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69-461: The company evolved from the Helm Foundry, a foundry that supplied cast metal fittings and components to grist and flour mills throughout Northumberland County . James Crossen Jr. (1826-1890) emigrated from Ireland to Batavia, New York in 1842 with his family. At the age of 17, Crossen left his family behind and moved to Cobourg, Ontario where he began work in the Helm Foundry. He moved up

138-464: A Torontonian developed an air brake for streetcars. Initially, streetcars did not carry an air compressor; thus, air recharging stations were required along streetcar routes. Later, on-board air compressors were installed. After the TRC completed electrification, some horsecars were converted into trailers where one or two would be hauled by a motor car. However, horsecar trailers were found to be unsuited for

207-648: A few of which were built for other streetcar and radial operators. On August 15, 1892, the TRC became the second operator of horse-drawn streetcars in the Toronto area to convert to electric trams, the first being the Metropolitan Street Railway which electrified its horsecar line along Yonge Street within the Town of North Toronto on September 1, 1890. (In 1912, the City of Toronto would annex North Toronto.) In 1891,

276-445: A hollow cavity of the desired shape, and then allowing it to cool and solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process. Casting is most often used for making complex shapes that would be difficult or uneconomical to make by other methods. Melting is performed in a furnace . Virgin material, external scrap, internal scrap, and alloying elements are used to charge

345-401: A liquid, pouring the metal into a mold, and removing the mold material after the metal has solidified as it cools. The most common metals processed are aluminum and cast iron . However, other metals, such as bronze , brass , steel , magnesium , and zinc , are also used to produce castings in foundries. In this process, parts of desired shapes and sizes can be formed. Foundries are one of

414-500: A material. Heat treatment techniques include annealing , case-hardening , precipitation strengthening , tempering , and quenching . Although the term "heat treatment" applies only to processes where the heating and cooling are done for the specific purpose of altering properties intentionally, heating and cooling often occur incidentally during other manufacturing processes such as hot forming or welding. After degating and heat treating, sand or other molding media may remain adhered to

483-430: A mold yields leftover metal — including heads, risers, and sprue (sometimes collectively called sprue) — that can exceed 50% of the metal required to pour a full mold. Since this metal must be remelted as salvage, the yield of a particular gating configuration becomes an important economic consideration when designing various gating schemes, to minimize the cost of excess sprue, and thus overall melting costs. Heat treating

552-537: A one-time payment to the city of $ 1,453,788 for the assets of the TSR, the same amount the city paid for TSR assets when it took over the horsecar system in 1891. Each year, the TRC was required to pay the city $ 800 per mile of track, plus a percentage of the gross earnings. Fares were: five cents cash for adults, six tickets for twenty-five cents; three cents cash for children with school tickets at ten for twenty-five cents; ten cents cash for night streetcars. The fare entitled

621-402: A referendum during the 1910 election, but also elected a mayor who opposed it. Thus, this proposal died. By 1912, there was a second city proposal to build three underground routes: streetcar tunnels under Queen and Bloor Streets, and a rapid transit subway along Yonge Street. These routes would have connected with surface streetcar routes and radial railways. The idea died after voters rejected

690-425: A referendum earlier that month. This was controversial at the time; churches feared Sunday streetcar service would lead to other activities inappropriate for a Sunday such as sporting events and the sale of alcoholic beverages. The referendum, which had been preceded by two prior unsuccessful attempts, was won by a narrow margin of 0.7 per cent out of 32,000 votes cast. There came to be problems with interpretation of

759-424: A single piece or solid pattern. More complex designs are made in two parts, called split patterns. A split pattern has a top or upper section, called a cope, and a bottom or lower section called a drag. Both solid and split patterns can have cores inserted to complete the final part shape. Cores are used to create hollow areas in the mold that would otherwise be impossible to achieve. Where the cope and drag separates

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828-426: A steel foundry will use an EAF or induction furnace. Bronze or brass foundries use crucible furnaces or induction furnaces. Most aluminium foundries use either electric resistance or gas heated crucible furnaces or reverberatory furnaces. Degassing is a process that may be required to reduce the amount of hydrogen present in a batch of molten metal. Gases can form in metal castings in one of two ways: Hydrogen

897-401: Is a common contaminant for most cast metals. It forms as a result of material reactions or from water vapor or machine lubricants. If the hydrogen concentration in the melt is too high, the resulting casting will be porous; the hydrogen will exit the molten solution, leaving minuscule air pockets, as the metal cools and solidifies. Porosity often seriously deteriorates the mechanical properties of

966-416: Is a group of industrial and metalworking processes used to alter the physical, and sometimes chemical, properties of a material. The most common application is metallurgical. Heat treatments are also used in the manufacture of many other materials, such as glass. Heat treatment involves the use of heating or chilling, normally to extreme temperatures, to achieve a desired result such as hardening or softening of

1035-703: Is a partial list of sales: About that time, the Toronto and York Radial Railway, the Toronto Suburban Railway and the Winnipeg Electric Street Railway Company were all affiliated with the owners of the Toronto Railway Company. According to a source, the Monterrey Railway, Light & Power Co. was founded in Toronto. The following is a list of preserved TRC passenger and work cars. All except car 327 were built by

1104-463: Is called the parting line . When making a pattern it is best to taper the edges so that the pattern can be removed without breaking the mold. This is called draft . The opposite of draft is an undercut where there is part of the pattern under the mold material, making it impossible to remove the pattern without damaging the mold. The pattern is made of wax, wood, plastic, or metal. The molds are constructed by several different processes dependent upon

1173-567: Is common to paint castings to prevent corrosion and improve visual appeal. Some foundries assemble castings into complete machines or sub-assemblies. Other foundries weld multiple castings or wrought metals together to form a finished product. More and more, finishing processes are being performed by robotic machines, which eliminate the need for a human to physically grind or break parting lines, gating material, or feeders. Machines can reduce risk of injury to workers and lower costs for consumables — while also increasing productivity. They also limit

1242-546: Is dependent on the alloy system quantities produced. For ferrous materials EAFs, cupolas, and induction furnaces are commonly used. Reverberatory and crucible furnaces are common for producing aluminium, bronze, and brass castings. Furnace design is a complex process, and the design can be optimized based on multiple factors. Furnaces in foundries can be any size, ranging from small ones used to melt precious metals to furnaces weighing several tons, designed to melt hundreds of pounds of scrap at one time. They are designed according to

1311-493: Is happening inside the mold or die during the casting process. Toronto Railway Company The Toronto Railway Company (TRC) was the operator of the streetcar system in Toronto between 1891 and 1921. It electrified the horsecar system it inherited from the Toronto Street Railway , the previous operator of streetcar service in Toronto. The TRC was also a manufacturer of streetcars and rail work vehicles,

1380-510: Is the only reminder of the company's existence in the area. The homes of James Crossen at 465 George Street remains near the former manufacturing site. The company built cars for the Toronto Railway Company (SE-ST-M) and Birney cars for rival and city owned Toronto Civic Railways . Railcars were bought by: Foundry A foundry is a factory that produces metal castings . Metals are cast into shapes by melting them into

1449-541: Is then removed from its mold. Where the mold is sand based, this can be done by shaking or tumbling. This frees the casting from the sand, which is still attached to the metal runners and gates — which are the channels through which the molten metal traveled to reach the component itself. Degating is the removal of the heads, runners, gates, and risers from the casting. Runners, gates, and risers may be removed using cutting torches , bandsaws , or ceramic cutoff blades. For some metal types, and with some gating system designs,

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1518-470: The " Tilley Tariff ", duties and taxes where put on the importation of products from outside of Canada. This tariff allowed the Cobourg Car Works to flourish, as they could provide an equivalent product at a cheaper cost to railway companies. James Crossen died at the age of 64, leaving control of his company to his six children in 1890. The family re-organized and incorporated the company in 1891 under

1587-447: The 30-year franchise with the Toronto Street Railway (TSR) for horsecar service expired. At the end of the TSR franchise, the city ran the horsecar system for eight months, but ended up granting another 30-year franchise to a private operator, a group involving railway entrepreneur William Mackenzie . The franchise, which involved converting the horsecar system to electric operation, went into effect on September 21, 1891. The TRC made

1656-623: The TRC roster at four points during its franchise: The TRC had several types of work cars, all built in the TRC car shops. Here is a brief description of some of the types of non-revenue cars the TRC had: The TRC sold a small percentage of the streetcars it built to other operators. The TRC had a subsidiary company, the Convertible Car Company of Toronto, that built cars for systems in Mexico, South America, and Western Canada. Some sales were for used streetcars that had run in Toronto. Here

1725-484: The TRC took control of the Toronto and Mimico Electric Railway and Light Company along Lake Shore Road, and in 1895, the Toronto and Scarboro' Electric Railway, Light and Power Company along Kingston Road. In 1904, both suburban operations were turned over to the Toronto and York Radial Railway , thus ending the TRC's suburban operations. On May 23, 1897, Sunday streetcar service started after city voters gave approval in

1794-538: The TRC's surface streetcar lines. At this time the city was unhappy with the quality of TRC service and with the TRC's refusal to serve newly annexed areas. The TRC had an exclusive franchise for surface streetcars but competing subways would not violate the franchise. In 1909, a British syndicate proposed two lines, one under Yonge Street and a second from East Toronto via Queen Street East, Dufferin Street and Dundas Street West to West Toronto. Voters supported this proposal in

1863-518: The TRC, and all were used by the TTC. In all, the TRC had seven carhouses, although no more than six at any one time. They are listed here alphabetically by name: The TRC had several facilities near the intersection of Front and Frederick streets. Many of these facilities were inherited from the Toronto Street Railway (TSR), and the TRC repurposed them for the electric streetcar system. In 1924,

1932-425: The TTC retired 471 of the 830 streetcars the city accepted from the TRC, including the double-ended and Crossan-built streetcars. It retained only 351 single-end, double-track motor cars for longer term use, the last of which were retired in 1951. The TTC did retain one horsecar trailer and a single-ended streetcar from 1892, preserving them as relics ultimately to be given to a museum. The following are summaries of

2001-501: The Toronto Railway Company's operations were taken over by the Toronto Transportation Commission. Routes marked 1923 by TTC were TRC routes discontinued by the TTC as a result of a major reorganization of routes on July 1, 1923. The city built and owned some of the streetcar trackage operated by the TRC. The city-owned, TRC-operated tracks were: By 1909, there were proposals to build subways in competition to

2070-569: The amount of material being removed. These steps are done prior to any final machining. After grinding, any surfaces that require tight dimensional control are machined. Many castings are machined in CNC milling centers. The reason for this is that these processes have better dimensional capability and repeatability than many casting processes. However, it is not uncommon today for castings to be used without machining. A few foundries provide other services before shipping cast products to their customers. It

2139-512: The capabilities of his foundry to manufacture the metal wheels and under carriage components of the cars, and knowing of a nearby supply of timber, agreed to fill the order. Eventually, one order for cars and rolling stock replaced the previous. By 1873 various railway companies were coming to the Ontario Foundry to have cars built, and Cossen took the opportunity to form the Cobourg Car Works. The Ontario Foundry faded as his attention turned to

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2208-436: The casting surface. Numerous materials may be used to clean cast surfaces, including steel, iron, other metal alloys, aluminium oxides, glass beads, walnut shells, baking powder, and many others. The blasting media is selected to develop the color and reflectance of the cast surface. Terms used to describe this process include cleaning, bead blasting, and sand blasting . Shot peening may be used to further work-harden and finish

2277-423: The casting. To remove any mold remnants, the surface is cleaned using a blasting process. This means a granular media will be propelled against the surface of the casting to mechanically knock away the adhering sand. The media may be blown with compressed air, or may be hurled using a shot wheel. The cleaning media strikes the casting surface at high velocity to dislodge the mold remnants (for example, sand, slag) from

2346-423: The city agreed to accept along with a number of work cars. It also had 18 open motors and 43 open trailers in storage which the city refused to accept due to the 1915 ban on open streetcars. In 1921, the TRC had twelve double-ended streetcars, three double-truck and nine single-truck; all other streetcars were single-ended. Two of the ten Crossan-built, single-truck streetcars survived to 1921. Between 1921 and 1924,

2415-459: The city granted the TRC an exception to purchase ten single-ended, single-truck streetcars from James Crossen-Cobourg Car Works in Cobourg, Ontario in 1893. The TRC streetcars were made of wood over a steel underframe. Cars had a clerestory roof with a destination sign fixed near the front edge of the roof. Seats were wood slat but the TRC provided each with a seating cushion. There was a stove at

2484-466: The company's directors liquidated factory's assets soon afterwards. The Gallery referenced, their source of information and materials, as obtained from a great grand daughter of James Crossen, company records and a scrapbook in her possession. It was also stated that the company's demise came as a result of the introduction of the all-steel cars in 1910. At the time, the company did consider converting their operations to all-steel production, but when one of

2553-649: The company's largest and oldest customers, the Canadian Pacific Railway decided to open their own manufacturing facilities to build cars, it put an abrupt end to the Crossen Company's deliberations. William Crossen died in Toronto in 1927. The production facilities were later acquired by Dominion Wheel & Foundries Limited and vacated in 1960. The site (northwest of University Avenue West and Division Street) still remains vacant and all buildings relating to Crossen demolished. A small street, Crossen Street,

2622-458: The company's peak, it provided employment to as many as 500 workers, and the company's production output rose to as high as 7 passenger cars and 150 freight cars per month. In a display of photographs and materials presented by the Art Gallery of Northumberland, in the 1989 exhibition "Some Prominent Citizens" the exhibit claimed, that Crossen Car Manufacturing Company ceased operations in 1913 and

2691-552: The end of the franchise. By 1915, there were complaints of overcrowding due to a shortage of streetcars. In December 1916, a fire destroyed the TRC's King carhouse and 163 motor cars and trailers within it. Repeated court battles did force the TRC to build new cars, but far less than what the city was requesting, and the new cars were of an old design dating from 1906, or 1908 for the newest cars. Streetcars and track were not well maintained, and carhouses and shops were obsolete or deteriorating. The TRC franchise ended on August 31, 1921, and

2760-487: The entire casting manufacturing route. Casting process simulation was initially developed at universities starting from the early ' 70s , mainly in Europe and in the U.S. , and is regarded as the most important innovation in casting technology over the last 50 years. Since the late ' 80s , commercial programs (such as PoligonSoft, AutoCAST and Magma) are available which make it possible for foundries to gain new insight into what

2829-433: The facility. The process includes melting the charge, refining the melt, adjusting the melt chemistry and tapping into a transport vessel. Refining is done to remove harmful gases and elements from the molten metal to avoid casting defects. Material is added during the melting process to bring the final chemistry within a specific range specified by industry and/or internal standards. Certain fluxes may be used to separate

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2898-558: The franchise terms for the city. A series of annexations, especially in 1908–12, significantly extended the city limits to include such areas as Dovercourt , Earlscourt , East Toronto , Midway (formerly between Toronto and East Toronto), North Toronto , and West Toronto . After many attempts to force the TRC to serve these areas, the city created its own street railway operation, the Toronto Civic Railways to do so, and built several routes. The TRC system deteriorated towards

2967-426: The front of the car for winter heating. Early streetcars had open platforms; later cars had enclosed vestibules. The rear vestibule could have a single or double rear door. Cars with a double rear door could haul a trailer and had a two-man crew. One-man cars had a treadle-operated single rear door. There was a hook at the rear of each car to hang a baby carriage. At first, TRC streetcars had hand brakes, but in 1905,

3036-401: The furnace must be designed for temperatures over 1,600 °C (2,910 °F). The fuel used to reach these high temperatures can be electricity (as employed in electric arc furnaces ) or coke . The majority of foundries specialize in a particular metal and have furnaces dedicated to these metals. For example, an iron foundry (for cast iron) may use a cupola , induction furnace, or EAF, while

3105-505: The furnace. Virgin material refers to commercially pure forms of the primary metal used to form a particular alloy . Alloying elements are either pure forms of an alloying element, like electrolytic nickel , or alloys of limited composition, such as ferroalloys or master alloys. External scrap is material from other forming processes such as punching , forging , or machining . Internal scrap consists of gates , risers , defective castings, and other extraneous metal oddments produced within

3174-403: The higher speed of electric streetcar operation. Very early on, in 1894, the TRC decided on single-ended operation. Many of the early streetcars were "open" cars, where there was benches across the width of the car and thus no centre aisle. Passengers had to board on the curb-side of the open car, and for safety, there had to be a barrier along the length of the car on the opposite side. Before

3243-433: The horsecar system, the distance between the tracks (the devil strip) was 3 feet (910 mm); the TRC widened the devil strip to 3 feet 10 inches (1,170 mm). Until 1908, the city prohibited the TRC from making the devil strip wider. Because of the narrow devil strip, later cars were built with a taper to the roof on the passing side, and car bodies were offset to the right by four inches, sitting off-centre on

3312-463: The king pin. The offset allowed a wider car to safely pass another traveling in the opposite direction. From 1903, the TRC built all new track with a devil strip of 5 feet 4 inches (1,630 mm). In 1921, there was still 27 kilometres (17 mi) of double track with a narrow devil strip which the successor TTC widened as it replaced old TRC tracks to handle wider equipment. Routes marked to TTC were operating on September 21, 1921, when

3381-403: The largest contributors to the manufacturing recycling movement, melting and recasting millions of tons of scrap metal every year to create new durable goods. Moreover, many foundries use sand in their molding process. These foundries often use, recondition, and reuse sand, which is another form of recycling. In metalworking , casting involves pouring liquid metal into a mold , which contains

3450-498: The metal from slag and/or dross and degassers are used to remove dissolved gas from metals that readily dissolve in gasses. During the tap, final chemistry adjustments are made. Several specialised furnaces are used to heat the metal. Furnaces are refractory-lined vessels that contain the material to be melted and provide the energy to melt it. Modern furnace types include electric arc furnaces (EAF), induction furnaces , cupolas , reverberatory , and crucible furnaces. Furnace choice

3519-430: The metal. An efficient way of removing hydrogen from the melt is to bubble a dry, insoluble gas through the melt by purging or agitation. When the bubbles go up in the melt, they catch the dissolved hydrogen and bring it to the surface. Chlorine, nitrogen, helium and argon are often used to degas non-ferrous metals. Carbon monoxide is typically used for iron and steel. There are various types of equipment that can measure

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3588-490: The name Crossen Car Manufacturing Company of Cobourg. James oldest son, William, served as the company's General Manager while his son Frederick served as Secretary Treasurer. His son-in-law, William Renwick Riddell , a prominent Cobourg lawyer, husband of Anna Crossen was elected as the Company President. In 1896, Frederick Crossen, died at the age of 26 and the continuation of the company was left to William Crossen. At

3657-843: The new market. Some of company's earliest customers included the Grand Trunk Railway (GTR), the Canadian Pacific Railway (CPR) and the Intercolonial Railway . By 1878, the Cobourg Car Works added First Class Passenger Coach Construction to its operations putting it into direct competition with the American firms of the Pullman Company and the Barney and Smith Car Company . In 1879, the Canadian government passed legislation to restrict American Imports of manufactured goods and products. Called

3726-512: The next day, the Toronto Transportation Commission started operating a system that combined the TRC system with the city-operated Toronto Civic Railways lines. In 1924, the city paid $ 11,483,500 for the assets of the TRC. The TRC ceased to exist when it was legally dissolved in 1930. In 1891, the TRC inherited 109 kilometres (68 mi) of horsecar track from its predecessor, the Toronto Street Railway. The TRC learned from

3795-489: The potential for human error and increase repeatability in the quality of grinding. Casting processes simulation uses numerical methods to calculate cast component quality considering mold filling, solidification and cooling, and provides a quantitative prediction of casting mechanical properties, thermal stresses and distortion. Simulation accurately describes a cast component's quality up-front before production starts. The casting rigging can be designed with respect to

3864-400: The presence of hydrogen. Alternatively, the presence of hydrogen can be measured by determining the density of a metal sample. In cases where porosity still remains present after the degassing process, porosity sealing can be accomplished through a process called metal impregnating . In the casting process, a pattern is made in the shape of the desired part. Simple designs can be made in

3933-402: The proposal out of fear of higher taxes. As part of the franchise agreement, the TRC was to build all its streetcars locally. Thus, almost all TRC cars were built in-house at their car shops at Front and Frederick Streets. However, the TRC felt it lacked the capacity to build enough streetcars to convert the horsecar system it inherited to electrical operation by the city-imposed deadline. Thus,

4002-493: The ranks of this company and eventually became a full partner. Eventually the company was renamed Ontario Foundry and, by 1865 James Crossen was listed in a Northumberland/ Durham Counties Directory as the sole proprietor of the company. The Ontario Foundry was approached by the Cobourg, Peterborough & Marmora Railway and Mining Company to build twelve wooden railway dump cars for the transportation of ore . Crossen, realizing

4071-413: The required component properties. This has benefits beyond a reduction in pre-production sampling, as the precise layout of the complete casting system also leads to energy , material, and tooling savings. The software supports the user in component design, the determination of melting practice and casting methoding through to pattern and mold making, heat treatment , and finishing. This saves costs along

4140-542: The rider to a free transfer between routes. A key requirement of the franchise agreement was that the TRC had to electrify the first line within one year of the beginning of the franchise and the last line within three years. The TRC met this requirement. The first run of an electric car was on August 10, 1892. Car 270 ran from the Frederick Street stables at Front Street , up Church Street , along Bloor Street and Sherbourne Street to Rosedale . The first passenger

4209-462: The spring, and re-connected in the fall, thus changing from an open car to a closed car. A dangerous feature of open cars was the running board where passengers could stand while the car was in motion. Because of safety concerns, the Railway and Municipal Board banned open cars from the streets on November 22, 1915. At the end of its franchise in 1921, the TRC had 830 streetcars on its active roster that

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4278-444: The sprue, runners, and gates can be removed by breaking them away from the casting with a sledge hammer or specially designed knockout machinery. Risers must usually be removed using a cutting method (see above) but some newer methods of riser removal use knockoff machinery with special designs incorporated into the riser neck geometry that allow the riser to break off at the right place. The gating system required to produce castings in

4347-419: The summer of 1893, there were double-ended open cars, which required two men to move the barrier to the other side of the car at the end of the line. Some open cars had one-man crews, requiring a helper to be stationed at the end of the line. Having single-ended cars with loops or wyes saved staff time. Also, both open and closed motor cars could pull one or two trailers; thus, single-ended operation eliminated

4416-408: The surface. The final step in the process of casting usually involves grinding, sanding, or machining the component in order to achieve the desired dimensional accuracies, physical shape, and surface finish. Removing the remaining gate material, called a gate stub, is usually done using a grinder or sander . These processes are used because their material removal rates are slow enough to control

4485-411: The time needed to rearrange the consist at the end of the line. Open cars were popular in warm weather. When it rained, there were side curtains that one could unroll from the roof to keep one dry. However, the motorman would stand exposed to wind and rain on the front platform. To handle both warm and colder months, the TSR used the "convertible car" in which the nearside of the car could be removed in

4554-493: The troubled experiences of the Metropolitan Street Railway in North Toronto , which had previously done a horse to electric conversion. Thus, between 1891 and 1894, the TRC replaced all the horsecar track, using heavier rail that could properly support the faster, heavier electric streetcars. The TRC used 69-pound rail on some lightly used lines, and 71-pound rail elsewhere, including all downtown track. For parallel tracks on

4623-482: The type of foundry, metal to be poured, quantity of parts to be produced, size of the casting, and complexity of the casting. These mold processes include: In a foundry, molten metal is poured into molds . Pouring can be accomplished with gravity, or it may be assisted with a vacuum or pressurized gas. Many modern foundries use robots or automatic pouring machines to pour molten metal. Traditionally, molds were poured by hand using ladles . The solidified metal component

4692-414: The type of metals that are to be melted. Furnaces must also be designed based on the fuel being used to produce the desired temperature. For low temperature melting point alloys, such as zinc or tin, melting furnaces may reach around 500 °C (932 °F). Electricity, propane, or natural gas are usually used to achieve these temperatures. For high melting point alloys such as steel or nickel-based alloys,

4761-478: Was a half-sober gentleman who insisted he had the right to board the streetcar at the Metropolitan United Church and pay his fare. The first electric car ran in scheduled service on Church Street starting August 15, 1892, and the last horse car ran on McCaul Street on August 31, 1894. From 1893 to 1904, the TRC had suburban radial operations, often using vehicles resembling streetcars. In 1893,

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