Updated Brake Van preview, Options for resuming production

[Mayner]

I had commissioned Railtec to prepare sample transfers for the updated version of the 20T Brake Van before deciding to cease/pause production and eventually found time to complete two variations of the vans updated with sheet metal duckets.

20T Van with plywood sheeted cabin and vertical boarded balconies.  Produced by a supplier trialed in 2022 not the greatest of prints, need to remove fabric/hair!

All planked version with sheet metal ducket, similar to the Cultra van. Although the windows in the duckets on the Cultra Van have rounded corners, the duckets had squared corners in in-service photos.

The biggest challenge was producing 2D artwork for the ducket stripes that would fit the 3D profile of the ducket.

Although CIE built a single batch of 20T Brake Vans in 1950, there were several distinct variations in existence by the time the vans were withdrawn from service during the late 70s. Originally built with planked duckets, on some vans the planking was covered by sheet metal (aluminium) during the 1950s and later replaced with all metal duckets from the 1960s onwards and on some vans the planked bodywork replaced by plywood.

Options for resuming production.

I have been considering a number of options for resuming production of the 3D printed wagons in rtr or kit form and will be contacting customers for their feedback.

Although it was in initially intended to market and sell our wagons in CKD or kit form demand has primarily been for rtr models with over 90% of brake vans selling in rtr form while demand for other types split more evenly between rtr models and kits.

We would have to substantially increase the price-point to viably produce rtr models with a smaller increase for models in CKD or kit form.

Edited June 30 by Mayner

[Patrick Davey]

Interested!

[flange lubricator]

I would be interested in a couple of CKD kits John . 

[iarnrod]

Interested in RTR versions only of any of your kits as they nicely compliment the recent IRM releaes.

Thanks.

[LRJohn]

I'd be interested in them in kit form. J

 

[floorster]

Interested!

[iarnrod]

Unable to reply to your email that you sent earlier today.

Instant error message received when  I replied.

 

[Mayner]

9 hours ago, iarnrod said:

Unable to reply to your email that you sent earlier today.

Instant error message received when  I replied.

 

An e-mail to all customers to advise that I required a minimum of 25 Pre-Orders by 1st Aug in order to proceed with the latest version of the Brake Van.

I re-sent the message this morning as there was no record of the outgoing message or the inbox was full in the system.

I apologise for any inconvenience caused

Edited July 13 by Mayner

[Mayner]

The 3D parts for our current RTR wagons orders are currently proceeding to production with our suppliers with an expected 4-5 week lead time for delivery to our workshop.

I will provide and update and expected timeframe to order fulfillment when we receive the parts and have completed receiving inspection.

[Mayner]

The 3D parts required to fulfill our current orders arrived from our supplier in China today. Although I included an allowance for print defects and shipping damage all parts in todays shipment successfully passed receiving inspection. 

At this stage I expect to begin fulfilling orders during October 2024, Brake Van decals are currently in transit from the UK!

Todays delivery included parts for a variety of wagons including Brake Vans, GSR Bulk Grain, GSWR/GSR, CIE 1946 and CIE LMA versions of the H Van

Once we have fulfilled current orders a small number of each type of wagon will be available in CKD or kit form.

"Receiving Inspection" prints are in a light green SLA resin with ABS properties which has similar resilient characteristics to injection moulded plastic.

CIE 1946 Version of the H Van. In the past he tapered ends of the corner angles and buffer shanks had been challenging to print with breakages a problem.

GSWR/GSR Van on earlier 9'6" version of the steel chassis with plate axleguards. 

GSR Grain wagon discharge handwheel side.

Underside of Grain Wagon chassis. We modelled the discharge gear to test the capability of 3D printing and were quite impressed with the results.

The 3rd iteration of our 1st model the 20T Brake Van introduced in 1950 rebuilt late? 1960s with all metal duckets.

Our RTR wagons first receive a coat of grey primer before final clean up and removal of excess resin from the prints.

[leslie10646]

Glad to see some progress with your 3D stuff again, John. I can give them a very positive testimony - by far the best 3D prints I've seen to date.

I'll be in touch as I have PARTS of some wagons upstairs!

Good luck with this run.

[Mayner]

Brake Van decals arrived on Saturday exactly 1 week after posting in the UK, so production line has started!

One of the first steps with the RTR vans in a coat of primer to highlight defects.blemishes before painting.

All planked version of Brake Van. Traces of temp supports visible on bottom web of solebar and footsteps, small blemishes on the body may be where temporary supports were removed after printing. The supports are likely to have been generated when the CAD file was 'sliced" (prepared for pinnting) at the factory.

Ply bodied version of Brake Van. In typical CIE make do and mend fashion balconies retained their planking on many vans.  Photo is taken on the goods side of both the chassis and body (opposite side to temporary supports) which show fewer blemishes.  Layered nature of the SLA printing process is more noticable on smooth surfaces than the planked areas.

Discharge wheel side of Grain Hopper showing nicely reproduced rivet head detail., again some minor blemishes visible.

Reproducing the hopper operating gear was one of my challenges to Ben the 3D modeller designing his second wagon and also to test the limited of 3D printing. Ben now works as an engineer for Rocket Lab who design and launch rockets into space. Again the coat of primer shows the remains of supports and excess resin which typically remains after the post printing clean up process .

GSWR/GSR Van blemishes now visible after priming.

CIE 1946 version of H Van

LMA version of H Van. Very small batch (10) wagons light metal alloy body (LMA) introduced immediately before Bulleid H Van

Hybrid version of GSWR/GSR van aluminium sheeted body with planked doors. The prototype wagons actually had a planked body covered by aluminum sheeting.

Van was part of a test batch of wagons printed in Singapore as an alternative to NZ. The body SLA printed in a detail resin the chassis printed in nylon using the FDM process as they did not have the capability to print in a resin with ABS properties.