Alco IR GE 60T Boxcab Project

rray Mar 10, 2023

  1. MMR283

    MMR283 TrainBoard Member

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    The trucks will definitely give you more points! Great job so far! Are you trying to have this ready for the next 3rd Division meeting, so it can be judged? Looking forward to judging this for you!
     
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  2. rray

    rray Staff Member

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    Yes, that's my hope is that I can get it judged in 2 weeks at the meet.
     
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  3. Zscaleplanet

    Zscaleplanet TrainBoard Supporter

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    Do they give any extra consideration, or subtract based on scale? Obviously Z would be more challenging as opposed to say HO, due to its smaller size. So I’d think one would be given consideration based on that.
     
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  4. MMR283

    MMR283 TrainBoard Member

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    All models and scales are judged the same. There are five different categories that include: Construction, Detail, Conformity, Finish/Lettering, and Scratchbuilt. A model needs to score at least 87 1/2 points in order to earn a merit award. Judges use a matrix scoring chart for each category in order to get a fair score for what the modeler has done. The more work and difficulty of any model regardless of scale will earn more points!
     
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  5. rray

    rray Staff Member

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    So, I decided I will build 2 at a time, one with the brass shell that I modify, and one that will have a completely scratchbuilt cab. I know the heavy one will pull the best, but the lighter one will earn more points being scratchbuilt. So time to rinse and repeat the past couple days work so I have 2 mechanisms stretched out for the Boxcabs:


    Make first 2 cuts with razor thin blade:
    001.jpg

    San nubs off both sides smooth:
    002.jpg

    Make another cut carefully leaving material on both sides of cut for gluing extension in:
    003.jpg

    Glue extension material to bottom and sides and clamp the sides tight so the frame stays straight:
    004.jpg

    Glue material for coupler mounting and clamp:
    005.jpg

    Glue second layer of coupler mounting material. DO same for other coupler next:
    006.jpg


    Sand down excess coupler material then drill and tap coupler screw holes:
    007.jpg

    Sand everything nice and smooth to finish the underframe extension:
    008.jpg
     
  6. rray

    rray Staff Member

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    Laser cut truck sideframes:
    009.jpg

    Glue together more than you need in case one flies off onto oblivion, and put on painting stick then apply primer:
    010.jpg


    Sand truck sideframe detail off Rokuhan trucks, so you can glue the new one on:
    011.jpg

    Temporarily set frame on trucks to compare with previous underframe. Admire and delight in your work so far, then get to work on the air tanks:
    012.jpg

    The air tanks need straps to mount them, so cut copper foil tape and wrap around the tanks:
    013.jpg

    Mount one tank forward to back, and glue the other one side to side:
    014.jpg

    Paint trucks and underframes black:
    015.jpg

    Okay, that's it for today.
     
  7. kevsmith

    kevsmith TrainBoard Member

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    Just picked up on this thread Robert

    Spot on!

    I sometime believe we Z scale modellers are some of the most inventive in the hobby. Looking at the forums in the U.k the 00/H0 modellers are almost spoon fed with everything they want, be it RTR or Kits. Two of my fellow modellers, who live close to me, sometimes cannot comprehend when they ask "where did you get that from" and I say "I made it"

    The phrase used to be 'Cheque book modellers' but in the U.K no-one uses cheque books anymore!

    Kev
     
  8. CNE1899

    CNE1899 TrainBoard Member

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    Rob,
    Now you are in the groove! Twice as nice.(y):D
    Love those thin and tiny trucks!

    Scott
     
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  9. rray

    rray Staff Member

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    Haha! :D I feel the same way. I look at all the super details ready to run HO and N stuff available these days, and came to the conclusion that the only thing they need to master is a Woodland Scenics landscape learning kit to purchase a contest quality model railroad. In Z Scale if you want it, you have to build it.
     
  10. rray

    rray Staff Member

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    Had very little modeling time today. A trip to the bank was met by dead battery, and it was a zoo. After I finished the flying circus I only had time to do the wiring test on one of the mechanisms. So I used this uber flexible 30 gauge silicon wire for the trucks to the board.
    10 Flexible Wire.jpg


    I added the original car weights and finished the wiring, and not shown was I added a 100 ohm resistor so I can test the mechanism on track with a 9v battery. That limited motor current to 90 milliamps which should be safe, and the mechanism ran forward and back. It was a little balky, but the track and wheels are dirty, and I did not have the weight of the shell on, so I call it a win.

    11 Wired Add Weights.jpg
     
  11. Kurt Moose

    Kurt Moose TrainBoard Member

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    Wow, you never fail to amaze me, time after time!:cool:

    Always loved these little boxcabs ever since Roundhouse did they're HO one decades agao!
     
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  12. rray

    rray Staff Member

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    So a little switching of gears here, since it's going to be completely scratchbuilt. I decide to change from the demonstrator unit to the production unit that has end doors, because there are so many more photos of them:

    cnw1000.jpg


    The measurements are the same, but there are doors on the ends, 2 of those unidentified little boxes on each side of the end doors, and the headlights are moved on the roof instead of above the doors:

    CNW Boxcab 1000 Measurements.gif



    So I drew up the base shell parts and cut them out today. I was able to raster the rivet detail of the underframe components with the help of Chris333's drawings, the CNW 1000 measurement sheet, and the CNW1000 photo to get a really accurate placement of rivets:

    12 Shell Parts Cut.jpg


    I assembles the sides:

    13 Shell Sides.jpg

    And once the roof was on I test fit the base shell over the drive mechanism. Here is the side view:

    14 Base Shell Side.jpg


    And here is the end view:

    15 Base Shell End.jpg
     
  13. Chris333

    Chris333 TrainBoard Supporter

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    I *think* those 2 boxes on the ends are sand filler hatches. http://members.trainweb.com/bedt/indloco/errhs.html

    Also the demonstrator model had sheet metal that wrapped from the side up over the roof and down the other side. Later they had separate roof panels.
     
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  14. Zscaleplanet

    Zscaleplanet TrainBoard Supporter

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    What material are you using -- seems to appear to be Polybak/laserboard....but not...?

    Nice rivet detail and placement solely based on the pic that is provided. Also taking note of the roof panel and the relief lines cut in order to facilitate the necessary roof arc. A small thing to consider, but it also demonstrates great engineering skills.
     
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  15. CNE1899

    CNE1899 TrainBoard Member

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    Rob,
    Really nice laser work and assembly!
    I second Lances comments on rivets and the roof.

    Scott
     
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  16. rray

    rray Staff Member

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    I sat and thought and thought and could not find a way to cast or make the roof radiators for a couple hours. Then i had an idea... How about layers. So I drew up the idea, and this is the results. It took a long time to assemble one of them, but I will do the other one tomorrow:

    16 Roof Radiator Parts.jpg

    17 Radiator Part Stack.jpg

    18 First Radiator Assembled.jpg

    19 First Radiator See Through.jpg

    20 First Radiator Mounted.jpg
     
  17. rray

    rray Staff Member

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    It's .025" Polybak. The black is .010" Polybak.
     
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  18. CNE1899

    CNE1899 TrainBoard Member

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    Rob,
    I like it! Thinking outside the box(literally)!(y)(y)(y)

    Scott
     
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  19. HemiAdda2d

    HemiAdda2d Staff Member TrainBoard Supporter

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    Those radiators are killer! I love how you can create so much with that handy dandy laser.
     
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  20. rray

    rray Staff Member

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    Today I finished the roof detail. After building the other radiator I made the smokestack parts, and I am not sire if it's a radio antenna or what, but I made the wire thing between the smokestacks that is supported with 2 stanchions cut down from 1:300 two rope ship stanchions. I turned a small sewing pins to make the vent derail right. All mounted on 2 layers of Polybak:

    21 Smokestack Section.jpg



    All the other roof details except the headlights were made. The only commercial detail is the steam bell, allowed from the list of excluded details:

    22 Roof Details.jpg


    Next was to make the headlights. I used a V groove but in some plastic tube, then used a silver sharpie to color the inside. I threaded an 0402 LED through then filled it with UV glue to make the lens:
    23 Headlights.jpg


    Then I sanded wedges out of plastic strip to form the headlight number boards and super-glued to the sides of the headlights to complete the roof detail:
    24 Headlight Numberboards.jpg


    And now I can call the roof detail complete, with 61 separate pieces, of which all except the Bell and LED's I had to form or cut myself. That qualifies as a scratchbuilt roof. I'm tired so I'm done for the day:
    25 Roof  Detail 61 Parts.jpg
     

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