In 2012, The Spirit  of  Altoona  was  reconsolidated in the Harry Bennett Memorial Roundhouse at the Railroaders Memorial Museum. Through dedicated volunteers, consisting of employees from Norfolk Southern’s Locomotive Shop, the project was kept alive. The COVID-19 pandemic necessitated change at the museum. Former Norfolk Southern CEO Wick Moorman, who had previously launched the 21st Century Steam Program, became Board Chairman. As a result, other supporters, such as rail preservationist Bennett Levin, joined the organization. The combined vision and expertise of this newly constructed team allowed for a dramatic re-evaluation of the project.

In 2019, the Railroaders Memorial Museum recruited FMW Solutions to perform an inspection of K4s 1361, including a review of all previous restoration efforts. This railroad contractor and consulting firm brings mechanical engineering expertise and professional project management to the table. FMW Solutions is also an accomplished rail preservation resource, with knowledge in long-term maintenance and operations.

A six-month series of engineering calculations, non-destructive tests (NDT), radiographic examinations (X-Ray), and visual inspections resulted in the development of a detailed report. These tests identified welding defects that did not meet modern standards and were thus fully extracted. Further tests and repairs met the requirements of the American Welding Specifications (AWS), the National Board Inspection Code (NBIC), and the American Society of Mechanical Engineers (ASME). This thorough study was submitted to the Federal Railroad Administration (FRA) and a detailed plan was approved in early 2021, which permitted this long-awaited project to proceed.

In September 2021, two major milestones were reached. First, the weld defects in the steam dome flush patch were repaired. Secondly, the firebox and rear flue sheet were removed, both of which had posed serious concerns. Upon initial inspection by FMW, the firebox failed to comply with the minimum factor of safety (FoS) rating of four. This requirement calls for any locomotive boiler to withstand four times the Maximum Authorized Working Pressure (MAWP). In addition, the rear flue sheet had been excessively warped and thus did not abide by the requirements provided by the NBIC and the ASME. Both were subsequently removed for future reconstruction.