the engine room, including the car deck plating, car deck stringer supports and lighting, and the remaining portions of the vessel itself. This was done to allow full lighting of the engine room without the need for prolonged render time. The model's complexity is approaching the point where rendering these views takes a considerable amount of time - up to two days on the interior renders alone.

Modeling the Kalakala in 3D - Auxiliary Engine by Steven Rosenow, on Flickr

[Steve Rosenow]

Since my last post, I've made a significant discovery.

In the ever-constant and sometimes exhausting pursuit of accuracy, I decided on a whim to do a Google Image Search for the Kalakala auxiliary engine room, in the hopes that more than just the two photos I have, exist of that space.

While browsing the first few dozen image results, I stumbled upon a rare and thought-to-be-lost set of blueprints of the Kalakala that were drawn up by the Kalakala's design engineer, a man named Helmuth W. Schmitz.

The link took me to a series of pages at the National Archives' website, where I was able to find sheet upon sheet of Kalakala blueprints that were thought to be lost. What makes them remarkable, is that these blueprints were scans of the originals, drawn in 1934 and 1935 when the Kalakala was under construction.

They helped piece together a huge chunk of the missing puzzle, however they also created more questions.

I figured I'd share the following renders to show the changes made, based upon those findings.

Modeling the Kalakala in 3D - Two steps forward equals five steps back by Steven Rosenow, on Flickr

The propeller shaft's thrust bearings. There were two of these. One of them was located just aft of the main engine, the other was located immediately aft of the bulkhead.

Modeling the Kalakala in 3D - Two steps forward equals five steps back by Steven Rosenow, on Flickr

Note the changes in the freshwater cooling system. The design blueprints (available in my Flickr stream), show the tanks mounted horizontally. However, photographic reference show them mounted vertically. This presents a huge challenge to model them accurately, in terms of piping arrangements.

A call has been placed to the National Archives, and I plan on putting the model on hold for the time being until I hear back. According to the listings at the National Archives, the entire set (of which only 25 or so scans exist online) of blueprints exist.

Now, if only I can get the rest of them.

[trainguru]

Feb 22, 2018 14:36:26 GMT -8 Steve Rosenow said:

Since my last post, I've made a significant discovery.

In the ever-constant and sometimes exhausting pursuit of accuracy, I decided on a whim to do a Google Image Search for the Kalakala auxiliary engine room, in the hopes that more than just the two photos I have, exist of that space.

While browsing the first few dozen image results, I stumbled upon a rare and thought-to-be-lost set of blueprints of the Kalakala that were drawn up by the Kalakala's design engineer, a man named Helmuth W. Schmitz.

The link took me to a series of pages at the National Archives' website, where I was able to find sheet upon sheet of Kalakala blueprints that were thought to be lost. What makes them remarkable, is that these blueprints were scans of the originals, drawn in 1934 and 1935 when the Kalakala was under construction.

They helped piece together a huge chunk of the missing puzzle, however they also created more questions.

I figured I'd share the following renders to show the changes made, based upon those findings.

Modeling the Kalakala in 3D - Two steps forward equals five steps back by Steven Rosenow, on Flickr

The propeller shaft's thrust bearings. There were two of these. One of them was located just aft of the main engine, the other was located immediately aft of the bulkhead.

Modeling the Kalakala in 3D - Two steps forward equals five steps back by Steven Rosenow, on Flickr

Note the changes in the freshwater cooling system. The design blueprints (available in my Flickr stream), show the tanks mounted horizontally. However, photographic reference show them mounted vertically. This presents a huge challenge to model them accurately, in terms of piping arrangements.

A call has been placed to the National Archives, and I plan on putting the model on hold for the time being until I hear back. According to the listings at the National Archives, the entire set (of which only 25 or so scans exist online) of blueprints exist.

Now, if only I can get the rest of them.




***

Do you have the Main and Aux. Engine Model/Type Numbers? I'd like to find out more about the Type of Engines used on the Kalakala, and in Power Station applications.

[Steve Rosenow]

Aug 10, 2019 5:10:35 GMT -8 trainguru said:

No, sadly I don't. Since my last post in this thread I have since gained a ton of reference material (in the way of main and aux engine room photos taken in 1998 in both Alaska and Seattle, and in 2002 while on Lake Union) on the Kalakala by an individual who was part of the Kalakala foundation. The exchange of information on that end occurred through a Facebook group called "Seattle Vintage", upon which he is a member of.

I will resume work on this model sometime soon. A lot of personal stuff has happened in my life which has curtailed a lot of interest in anything lately, and I've been working through the trauma associated with that set of incidents.

Stay tuned!