Tales from the carriage shops

[Mayner]

Although I have done drafting for most of my adult life, 3D cad work or modelling is a relatively new ball game for me and the C&L & CVR vans first complete detailed models.

The majority of my range of Irish Broad Gauge wagons were designed by a freelance designer, though recent variants/improvements to the  "Standard Covered Wagon" are my own.

Although the initial print was successful the CVR Van is on its second variant as the end steps were to thin on the original and tended to curl up!

I am in the States and the moment and will post a photo of the completed van in approx. two weeks after we get back home.

Once I sort out the 4mm versions the next step is to re-size to 7mm or larger to find out what happens.

I will probably include some CVR vans in our next order from the Chinese supplier that prints our Broad Gauge wagons as the home printer is just not up to it for production printing in terms of consistency and quality of finish.

[Mayner]

Some progress with the 3D model of the C&L Milk Van.

Step 1.  was to import 2D side and end sketches I prepared earlier as templates for drawing the 3D Model

One of the quirks of my 2D CAD software is that the sketches appear as a mirror image when imported into Fusion 360 as a "Canvas'

Step 2.  1/4 of the basic bodyshell extruded as a 3D model. The Milk Vans and most wagons are symmetrical so its only necessary to prepare a detailed 3D model of a 1/4 of the model and then complete by copying and producing a mirror image.

Step 3.  Extruding the framing detail, the basic extrusion includes the thickness of outside framing and I then cut away the excess material to model the depth of the framing, a process not unlike milling or routing metal or timber without sharp rotating tools, swarf and dust!

Step 4. Outside framing modelled for 1/4 of Milk Van

Planking, strapping and bolt head detail will be reproduced by extruding profiles on the model.

The next step is to produce a test print, for planking, strapping and rivet detail using different widths, depths and material thicknesses before completing the Milk Van body detail.

 

 

 

 

 

 

 

[David Holman]

Seriously clever stuff, John!

As you say, real modelling, but without the mess, though I guess rude words are still an option! Not my scene (yet, anyway), but doesn't mean I can't admire the quality. Really interesting too.

Edited July 18, 2023 by David Holman

[Mayner]

I hadn't time to do anything in the Workshop since June as a result of family commitments, but managed to make some time for myself in recent weeks including dusting off some long unfinished projects.

 

First up is completing a OO Gauge 650 Class for a customer to be followed by some 21mm locos for myself. The 650 class was designed to be assembled in OO or 21mm gauge with a "fold up" OO gauge chassis to speed up assembly. I used a tapered broach to open up the axle holes for the bearings before folding up the chassis.

Basic chassis folded up and wheels fitted before test fitting the body to check running clearances.  The body is from a 2017 test build of the loco, I am not sure what happened to the original n/s boiler/smokebox assembly.

OO Gauge Chassis with non-working inside valve gear fitted, Alan Edgar a modeller in the UK assembled a 650 Class with working valve gear in 21mm gauge apparently using some of the valve gear parts. I temporarily fitted the wheels at this stage to check brake gear fit and clearances.

Loco chassis assembled with brake gear fitted. The brake gear is a separate removable sub assembly which helps simply painting and assembly.

Tender Chassis before folding to shape!

Basic tender assembly the tender is designed with a fixed trailing and floating leading and centre axles to transfer weight from the front of the tender to the rear of the loco important on locos like 2-4-0s and 4-4-0s

Completed loco and tender chassis ready for clean-up and painting.

I need to locate the remainder of that 2015 test build or assemble a replacement!

I have at least four MGWR 2-4-0-650 Class test builds to complete for myself (all different variations) which should keep me busy for a couple of years without starting any new projects. I may complete some as static models rather than motorise as the majority of the locos I built over that past 30 years have ended up in display cases and seldom run on a layout.

Edited November 3, 2023 by Mayner

[Gabhal Luimnigh]

Lovely work 

[Dempsey]

I'm always impressed by the level of craftsmanship that go into these builds.

[Flying Snail]

Just spotted the inside valve gear which will really set off the look. There really is a lot going on here - as Dempsey says: craftsmanship

[Mayner]

Quite a break through today when I found a set of loco driving wheels I mislaid over a year ago while assembling a 52 Class 4-4-0.

The collection of unfinished projects gets temproariily ? larger before it gets smaller

1-52 Class waits its driving wheels, 4 part built 650 Class 2-4-0, 3 J15/101 Class.

I thought the best option was to pause work on the MGWR 2-4-0 and fit No 93s wheels and return the loco to working order before I mislay/loose the parts again. Interestingly I packed the 4-4-0 wheel sets in a drawer labeled "Gibson 6'7" wheelsets when I mislaid the parts in 2022!

1st job is to degrease the wheelsets, before masking the tyres before priming and painting the parts before re-assembling the loco, decided at the same time to fit buffer heads and number plates to a J15 as the final touches in completing a J15 started about 20 years ago!

[Tullygrainey]

That's a very impressive production line John with some very fine modelling in there. I'm not surprised you lose the odd wheel set. I for one I couldn't keep that many balls in the air at once without losing my place eventually 

[David Holman]

Some real gems there, John - especially  the 4-4-0!

[Mayner]

Managed to make time to fit No98s wheels and coupling rods, but need to fit front vacuum pipe and screw couplers before returning the loco to the display case.

I masked the tyres with Tamiya 2mm masking tape before priming and painting the wheels in GSR grey (matched locally from a sample supplied by JHB)

The Markits driving wheels are locked in place by a slotted nut, the nuts in turn disguised by etched Markits "axlenut covers secured in place by the crankpin.  While the original Romford crankpins were robust and easy to use the current Markits SuperDelux crankpins are threaded 14BA and require care in fixing to avoid damaging the pin.

98 back on her wheels, the number plate seems to be a temporary the real 93 was a slightly larger 60 Class or D14 which was re-built with a superheated belpair boiler during the 1930s.

Model of 98 is inspired by a photo of the loco at Inchacore during the late 40s, she retained her raised round topped firebox until withdrawn in 1954. 

https://transportsofdelight.smugmug.com/RAILWAYS/IRISH-RAILWAYS/CORAS-IOMPAIR-EIREANN-STEAM/i-zC9Ff7f/A

 

[David Holman]

Fine model of a lovely locomotive.

[jhb171achill]

14 hours ago, Mayner said:

Managed to make time to fit No98s wheels and coupling rods, but need to fit front vacuum pipe and screw couplers before returning the loco to the display case.

I masked the tyres with Tamiya 2mm masking tape before priming and painting the wheels in GSR grey (matched locally from a sample supplied by JHB)

The Markits driving wheels are locked in place by a slotted nut, the nuts in turn disguised by etched Markits "axlenut covers secured in place by the crankpin.  While the original Romford crankpins were robust and easy to use the current Markits SuperDelux crankpins are threaded 14BA and require care in fixing to avoid damaging the pin.

98 back on her wheels, the number plate seems to be a temporary the real 93 was a slightly larger 60 Class or D14 which was re-built with a superheated belpair boiler during the 1930s.

Model of 98 is inspired by a photo of the loco at Inchacore during the late 40s, she retained her raised round topped firebox until withdrawn in 1954. 

https://transportsofdelight.smugmug.com/RAILWAYS/IRISH-RAILWAYS/CORAS-IOMPAIR-EIREANN-STEAM/i-zC9Ff7f/A

 

Absolutely fantastic model, looks great. Pity I couldn't raid the piggy bank when these were available....!

On 3/11/2023 at 9:53 AM, Dempsey said:

I'm always impressed by the level of craftsmanship that go into these builds.

Couldn't agree more.

[Mayner]

Managed to fit 98 with a correct set of number plates, couplers, and couple the loco and tender together again.

98 was assembled from the original test etch to check that the parts would fit and the assembly a bit rushed.

I am planning to model the GSR era so no flying snail to bother about.

 

I am planning to model the GSR area so no flying snail to worry about.

I removed the tender body in order to retro-fitted the tender with a NEM coupler pocket from a production etch, exposing the weight that's partially supported by the loco draw-bar to improve traction. The wheels are temporary until I find the correct spoked wheels that are hidden away somewhere.

Underside of tender, insulated drawbar is formed from a copper clad sleeper with the copper removed, the trailing axle is in rigid bearings, the leading and centre axle non-load bearing, lightly sprung free to move up and down in the axle slots, the brass wires are retainers to stop the wheelsets dropping out!

Chassis viewed from above on Hornby No3 or 4 curve, the loco-tender drawbar is fitted to the underside to the frame spacers and slots through the existing holes in the loco and tender drag-beams.

Assembled chassis from below drawbar is basically fixed with minimal movement at the tender end, free to pivot on the bolt at the rear of the loco. 

The bogie has a pivot point positioned ahead of the leading  driving wheels and is free to slide from side to side in a curved  slot at the bogie centre, with a retaining nut to prevent the bogie flopping about.  Mercifully there were large frame cut outs around the bogie wheels on GSWR 4-4-0s and my OO gauge 52 Class builds navigate 3rd radius curves without shorting, though the same approach would not work with MGWR 4-4-0s with the absence of frame cut outs and larger diameter bogie wheel.

 

 

 

[Tullygrainey]

That is a very impressive piece of miniature engineering John. I begin to see how tricky it is to make that particular wheel configuration work properly. So many variables! On 98's tender, do the wire keepers for the front and middle axles also provide springing or is there something else in there as well?

Alan

[David Holman]

Mmmm.... Clever, very clever! Looks great too.

[Mayner]

The weighted tender set up is basically a modified version of the system used by Terry McDermott (TMD) on the GNR(I) S Class during the 1980s and the current SSM kit!

I substituted an insulated drawbar for the metal drawbar used by SSM because I use the "American" pick-up arrangement where the loco picks up power on one side and the tender on the opposite side using live axle pick up. I find this arrangement simpler than using wiper pick ups. 

Two pieces of light gauge phospor bronze wire provide springing/keep the leading and centre axle in contact at all times with the track.

I used the same weighted tender principal on the MGWR 2-4-0, with this arrangement both the 2-4-0 and 4-4-0 continuously hauled 15 IRM 4w wagon on test.

The unpainted brass wire keepers is a temporary arrangement until I find/get the correct spoked wheels and I will trim back the excess.

 

 

Edited December 3, 2023 by Mayner

[Mayner]

Back to work on the MGWR 2-4-0 now that work on 98 is complete until I find her tender wheels.

The 2-4-0 is based on a loco that was re-built with a superheated boiler in 1924, received the original type saturated boiler in 1930 before being fitted with a Y Type GSR superheated boiler in 1935, before going two further boiler changes before the loco was withdrawn in 1961!

650 in early GSR condition with canopy cab superheated roundtopped boiler with extended smokebox and Inchacore pattern chimney.

The loco would have been fitted with an extended smokebox to accomodate the superheater header when re-built in 1924, its unclear from photos whether the loco retained the extended smokebox when it was fitted with a saturated boiler in 1930. Photos of the actual loco are basically 3/4 views from the front and rear, though the smoke box is straight sided without the small flare visible in 3/4 front photos of superheated members of the class

MGWR 2-4-0 as rebuilt with canopy cab and superheated boiler with extended smokebox.

Originally assembled as a test build, I have replaced the boiler/firebox and splashers with updated parts.

MGWR 2-4-0 rebuilt with canopy cab, saturated boiler with riveted version of standard smokebox.

The pewter castings require cleaning up!

I designed the kit to be assembled either in saturated or superheated form including a set of smokebox parts that could be assembled in its original flush or later pop riveted versions (embossed rivets)

I originally planned to emboss the rivets using a rivet press, but turned out simpler and quicker to use a simple

riveting tool I bought from London Road Models at a UK exhibition many years ago!

I used a small Tool Makers Clamp to hold the wrapper in position as I soldered it to the smoke box former gradually working around from one side, dressing to the profile of the former.

The moment of truth wrapper to the smokebox former before making the final soldered joint.

 

 

 

 

[David Holman]

Excellent stuff John and some very useful tips too.

[Mayner]

Finished basic assembly work on the ex-MGWR 2-4-0 decided to fit the standard rather than the expended smokebox. 

Boiler fittings were cast in pewter with rather prominent mould lines removed with a craft knife with a chisel blade and sanded/polished with fine emery paper in the lathe.

Loco and tender sheetmetal work largely complete, remaining work mainly fitting handrails and castings, before final assembly and painting.

No tender coal rails or plates in photos of the loco modelled and most 2-4-0s with Stirling cabs, coal mush have been of reasonable quality up to the mid 1930s!

Cab interior is a sub assembly, had to do some trimming back on the cab splashers and floor to fit! Didn't notice the bent up cab rear footstep when I took the photo.

Some work required on the fit between the tender body and tank/bunker assembly.

Loco breaks down into a series of bolt or slot together sub assemblies.

Hope to assemble/fit the motor, gearbox and wheels before Christmas, with painting/final assembly after the Christmas/New Year holidays.

[Gabhal Luimnigh]

Brilliant work 

[Mayner]

Something of a break through made time this week for some overdue maintenance on the garden railway and carry out some detailing on No 664 

A section of track on the Garden Railway was damaged by a by a falling tree in a storm last year and locos continued to de-rail on this section of track despite attempted repairs. One of the rails on this section was buckled narrowing the gauge and needed replacement.

Left rail buckled, moulded rail fastening have failed combination of storm damage and plastic ties (sleepers) and fastening becoming brittle after 16 years exposure to the weather.

I replaced the section of track  with the buckled rail with a spare section from the workshop though the ties/sleepers  are not in great shape.

464 navigated the repaired section without de-railing so the railway should get through this years 'Fall Stock Rush"

I have bitten the bullet and ordered €300 worth of replacement tie strip to replace approx 60' of failed ties/sleepers on the main circuit, I replaced the ties on the remainder of the main line about 10 years ago, the new ties should be good for another 15-20 years similar to full size wooden sleepers.

The next big way and works job is to replace a series of fence posts (that have rotted) that support the trackbase on the High Line from the Workshop to the main circuit, like a full size railway there is no end to the maintenance and replacement work as components reach the end of their working life.

664 main sub assemblies. Loco was dismantled following trial fitting of gearbox and motor. I had just cut a slot out of the lower section of the boiler to allow the motor to fit. The loco is weighted with Woods Metal cast in the loco and tender body. The weight under the motor needs to be tidied up, Woods Metal appears to expand during casting.

Most of the detailing has been applied to the loco, although I need to fit front buffers, vac pipes and ejector pipework.

More substantial work is required on the tender chassis including fitting an NEM coupler pocket similar to that used on the 52 Class 4-4-0 sorting out locotender drawbar and power pick up wiring.

I will dismantle the loco into a set of sub assemblies and complete the mechanical assembly after I have completed painting (GSR Grey) and varnishing the model.

Although 657 (33 Arrow) and 664 (23 Sylph) were both re-built in the mid 1920s with superheated boiler and canopy cab 664 was rebuilt with a saturated boiler (original MGWR Type) in 1930 and went through two further boiler changes and an Inchacore 'style" cab before withdrawl in 1961. 

Edited March 13 by Mayner

[Gabhal Luimnigh]

Lovely work lad.