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General Category => Modellers At Work => Topic started by: fspg2 on April 21, 2011, 01:42:16 AM



Title: Feldbahnmodule with ship
Post by: fspg2 on April 21, 2011, 01:42:16 AM
Here is the current state of my "Feldbahnmodule with ship". It is a follow-up from my chronicle in bbf (http://translate.google.com/translate?hl=de&sl=de&tl=en&u=http%3A%2F%2Fwww.buntbahn.de%2Fmodellbau%2Fviewtopic.php%3Fp%3D281696).

The bridge module should be as torsion-resistant as possible. In previous modules, I had reached a sufficient stiffness with frames.


Hafenmodul_001(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hafenmodul_001.jpg)
Size: 1,5 m x 1,0 m

... Sufficient rigidity?

The  new module  (http://www.buntbahn.de/fotos/showphoto.php?photo=68408&size=big&password=&sort=7&thecat=7452) is about 2.0 meters long and about 0.9 m wide, so that all parts will fit on it.


Brueckenmodul_9(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Brueckenmodul_9.jpg)


Hubbruecke_Aufsicht(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubbruecke_Aufsicht.gif)


Copyright: Lauenburger Elbschiffahrtsarchiv(fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Hubbr_cke_LEA-261b.jpg)
First bridge shortly after the construction of 1901

 Here (http://translate.google.com/translate?sl=de&tl=en&u=http%3A%2F%2Fwww.buntbahn.de%2Fmodellbau%2Fviewtopic.php%3Fp%3D261906) there is some more information to the original.



After I initially thought about a steel frame, I came by chance on a much easier solution:  honeycomb (http://de.wikipedia.org/wiki/Bienenwabe)

... no, I do not intend to ask the hard-working little helpers, to give me her glue. :):

The principle of the comb is still used in many doors:


(http://www.tueren-albrecht.de/tuerenkalkulation/hilfe/images/wabe.jpg)
found at: http://www.tueren-albrecht.de/tuerenkalkulation/hilfe/images/wabe.jpg

So, such a door has been misused!


Module-Montage_001(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Modul-Montage_001.jpg)


The principle you can see on the drawing above.


Currently the board is on two sawhorses, it is already so rigid in its current state, as I had hoped ... and it get more adhesions.


Modul-Montage_002(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Modul-Montage_002.jpg)


Recesses were sawed at the corners for the aluminum legs.


Module-Montage_003(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Modul-Montage_003.jpg)

Module-Montage_004(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Modul-Montage_004.jpg)


Frithjof


Title: Re: Feldbahnmodule with ship
Post by: lab-dad on April 21, 2011, 05:58:15 AM
 :o WOW!  :o ;D
-Marty


Title: Re: Feldbahnmodule with ship
Post by: artizen on April 21, 2011, 06:33:29 AM
I know this is stunning work because I have been following it on Buntbahn.de forum. But every photo is grey across the bottom third? Anyone else having this problem?


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on April 21, 2011, 10:16:16 AM
If I have a slow wireless connection, pictures are gray with me in the lower third sometimes. With LAN connection, all images back to normal.

Frithjof


Title: Re: Feldbahnmodule with ship
Post by: nalmeida on April 21, 2011, 11:23:06 AM
Wonderful work, I love all the planing involved. Lot's of head scratching I'm sure. Looking forward to watch your progress on this.


Title: Re: Feldbahnmodule with ship
Post by: mad gerald on April 21, 2011, 12:13:46 PM
... Here is the current state of my "Feldbahnmodule with ship". It is a follow-up from my chronicle in bbf (http://translate.google.com/translate?hl=de&sl=de&tl=en&u=http%3A%2F%2Fwww.buntbahn.de%2Fmodellbau%2Fviewtopic.php%3Fp%3D281696) ...

Well Frithjof, THAT will really keep you busy ... your building report concerning progress in "Feldbahmodule mit Schiff" in just another forum  (hope it does not keep you away from modelling itself  ;D) ... but when there is a forum which is worth it, THIS forum is ...  8)

Kind regards


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on April 21, 2011, 01:22:06 PM
I like the interlocking bricks at the edges of each wall. Why can't commercial manufacturers do that more often? -- Russ


Title: Re: Feldbahnmodule with ship
Post by: shropshire lad on April 21, 2011, 01:33:53 PM
I like the interlocking bricks at the edges of each wall. Why can't commercial manufacturers do that more often? -- Russ

  More often ? Why can't they do that at all ?

   Nick


Title: Re: Feldbahnmodule with ship
Post by: Philip Smith on April 21, 2011, 02:06:32 PM
great project! especially the track going through center of the lock during construction...

phil 8)


Title: Re: Feldbahnmodule with ship
Post by: artizen on April 21, 2011, 04:54:01 PM
OK - I just tried an experiment. I surf in Safari but tried looking at this thread with Firefox. Same problem except I don't get the grey at the bottom now, I just get a blank area! I notice that the images are being imported into this thread from buntbahn.de which is the only other forum that gives me this grief so I will blame the technology somewhere between buntbahn, the US and Australia in giving me only part of an image.  ???

Shame really, this work is truly inspiring.


Title: Re: Feldbahnmodule with ship
Post by: SandiaPaul on April 22, 2011, 04:04:47 AM
Thank you for starting this thread, I have followed your work and spent a LOT of time admiring it!

Paul


Title: Re: Feldbahnmodule with ship
Post by: Chuck Doan on April 22, 2011, 07:51:02 AM
Same as Paul, I have read through the pages of your posts on another Forum. Very enjoyable to see, welcome here!


Title: Re: Feldbahnmodule with ship
Post by: Dennis McCarthy on April 22, 2011, 09:45:17 AM
Ian,

The incomplete image seems to be a Mac thing with certain websites .

Try this: open the image in a new tab and click the "reload page" button.  A nuisance, but will usually display the whole image.

Regards,
Dennis



Title: Re: Feldbahnmodule with ship
Post by: artizen on April 23, 2011, 05:57:27 AM
Thanks Dennis - that worked!

Yes a Mac thing. Thank you Mr Jobs! Had never known that workaround but will now use it on buntbahn whenever it happens as well.


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on April 29, 2011, 02:17:44 PM
I am pleased that you like my posting. It is certainly easier for you if you don´t have to read in the bbf ... and I can improve my knowledge of English a little!

@ Ian Can you see now all the pictures correctly?


Sometimes I use my buiseness tripps in the evening to draw, so I can give the tap-files to the milling machine if I´m back at home. Mostly - but not always - the result looks satisfactory.

Thus was the drawing of the upper lateral sluice stair...

Hubbruecke_Sockel_links_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubbruecke_Sockel_links_01.gif)
Excerpt from drawing revision of 1899 - Copyright Plan: WSA-Lbg[

... drawn and converted to milling files within an hour.


Seitentreppe_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Seitentreppe_01.jpg)


Seitentreppe_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Seitentreppe_02.jpg)


The milling of MDF took about an hour, the stairs were ready to install in 35 minutes.


Seitentreppe_03 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Seitentreppe_03.jpg)


Seitentreppe_05 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Seitentreppe_05.jpg)


Before gluing the steps, I want to deform them with sandy paper a little bit. They should look like after 60 years of use!

In the deepening between the steps, sand will be glued later .

Frithjof


Title: Re: Feldbahnmodule with ship
Post by: artizen on April 29, 2011, 07:17:52 PM
My internet is playing up. I am waiting for a new modem to arrive on Tuesday (Monday is Queen's Birthday). I can now see all the photos in full because when the internet is on, it's blindingly fast and then it's off!!!! Without warning and up to 24 hours. The techo on the phone has assured me it's the modem at fault so we will see soon.

Keep posting - the model looks great!


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on July 17, 2011, 02:20:11 PM
In 1992  I found two pictures of the former fire station of my hometown in an old photo album,

Feuerwehrhaus_Lbg-1953_01(fspg2)
(http://www.buntbahn.de/fotos/data/8702/2903Feuerwehrhaus_Lbg-1950_01.jpg)


Feuerwehrhaus_Lbg-1953_02 (fspg2)
(http://www.buntbahn.de/fotos/data/8702/2903Feuerwehrhaus_Lbg-1950_02.jpg)


The building was rebuilt in the early years of 1950 from a barn.
At 20 February 1982 the fire brigade of Lauenburg (http://www.feuerwehr-lauenburg.de/) was drawn to her new home, the old fire station served as a residence for some time before it was demolished.
In 1992 the building looks very come down, as you can see at these pictures.

Feuerwehrhaus_Lbg-1992_01(fspg2)
(http://www.buntbahn.de/fotos/data/8702/2903Feuerwehrhaus_Lbg-1992_01.jpg)


Feuerwehrhaus_Lbg-1992_02(fspg2)
(http://www.buntbahn.de/fotos/data/8702/2903Feuerwehrhaus_Lbg-1992_02.jpg)


Feuerwehrhaus_Lbg-1992_03(fspg2)
(http://www.buntbahn.de/fotos/data/8702/2903Feuerwehrhaus_Lbg-1992_03.jpg)


Feuerwehrhaus_Lbg-1992_04(fspg2)

(http://www.buntbahn.de/fotos/data/8702/2903Feuerwehrhaus_Lbg-1992_04.jpg)


Feuerwehrhaus_Lbg-1992_06(fspg2)
(http://www.buntbahn.de/fotos/data/8702/2903Feuerwehrhaus_Lbg-1992_06.jpg)


Feuerwehrhaus_Lbg-1992_07(fspg2)
(http://www.buntbahn.de/fotos/data/8702/2903Feuerwehrhaus_Lbg-1992_07.jpg)


Sad to say, but occupational I can not build my models currently. My milling machine has to wait now. However, I can draw my next project on the computer.


Feuerwache_Lbg_Front_1 (fspg2)
(http://www.buntbahn.de/fotos/data/8702/2903Feuerwache_Lbg_Front_1.jpg)


Feuerwache_Lbg_Front_2 (fspg2)
(http://www.buntbahn.de/fotos/data/8702/2903Feuerwache_Lbg_Front_2.jpg)


Feuerwache_Lbg_Front_5 (fspg2)
(http://www.buntbahn.de/fotos/data/8702/2903Feuerwache_Lbg_Front_5.jpg)



Feuerwache_Lbg_Front_6 (fspg2)
(http://www.buntbahn.de/fotos/data/8702/2903Feuerwache_Lbg_Front_6.jpg)

Straight masonry at the front and crooked timber round about, that is the attraction for me.





Title: Re: Feldbahnmodule with ship
Post by: fspg2 on July 31, 2011, 08:00:06 AM
Yesterday I could mill the outside of the front wall. Because my router can mill parts up to a length of only 70cm, the wall was built in two sections.


Feuerwache_Lbg_Front_007 (fspg2)
(http://www.buntbahn.de/fotos/data/8702/2903Feuerwache_Lbg_Front_007.jpg)

By gearing, the two halves align well.


Feuerwache_Lbg_Front_008 (fspg2)
(http://www.buntbahn.de/fotos/data/8702/2903Feuerwache_Lbg_Front_008.jpg)

Here you see the parts joined together loosely.

Feuerwache_Lbg_Front_009 (fspg2)
(http://www.buntbahn.de/fotos/data/8702/2903Feuerwache_Lbg_Front_009.jpg)

The total length is now 74cm.

Feuerwache_Lbg_Front_010 (fspg2)
(http://www.buntbahn.de/fotos/data/8702/2903Feuerwache_Lbg_Front_010.jpg)

I build the fire station in 1:22.5 scale .... very significantly you can detect the size difference is seen to fire truck, it has only 1:24!

But I'm just happy to get anything to do at this scale!


To see the wall joints in the door- and gate jamb, I had previously drilled the corresponding grooves with a 0.5 mm drill (green).

Feuerwache_Lbg_Front_0110 (fspg2)
(http://www.buntbahn.de/fotos/data/8702/2903Feuerwache_Lbg_Front_0110.jpg)

The colors mean:
green = drill (0.5 mm) after visible inside corner holes or slots for smaller corner radius at the outer contour,
blue = 0.5 mm wall joints with a router,
purple = 1.5 mm inner contour milling,
red = 1.5 mm outer contour cutter




Title: Re: Feldbahnmodule with ship
Post by: finescalerr on July 31, 2011, 01:32:08 PM
Would a laser be able to cut straight enough to accomplish interlocking bricks as square as those? Outstanding work! -- Russ


Title: Re: Feldbahnmodule with ship
Post by: DaKra on August 05, 2011, 07:03:32 AM
In this scale, yes, because the minimal taper would be hidden within the mortar lines and covered over on the completed model.    In HO, no.   There are HO laser cut kits on the market with interlocking brick corners... the results speak for themselves. 



Title: Re: Feldbahnmodule with ship
Post by: finescalerr on August 05, 2011, 01:16:26 PM
I presume, then, that in 1:48 the taper also might be too obvious but, by 1:32, things would start to improve? It sounds as though milling might be a more universal way to create interlocking corners. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Design-HSB on August 05, 2011, 03:46:36 PM
Yes I use mine on my model the same technology and have milled for Frithjof also the first parts.
In the original, a stone wall to a joint width 10 -11 mm width yields the 1:22.5 scale has an average of 0.5 mm. Frithjof and I milled yes because we have just milling itself. With 0.5 mm width joints are also milling about quite well. Everything is smaller, is certainly better to solve with laser cut.
Frithjof and I use wood fiber materials, which naturally arise not 100% completely smooth milling surfaces. This is not a disadvantage but rather an advantage, because the fibers enhance the bonding and close small gaps.
I'd like to create a table to represent the joint width.

  scale   Joint width   length stone   stone thickness
  1 / 1         10                240                120
1 / 22.5       0.5              10.7                  5
  1 / 35        0.3                6.8                  3
  1 / 48        0.2                5                     2.5
  1 / 87        0.1                2.6                  1.4

This table is easy to see that cut grooves in wood fiber panels with less such as 0.5 mm in width and not more sensible.
The slight slope in the laser cut is safe because the wood fiber material, the small problem.
The bigger problem is that I believe burned cut surfaces do not absorb the glue as well as milled fibrous cut surfaces.


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on October 16, 2011, 01:28:16 PM
Click here (http://www.ndetail.de/modellbahn/de/eisenbahner-wohnhaus.html) you will see a laser-cut house. The interlocking brick corners are are made very accurately.

(http://www.ndetail.de/spur-0/modell/eisenbahner-wohnhaus-5-650.jpg)
http://www.ndetail.de/modellbahn/de/eisenbahner-wohnhaus.html


In the right part of my module system there will be a  port area  (http://www.buntbahn.de/fotos/data/7452/2903Grundriss_Module_005.jpg). An old grab crane can load sand from a ship into a hopper. From them light railway wagons can be loaded later.


My research in Lauenburg (here the original crane was demolished in the 1980ger (?) years) was not very productive unfortunately. Only five photos I could find to  imagine the rough dimensions.


Muenzel_Kran_Lauenburg_-1956_b (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Muenzel_Kran_Lauenburg_-1956_b.jpg)


So we give it a compromise now. The structure will be similar to the Hamburg crane,

Possible Vorbild_Hafenkran (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hafenkran_1.jpg)

... Only the cab window later pre-built , I don´t like to build. This crane - now demolished - I took pictures four years ago.


For the first rehearsal I've milled out the walls which I have drawn in Cad.

Münzel-Kran_001 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_001.jpg)


Münzel-Kran_002 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_002.jpg)


Münzel-Kran_005 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_005.jpg)


However, I will extend the window at the front to further series of slices down probably so that the crane operator gets a better field of vision.
Pictures of old Hamburg harbor cranes shows windows of various sizes.

Münzel-Kran_Lauenburg (Copyright W.Hinsch-LEA) (fspg2)

(http://www.buntbahn.de/fotos/data/7452/2903Hafenkran_Lbg_1-klein.jpg)


At the picture of the original I'm not sure if there were placed metal plates in front of the windows probably present.

Münzel-Kran_006 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_006.jpg)


The picture above shows the plate from the bottom up. In the center hole all the cables for the power supply will be carried out. I´m thinking about an endless sliding contact, so the cables will not disrupt exactly after  4536.7 rotations. ;)


The rear wall is provided with lateral grooves. So the two little side panels could be bended easily after the circular bending.


To bend the plate properly, I used a second metal sheet as a victim under the original sheet...

rolls bending machine_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7443/2903Rollenbiegemaschine_02.gif)

...like here:

rolls bending machine_03 (fspg2)
(http://www.buntbahn.de/fotos/data/7443/2903Rollenbiegemaschine_03.jpg)


Frithjof


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on October 16, 2011, 01:43:13 PM
This is more than modeling: It is small scale manufacturing. Impressive. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: artizen on October 16, 2011, 03:43:17 PM
Hi Frithjof - the link is to a kit in 1:45? Here is a link to kits made in 1:43 and also available in 1:76 scales - http://www.finescale.org.uk/index.php?option=com_virtuemart&Itemid=55

All laser cut out of thin plywood. Once painted it appears that the corners and brick detail is acceptable from normal viewing distances.

What is being described here with the crane etc is true art!


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on December 05, 2011, 02:22:40 PM
Hi,

Today a small update about of my crane only.

The front window was extended downwards compared with the first drawing.


Münzel-Kran_008(fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_008.jpg)


Münzel-Kran_009(fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_009.jpg)


The template for milling with sheetcam:

Münzel-Kran_0011(fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_0011.png)


Round about two hours later, the frame was milled. I am amazed about the stability of the framework mostly.

Münzel-Kran_012(fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_012.jpg)


Münzel-Kran_014(fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_014.jpg)

The next parts will be the movable windows and the hinges (hole diameter: 0,5mm)

Frithjof


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on December 05, 2011, 02:36:03 PM
Wow. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on December 05, 2011, 03:01:34 PM
Double wow! That is really impressive work. Is the window frame milled out of brass?



Title: Re: Feldbahnmodule with ship
Post by: Gordon Ferguson on December 05, 2011, 04:26:17 PM
Superb, not only in the use of modern technology but in the interpretation and skill shown


Title: Re: Feldbahnmodule with ship
Post by: marc_reusser on December 07, 2011, 11:34:12 PM
Boah!...mensch ist das eine spinnerei! Just beautiful!

M


Title: Re: Feldbahnmodule with ship
Post by: michael mott on December 10, 2011, 06:33:59 PM
Excellent work!

Michael


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on December 30, 2011, 01:39:05 AM
Hi,
Thanks for your positive consent.

@ Marc
It's fun to spin a little. ... But you know what you're talking about. Many things here in the forum are spun great also ! :)

Yesterday my router has to work hard.
Thus, the hinges and the moving window frames made of 1.5 mm Ms58 were machined first.


Münzel-Kran_018(fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_018.jpg)


The crane has been modified a little bit. The lower U-profiles are no longer visible from outside. They are masked by the deep-drawn sheet metal.


Münzel-Kran_017(fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_017.jpg)


Since my 0.5 mm Ms58 material had gone to an end and I could not get new timely, instead German silver (Neusilberblech) was stuck with a wafer-thin double-sided tape on a MDF board and placed under the cutter.

Münzel-Kran_019(fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_019.jpg)


The German silver can not be milled as good as Ms58. So I had to adjust the feed rate much slower. Also was greased with a few drops of oil.


Münzel-Kran_020(fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_020.jpg)

0.15mm deep marks were placed with a small V-Cutter. So I could put the rivets very accurately with the embossing machine later.

After the vacuum cleaner and a little bit of crepe paper had removed all the dirt, I was able to lift the rivet bands with a thin cutter blade from the board and rub off the adhesive tape.


Some rivets had to be set from the back side directly into the walls (they have no external rivets band). In addition I have milled 1mm deep pockets in the MDF board. All milled walls of the crane house were placed with the outside face down in his pockets.


Münzel-Kran_021(fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_021.jpg)


Now the router could set the markers very easily.

In addition to the markers I used a rip fence, so as not in the heat of battle, the rivets can dance to it. Nothing is worse than when the last rivet is set incorrectly. ;)


Münzel-Kran_022(fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_022.jpg)


In the exterior walls of all the pages I have milled a deepening of 0.25 mm for the rivet bands, which are soldered in later.


Münzel-Kran_023(fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_023.jpg)

Frithjof


Title: Re: Feldbahnmodule with ship
Post by: mad gerald on December 30, 2011, 02:02:36 AM
Frithjof,

found some spare time to get back at the work bench again ... ?!  ;)


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on December 30, 2011, 02:34:17 AM
Impressive. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Gordon Ferguson on December 30, 2011, 02:44:57 AM
Frithjof,

Impressive ? ...................... absolutely superb !!!!


May just pack away my modelling tools after seeing this quality of work


Title: Re: Feldbahnmodule with ship
Post by: marc_reusser on December 30, 2011, 03:09:27 AM
HUCH!   WOW!! :o :o

It's like jewlery.

M


Title: Re: Feldbahnmodule with ship
Post by: Frederic Testard on December 30, 2011, 05:06:32 AM
Now, this is rivetting at its best!


Title: Re: Feldbahnmodule with ship
Post by: lab-dad on December 30, 2011, 07:46:08 AM
While the parts are most impressive, the SBS is superb!!!!!!
Thanks for posting.
Mj


Title: Re: Feldbahnmodule with ship
Post by: Hauk on December 30, 2011, 11:37:07 AM
I have never seen such crisp embossed rivets before. I thought that 0,5 mm was far to thick for embossing crisp.
Absolutely beautiful work.

Regards, Hauk


Title: Re: Feldbahnmodule with ship
Post by: EZnKY on December 30, 2011, 08:15:34 PM
Very, very impressive I would say!


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on December 30, 2011, 10:09:00 PM
Stunning, especially the rivets! They look like real rivets, not at all like embossed rivets.


Title: Re: Feldbahnmodule with ship
Post by: vincep on December 30, 2011, 10:17:18 PM
Another mind blowing project!!!!


Title: Re: Feldbahnmodule with ship
Post by: pwranta193 on December 31, 2011, 12:05:46 PM
 :o  :o  :o

Stunning.  I feel like I'm working with Crayons... (talent wise... not the finely cast colored wax implements).


Title: Re: Feldbahnmodule with ship
Post by: michael mott on December 31, 2011, 01:02:29 PM
Excellent, they are worth counting!

Michael


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on December 31, 2011, 02:24:56 PM
Hi,

Now I am amazed about so much recognition ... while there are only a few simple rivets! Thanks a lot!!


Just before the start of the new year I wanted to solder some parts for the crane.

Once again Pertinax serves as gage.



Münzel-Kran_026 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_026.jpg)


The result: a subframe for the front and side walls of the crane.


Münzel-Kran_027 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_027.jpg)


This allows me to pull off the walls like a shoe box from the bottom board in case of service. The whole mechanism will be on the baseboard at a later date.


Münzel-Kran_028 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_028.gif)

A happy new year to all of you!


Title: Re: Feldbahnmodule with ship
Post by: EZnKY on December 31, 2011, 02:48:28 PM
While they may "only be rivets," to the crazies on this forum, the quality of details like this is what makes the model.  (They don't call us rivet counters for nothing.)
I'm as impressed with your fabrication and assembly methods as the model.  My grandfather was a machinist, and he always said the quality of your final work was dictated by the care you put into "making the parts to make the parts."
I've grown to understand this phrase more and more as I get older - it didn't make much sense to a ten year old. 

I enjoy watching you do the same thing.  Like making a soldering jig to keep parts correctly positioned, etc. This is where I still have so much to learn.
Thanks for sharing it with all of us!


Title: Re: Feldbahnmodule with ship
Post by: artizen on December 31, 2011, 05:56:04 PM
I am definitely modelling with crayons... and ten thumbs!


Title: Re: Feldbahnmodule with ship
Post by: Hauk on January 01, 2012, 04:00:53 AM
I have browsed all the pages of your postings on different forums, and it seems you use blackening a lot on your brass parts. If I understand things correctly, you use a grit blaster before blackening the parts.

So my questions are:

-What type of blackening do you use, and how do you apply it?
-And what type of grit blaster do you use, and with what blasting medium?
I also wonder what type of CNC-machine you are using.

Hope I am not poking into any trade secrets...

Best regards, Hauk


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on January 05, 2012, 07:09:40 AM
Hi,

@Eric
Thanks for your comment. I am very satisfied, if you count rivets ...and finally you gets a very accurate miniaturization of the prototype. The effort to build a soldering gig will probably takes a little bit longer, but the result is usually faster and better built very often ;)

@Ian
Ten thumbs are much better than only five ;)

@Hauk
First I blasted the parts with a small sand blasting gun Badger, like this (http://www.amazon.com/Badger-Air-Brush-Co-260-1-Abrasive/dp/B0038D59UM).
The blasting material I bought here (http://www.fohrmann.com/lackieren-farbspritzen/blasting-material.html), it has a very smal grain size.
For larger parts like the crane cabin this blasting gun is to small but it works - only it takes a while.

I´m using a burnishing stain from a friendly professional company. Previously I had used a stain from the Tiffany area.
At the following picture you can see the way from brass, sandblasted, two minutes bathed in the burnishing stain and four minutes at last.

(http://www.buntbahn.de/fotos/data/7443/2903HF_und_HK_130_C_Gestaenge_5.jpg)

My CNC-machine is this one:

(http://cnc-step.de/images/stories/Produkte/High-Z_S/S_720_Fraesmaschine_vorne_CNC_STEP.jpg)
found at: http://cnc-step.de/


For more information you can see here (http://cnc-step.de/en/products-cnc-routers-cnc-router-cnc-engravers/high-z-standard-series-cnc-routers-engraving-machines-engraver/71-high-z-fraesmaschinen-3d-3d-cnc-qualitaet-top-preis-guenstiger)!


Meanwhile I have soldered the chassis. I am always pleased how accurately works such a ("cheese"-) milling machine. I had used a lot of time to make a to small sawn part again in former times, so now a lot of the time goes into designing at the computer. It makes much fun if I can put the milled parts together simply without any rework at the end! : D

Münzel-Kran_029 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_029.jpg)









Title: Re: Feldbahnmodule with ship
Post by: Hauk on January 05, 2012, 07:46:41 AM
Thanks a lot for the reply! Your crane is coming along beautifully.

I know what you mean when it comes to CNC-milling.  I had access to a large CNC hi-speed milling machine for a couple of years, and it was flat out addictive. Do you do all of your milling on the Hi-Z S720? I am seriously considering purchasing one.

And what type of milling motor do you use? I guess it is quite important to get a good one.

Best regards, Hauk

PS: That browning potion seems to work darn good. Any more clues on brand, contents, etc?


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on January 05, 2012, 10:29:46 AM
At buntbahn forum (http://translate.google.de/translate?sl=auto&tl=en&u=http%3A%2F%2Fwww.buntbahn.de%2Fmodellbau%2Fviewtopic.php%3Fp%3D231563) you can get some more information about blackening of metal (it is the google translation from the original German web page (http://www.buntbahn.de/modellbau/viewtopic.php?p=231563&highlight=pariser+oxid#231563)).

I don´t know the brand from the fluid I use currently, but at RS-Modell (http://www.rs-modelle.de/) you can get the patination fluid I used in former times. It´s part No. 2004 (http://translate.google.de/translate?sl=auto&tl=en&u=http%3A%2F%2Fwww.rs-modelle.de%2Ffarben.htm). It is the same fluid that I saw in a tiffany shop. It works at brass, nickel silver, white metal and tin (solder).
By using this fluid take care that the workpiece is free of fat, e.g. sandblasting. Then immerse the metal part into the burnishing stain (while constantly rub with an old toothbrush) for about 10-15 seconds. Finally rinse well in soapy water.

I do all of my milling on the Hi-Z S720! There are better machines surely, but for milling part made of brass, plastic and wood the results are always fair enough for my hobby. The High-Z is not strong enough for steel and high speed milling! Some people are calling it "cheese"-milling machine...   but for my request it is acceptable mostly. For more than 2400 hours I used only the Kress milling motor E6990 (it is an older one). It is replaced from No. 1050 FME. The sound level ist very high so you need ear protectors!!
In addition I have placed a slot table and I use slot nuts to fix my parts on it.

(http://www.buntbahn.de/fotos/data/7835/2903Gmeinder_10-12_Getriebedeckel_01.jpg)

Here a little movie (http://vimeo.com/21721057) from milling with the Kress.

Best regards
Frithjof


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on January 16, 2012, 12:32:33 PM
Today a little update.
The roof of the crane shall be removable, also it should be stable, because it will carry the boom.


Münzel-Kran_033(fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_033.gif)

First I drawn the roof bow frame. It can be lifted from the housing together with the yellow U-profiles.


Münzel-Kran_034(fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_034.jpg)


The curved roof beams were milled from 2mm brass.


Münzel-Kran_038(fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_038.jpg)


Each two of them I soldered against each other. So I got this double-T profile in the correct roof rounding. It's easier to me than to bent a purchased profile without it is warping.
The lateral U-profiles were also made of 2mm brass with corresponding recesses to position the curved roof beams exactly.


Münzel-Kran_040(fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_040.jpg)


Münzel-Kran_035(fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_035.jpg)


As previously I have used a pertinax gage to align everything exactly.

Münzel-Kran_036(fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_036.jpg)


Münzel-Kran_037(fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_037.jpg)


Münzel-Kran_039(fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_039.jpg)


Title: Re: Feldbahnmodule with ship
Post by: Mr Potato Head on January 16, 2012, 12:38:42 PM
Do you just feed the 3D info into the mill? is that how you made the curved beems? :o :o
I think the Space program needs you!
MPH


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on January 16, 2012, 02:41:42 PM
I am impressed by every step. Wow. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Ken Hamilton on January 16, 2012, 06:19:27 PM
Holy Smokes.  This is......is........(I can't think of any words to describe it).


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on January 16, 2012, 07:16:07 PM
Holy frijoles! Simply masterful work!


Title: Re: Feldbahnmodule with ship
Post by: JohnP on January 21, 2012, 09:20:42 PM
What a treat! I like to see the CAD images and then the real parts.

From what I have read on the web the home CNC concept can become a self-absorbing hobby of its own, so it is nice to good results from a small machine.

John


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on January 22, 2012, 06:05:10 AM
@ MPH, Russ, Ken, Ray, John
Thanks for the appreciative statements

The modeling and the drawing, both are two areas of my hobby. In the CAD I can determine exactly all sizes.

I still remember a few years ago when I came into contact with the CAD, there was very often the "how can I do it?" in my head. Today, I can check with the CAD already the idea even before production! It does not have to start with a huge project. Step by step you can continue.

A friend helps me very well, so I'm now able to realize my next step.

The roof was the next challenge for me.

First, the curvature of the roof was drawn from the side and extruded into the depth.


Münzel-Kran_045 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_045.gif)

It was followed by a new layer from the top, which received the contours of the openings and the rear roof rounding. The next step was a negative extrusion into the depths of everything - like a punch.


Münzel-Kran_046 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_046.jpg)


It was followed by a winding-up of the rounded roof, in order to generate a DXF file. For each milling the corresponding lines have been inked.


Münzel-Kran_047 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_047.png)


The  visible black lines mark the lower contour of the once vaulted roof. They should not be milled.


Münzel-Kran_048 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_048.png)


Sheetcam (http://www.sheetcam.com/index.shtml) is a very helpful software to generate the neccessary  tap-file format .


Münzel-Kran_049 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_049.jpg)

Each color is assigned to a cutter. There are depth of cut, number of runs with different depths, speed, feed, ... predetermined.

Münzel-Kran_050 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_050.png)

I milled with a maximum of the half of the cutter diameter in the deep.

After cutting out the 2mm brass plate the next step was the bending  of the roof.


Experience I had already done with a 1mm sheet earlier. Shown here (http://www.buntbahn.de/fotos/data/7452/2903Tauchglocke_23.jpg).

So now, the sheet was annealed with a gas burner and then bent in several passes, each time the radius of the  bending machine (http://www.buntbahn.de/fotos/data/7443/2903Rollenbiegemaschine_03.jpg) was set narrower.

Some care is important so that the sheet is also parallel, it must be given absolutely perpendicular to the machine!
If you bent one too much ... no problem: Simply roll the plate with a large radius setting of the machine from the back flat again. Then go to work with the right attitude once more! The metal is soft enough from annealing.
The manufacturer of the bending machine stated as the greatest thickness at 1mm brass. I used on both sides "victim plates" and so I got to a total thickness of 3mm - the machine has survived without any effort!

But see for yourself - all parts are put together only loosely:

Münzel-Kran_041 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_041.jpg)


Münzel-Kran_042 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_042.jpg)


Münzel-Kran_043 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_043.jpg)


Münzel-Kran_044 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_044.jpg)


Title: Re: Feldbahnmodule with ship
Post by: 1-32 on January 22, 2012, 08:40:31 AM
hello munzel
from a person who does not have a clue as to how you do it-
just lovelly work
kind regards kim


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on January 22, 2012, 10:51:03 AM
Thanks for the step-by-step, very interesting!

The latest addition to the model is, as usual, superb.


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on January 22, 2012, 02:47:38 PM
Beyond comprehension. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on January 30, 2012, 01:15:18 PM
It continues with the substructure of the harbor crane.

Münzel-Kran_051 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_051.jpg)

When I played on this sand piles as a child, never I had dreamed that I would count the rivets on this crane, many years later.


The following snippet I placed as a background photo under the drawing...

Münzel-Kran_055 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_055.jpg)


... and the side wall was modeled rivet for rivets.


Münzel-Kran_052 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_052.jpg)


Münzel-Kran_053 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_053.png)

The cutter got this DXF file ...


Münzel-Kran_054 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_054.png)

... and I received a few nickel silver plates in which I have to press a few hundred rivets now.   ;)


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on January 30, 2012, 01:36:54 PM
I already can visualize the result. Wonderful. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on February 06, 2012, 03:16:21 PM
The upper and lower rivet band should be soldered right-angeld. So I have built a new gauge. This time it is not milled but sawed.
The rivet band is 0.5 mm thick, the rivets wear out to 0.65 mm. So the slots were cut with a 0.5 mm circular saw blade on my Böhler saw with different depths. Then the rivet bands were inserted vertically.
With the help of soldering flux and solder wire (0.5 mm) the side panel have been soldered together.



Münzel-Kran_056 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_056.jpg)


Münzel-Kran_057 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_057.jpg)


Münzel-Kran_058 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_058.jpg)


Still missing the riveted L-angle strips - with 920 rivets of 1.5 mm diameter.

Below you can get a small impression how it will look once.

Münzel-Kran_059 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_059.jpg)


Title: Re: Feldbahnmodule with ship
Post by: Hauk on February 06, 2012, 03:32:54 PM
That is some really sharp modelling. I look forward to every new posting on your project. A great inspiration.

Regards, Hauk


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on February 12, 2012, 04:50:04 PM
@ Hauk
Thank you for your interest in my work! Today comes a short update.

As a little finger exercise for in-between a small drawing was created: the panel for the electric drive of the port crane.

Münzel-Kran_060 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_060.jpg)


This resulted in the settlement:

Münzel-Kran_061 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_061.jpg)


... the dxf file with different colors for the 0.5 mm drill and the two different cutters:

Münzel-Kran_062 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_062.gif)


... and the milling file:

Münzel-Kran_063 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_063.gif)


Münzel-Kran_064 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_064.jpg)


The four roof side angle I had cut after bending to measure. A 1.5 mm thick brass sheet was used as spacers for the sheet metal cutting machine. Similar to shown here (http://www.buntbahn.de/fotos/data/7443/2903Abstandshalter_aus_MS.jpg).

Münzel-Kran_065 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_065.jpg)


The result for today - folded and soldered:

Münzel-Kran_066 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_066.jpg)


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on February 12, 2012, 07:08:46 PM
Nice! A very simple structure, elegantly engineered.


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on February 19, 2012, 11:24:41 AM
Thank you Ray for your nod.

The old harbor crane had a double shell type grab, which was closed and lifted with one rope only.


Münzel-Kran_067 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_067.jpg)


On top there were two movable hooks.
The hooks grabbed over a "mushroom-formed" objekt. By pulling a second rope the gripper opened.


Münzel-Kran_068 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_068.jpg)

Unfortunately I cant see the exact mechanism at the pictures.

Maybe someone has even a photo or drawing of just such a hook on which I can still see a few more details.


I'm in between pressing the rivets.

Münzel-Kran_069 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_069.jpg)


Title: Re: Feldbahnmodule with ship
Post by: David Emery on February 19, 2012, 11:26:09 AM
There are kits available for clamshell buckets, at least in HO and I think in O scale, too. 

dave


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on February 19, 2012, 01:50:13 PM
I don't know if these are the same kind but I found some plans for clamshell buckets online...

http://constructionbucket.tpub.com/TM-5-3815-200-23P/TM-5-3815-200-23P0022.htm (http://constructionbucket.tpub.com/TM-5-3815-200-23P/TM-5-3815-200-23P0022.htm)

http://constructionbucket.tpub.com/TM-5-3815-200-23P/TM-5-3815-200-23P0035.htm (http://constructionbucket.tpub.com/TM-5-3815-200-23P/TM-5-3815-200-23P0035.htm)

You can also find a lot of photos and plans by searching "clamshell bucket" on Google Images. Here's one...

(http://www.dredgingengineering.com/dredging/media/LectureNotes/Miedema/1992_Wodcon_13_Clamshell/Figure02.jpg)





Title: Re: Feldbahnmodule with ship
Post by: fspg2 on February 26, 2012, 03:36:43 PM
@Dave, Ray,
Thank you for your tips!

Looking for photos of my favorite model of clamshell buckets I got several emails from various people with useful notes, drawings and images.

Thanks to all of you!

Most of all I have enjoyed the help of two colleagues who had made their way to the Museum of Work in Hamburg/Germany and send some pictures of just such a gripper to me.

To recreate the look I put the photos to the background.


Münzel-Kran_076 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_076.jpg)

The 3-D drawing is the first step.  So I can build the gripper later in brass and nickel silver on a scale of 1:22.5.



Meanwhile the 4 beam supports for the roof were milled in brass of a 20mm x 8mm profile.
Since the parts are 5.5 mm thick only I have provided the profile of the back with 2.5 mm deep pockets.


Münzel-Kran_074 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_074.png)

The center bars are for the fixed clamping during cutting the opposite side.


Münzel-Kran_073 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_073.png)


The centrally exciting vice helps for fixing the parts correctly.

Münzel-Kran_077 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_077.jpg)


Then I milled a 9.0 mm deep pocket into a piece of hard paper.


Münzel-Kran_071 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_071.jpg)


The beam supports were placed in these pockets.
A 2.0 mm mill took off 0.5 mm material per each pass. In all 7,5mm he removed.

Münzel-Kran_070 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_070.jpg)


The two side plates with hex bolt and shims were milled for test only.
They should to be formed with a distance unit block.

Now the hexagon bolts will be assembled with the washers after the soldering of the support beams into the 2mm roof .

Münzel-Kran_072 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_072.jpg)


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on April 06, 2012, 12:28:22 PM
Today it´s only a little progress with the crane.

The two doors and window frames were milled from 0.5 mm brass MS58.


Münzel-Kran_079 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_079.png)


One frame shall soldered to the door. After painting a plexiglass disc will be inserted and glued with the second frame to the back of the door.

Münzel-Kran_080 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_080.jpg)


Münzel-Kran_081 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_081.jpg)


In this interior view the upper guide rail of the door is still missing. I wanted to see how it will look like.

Münzel-Kran_082 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_082.jpg)




Title: Re: Feldbahnmodule with ship
Post by: finescalerr on April 06, 2012, 12:36:39 PM
It is beautiful progress. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Hauk on April 06, 2012, 01:33:12 PM
Today it´s only a little progress with the crane.

No progress too small to be of interest!
I just love this project. A great inspiration.

Best regards,
Hauk


Title: Re: Feldbahnmodule with ship
Post by: marc_reusser on April 08, 2012, 12:06:26 AM
Wauw!  Beautiful. That interior shot could be of the real space.


Title: Re: Feldbahnmodule with ship
Post by: Junior on April 08, 2012, 08:14:40 AM
Superb work from all points of view :o!

Anders


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on April 29, 2012, 09:47:40 AM
Russ, Hauk, Marc, Anders,

Thanks for the acceptance :) I am glad to get praise from you.

Next, the doors have been provided with a circumferential angle belt. Then all parts were blasted, conscious mottled black finish and brushed with a dirty gray heavily diluted broth as a base coat. Under exfoliated paint there should no bare metal shine through later!


Münzel-Kran_084 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_084.jpg)


Before I am going to recreate the interior, first the upper door rails are soldered.
A 0.5 mm aluminum sheet (which was 0.3 mm longer than the door) served as a soldering help to get the exactly parallel distance to the lower rail.


Münzel-Kran_083 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_083.gif)


The inner riveted angle sections (counterparts to the externally visible rivets bands) will follow, because through the open doors and the front windows it will be quite able to see the interior - and even then it should look like "real". Since I unfortunately have no interior views of the original crane, I'm probably will copy a little bit from the demolished Hamburg harbor crane:


Hamburger_Hafenkran_050 (fspg2)
(http://www.buntbahn.de/fotos/data/8180/2903Hamburger_Hafenkran_050.jpg)


Hamburger_Hafenkran_052 (fspg2)
(http://www.buntbahn.de/fotos/data/8180/2903Hamburger_Hafenkran_052.jpg)


Hamburger_Hafenkran_053 (fspg2)
(http://www.buntbahn.de/fotos/data/8180/2903Hamburger_Hafenkran_053.jpg)


Hamburger_Hafenkran_051 (fspg2)
(http://www.buntbahn.de/fotos/data/8180/2903Hamburger_Hafenkran_051.jpg)


Hamburger_Hafenkran_054 (fspg2)
(http://www.buntbahn.de/fotos/data/8180/2903Hamburger_Hafenkran_054.jpg)



Today I drawn on the claw.


excavator-Museum-of-work-HH11-4 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Bagger-Museum-der-Arbeit-HH11-4.jpg)

Photos were used as a template from the Hamburg "Museum of Work". Two nice fellow had photographed such a grip there.

The gripper has a width of approximately 1300mm above all, the open blade measures approx 2500mm. So the results in 1:22.5 are 57.8 mm width and 111mm open.

In Photoshop the images were scaled accordingly and provided with guide lines.
In order to get the exact measurements the photos should be taken at right angle. Also, the taper to the rear perspective be considered in order to obtain the most accurate data.

Before I get the milling data it is already a long time, but is rewarded by the fact that the milled parts will fit without further treatment!

Münzel-Kran_087 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_087.jpg)


Münzel-Kran_085 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_085.jpg)


Münzel-Kran_086 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_086.jpg)


Münzel-Kran_088 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_088.jpg)


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on April 29, 2012, 02:22:07 PM
It is a pleasure to watch this project develop. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: artizen on April 29, 2012, 04:46:50 PM
Unbelievable detail.


Title: Re: Feldbahnmodule with ship
Post by: marc_reusser on April 29, 2012, 09:32:18 PM
WOW! I really look forward to seeing all this interior detail anf the clam-shell come to life!

Marc


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on May 01, 2012, 12:58:58 PM
A small but important detail: the small sprockets are machined from 2mm brass sheet. They serve to open the clamshells even.


Münzel-Kran_089 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_089.jpg)


Münzel-Kran_090/B] (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_090.jpg)


Münzel-Kran_091 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_091.jpg)


Münzel-Kran_092 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_092.jpg)


Münzel-Kran_093 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_093.jpg)


Title: Re: Feldbahnmodule with ship
Post by: lab-dad on May 02, 2012, 06:09:37 AM
 :o :o :o :o :o :o :o
Where can I order my kit!!!!!!!
Just awesome!!!!
-Marty


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on May 06, 2012, 07:21:51 AM
Marty,

Only one kit? ;)

Other clamps parts have been cut out and the first blade half was soldered together.


Münzel-Kran_094 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_094.jpg)

For easy mounting I have milled grooves in the individual parts.


However, I have discovered an error. :'( :'(

In an old drawing I found the width of the blade of 1300mm.

Yesterday I got more dimensioned photos from Gerald (many  thanks to you!). There  you can see the width of 1100mm.


Münzel-Kran_095 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_095.jpg)



Otherwise the length of the gripper is also incorrect!


Münzel-Kran_096 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_096.jpg)

So I'll scale everything once again. And the milling machine has to do a new job! 




Title: Re: Feldbahnmodule with ship
Post by: billmart on May 06, 2012, 08:03:28 AM
Fabulous work!  So neat and clean.

Bill Martinsen


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on May 06, 2012, 06:59:56 PM
Stunning! As Bill said, very neat, clean work!


Title: Re: Feldbahnmodule with ship
Post by: lab-dad on May 07, 2012, 06:00:07 AM
Yea, only one kit  ;)
I will take the "mistakes" though!

Just beautiful machining!
Why does the material look almost "cast" what is it? Or are you doing something to it?

-Marty


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on May 07, 2012, 10:59:23 AM
Bill, Ray and Marty,

It is certainly a neat way of working. However, it costs a little bit more of time!
But it satisfies me much more if I build properly! The way is the destination :)

@Marty
The parts are milled mostly from brass or nickel silver. All parts are sandblasted. So the surface gets this look. It just looks cleaner.


Title: Re: Feldbahnmodule with ship
Post by: lab-dad on May 07, 2012, 12:07:30 PM
Quote
@Marty
The parts are milled mostly from brass or nickel silver. All parts are sandblasted. So the surface gets this look. It just looks cleaner.

Yes it does!!!!!!
What media are you using and how are you spraying it?

-Marty


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on May 18, 2012, 01:01:58 AM
@Marty
I´m using a sandblasting booth (http://www.ebay.de/itm/Sandstrahlkabine-P1-Sandstrahlen-Sandstrahlgerat-/310375184642?pt=DE_Haus_Garten_Heimwerker_Druckluftwerkzeuge&hash=item4843cd7902) an very fine sand blasting medium (http://www.fohrmann.com/strahlmittel.html)


Right now it goes on in small steps.

The blade dimensions have been adjusted and everything is milled again.


Münzel-Kran_097 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_097.jpg)


Münzel-Kran_098 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_098.jpg)


The next parts are the U-profiles, the cover for the pulleys and the two blocks for the joints.

Münzel-Kran_100 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_100.jpg)


Since I had no suitable 8mm x 3mm U-profile, it was milled from a 3mm brass plate.

The cover to  protect the two pulleys is made of two parts: a shell of 8mm MS 58-flat section


Münzel-Kran_099 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_099.jpg)


Münzel-Kran_102 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_102.jpg)


and a cover plate made of 0.5 mm MS58-sheet, which is provided peripherally with a groove. Thus, the lid fits the pot.


Münzel-Kran_103 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_103.jpg)

For comparison, the picture below shows the sizes of the old and the new shell.

Münzel-Kran_101 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_101.jpg)

Now I am looking for pulleys, which are similar to the drawing: 15mm - 16mm outside diameter with recesses.

Münzel-Kran_104 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_104.jpg)

Either I have to go the way of  Helmut (http://www.buntbahn.de/fotos/data/6264/13P1050150a.jpg) or I will mill the recesses in a purchased pulley.
Perhaps there are those ready to buy.


Title: Re: Feldbahnmodule with ship
Post by: Hauk on May 18, 2012, 01:37:52 AM

(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_097.jpg)


I´m suffering from a serious case of CNC-mill envy.
But the cure is too expencive!

Regards,
Hauk


Title: Re: Feldbahnmodule with ship
Post by: mad gerald on May 18, 2012, 02:32:40 AM
Moin Frithjof,

...
For comparison, the picture below shows the sizes of the old and the new shell.
...
Münzel-Kran_101 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_101.jpg)
... now that's quite a difference ...  :o

I'll see that I'm gonna take some additional shots of the upper mechanisms at the first convenient opportunity ...

Cheers


Title: Re: Feldbahnmodule with ship
Post by: Wesleybeks on May 18, 2012, 06:32:11 AM
Stunning work. I'm so envious.


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on May 18, 2012, 12:29:31 PM
@Hauk
What can help? Tell me, I know a small medicine ;)

@ Gerald
There is no hurry, I still have a lot of small sites :)

@Wesley
I'm glad you like it!

Today the milled shovel parts were soldered together. I was curious if all the parts would fit.
What CAD did suggest has been confirmed: the shovel work without wobble.

Münzel-Kran_105 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_105.jpg)


Münzel-Kran_106 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_106.jpg)


Münzel-Kran_107 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_107.jpg)


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on May 18, 2012, 01:17:00 PM
Not bad. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: artizen on May 18, 2012, 03:31:08 PM
Beautiful work.


Title: Re: Feldbahnmodule with ship
Post by: 1-32 on May 19, 2012, 12:59:33 AM
but is it art?
regards kim


Title: Re: Feldbahnmodule with ship
Post by: artizen on May 19, 2012, 03:04:31 AM
I think it is!


Title: Re: Feldbahnmodule with ship
Post by: lab-dad on May 19, 2012, 02:50:30 PM
AMAZING!
I would wear it out just playing with it; opening & closing.
Hell, knowing me I'd be eating my rice crispies with it!

"art" is not an adequate description.
-Marty


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on June 03, 2012, 02:13:18 PM
Today it has rained cats and dogs - just right to do boring things.

I milled further 22 sheets of 0.5 mm nickel silver. They serve as a connection to the transverse carrier plates.


Münzel-Kran_110 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_110.jpg)

After about 300 rivets were pressed into the marked holes, the angles were bent.

From a oddment of hardpaper a bending help was constructed.
One side of the sheet was put in a 1mm slot . A second block was used as a punch.

Münzel-Kran_111 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_111.jpg)


On the hook only a few hex screws were placed.


Münzel-Kran_109 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_109.jpg)


Because I had caches my small nut driver size 1.0 mm anywhere a 1.5 mm U-profile has been misused in order to tighten the nuts.

Münzel-Kran_108 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_108.jpg)


Title: Re: Feldbahnmodule with ship
Post by: lab-dad on June 03, 2012, 03:04:50 PM
I love your metalwork and fixtures.
Always a lesson in your posts.
Marty


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on June 04, 2012, 01:56:18 AM
This project never ceases to astound me. I hope I can publish something about it when you finish. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on June 08, 2012, 02:14:35 PM
@Marty
Thanks, but I hope it´s not to much schoolmasterly ;)

@Russ
These are just little things, really!
So I ask you for your patience! Because of my job I can currently make small steps only. By the time I'm finished, it will still take some time!


We continue with the wheel tread.


Muenzel-Kran_112 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_112.jpg)


It consists of two parts that were cut from 2mm brass.


Muenzel-Kran_113 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_113.jpg)


Münzel-Kran_114 (fspg2)

(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_114.jpg)


As a positioning aid eight 0.5 mm holes were drilled in both strips. The parts were  aligned with small rivets and soldered together.

Münzel-Kran_115 (fspg2)

(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_115.jpg)


Tomorrow the sprocket will be milled on the milling machine.


Title: Re: Feldbahnmodule with ship
Post by: Gordon Ferguson on June 08, 2012, 04:11:21 PM
You are turning engineering into an art form ................ your work is so far, and unfortunately will continue to be,  so outside anything I could hope to achieve.

That could be depressing but I so look forward to seeing what you are going to do next and how you are going to do it , that is actually inspirational .

Keep up the great work 


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on June 09, 2012, 09:47:51 AM
Hi Gordon,

Thanks for the well-meaning statements. I hope the inspiration is greater than the little "depression"!

In a craft box I found a sprocket with two different sizes of the tooth module. The wall thickness is only 1.8 mm (including gears). To tighten it  in a lathe I would have to rotate a mating receptacle. With the milling machine I was faster.

In a 10mm thick Pertinax board I have milled a 1.85 mm thick and 3 mm deep groove. In addition, six holes were drilled at 1.5 mm.


Muenzel-Kran_116 (fspg2)

(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_116.jpg)


Into this dent, I inserted the cogwheel. At three points thin aluminum foil was placed in between. Thus, the seat became a bit tighter.


Muenzel-Kran_117 (fspg2)

(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_117.jpg)



Now a 3mm cutter came to use and the upper sprocket was milled off.


Muenzel-Kran_118 (fspg2)

(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_118.jpg)

Finally I had reached a height of 5mm.
Throgh the six holes 1.5 mm brass rods were inserted from the rear.
With gentle pressure the ring was gently expelled from the groove.


Muenzel-Kran_119 (fspg2)

(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_119.jpg)



Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on June 09, 2012, 12:16:35 PM
As always, this continues to be a very fascinating project!


Title: Re: Feldbahnmodule with ship
Post by: artizen on June 10, 2012, 02:19:29 AM
A work of art. Ingenious as well.


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on June 10, 2012, 01:45:31 PM
@Ray
I hope it will not be boring. I can make only small steps work-related.

@Ian
I like it to see growing up my own project. However there are a lot of different things I like to build... my old shed, my Gmeinder 10-12, my Bridge, ... But there is a little problem: 24 hours/day are not enough.

Hi,

the sprocket must be stabilized. For this, a reinforcing ring of 1mm brass was milled.

 
Münzel-Kran_120 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_120.jpg)


Münzel-Kran_121 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_121.jpg)


The vertical supports are inserted into small slots. They will be soldered with the sprocket and with the guide tube internally. Through this tube the electrical cables will conducted later.
   

Münzel-Kran_122 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_122.jpg)


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on June 11, 2012, 02:40:25 PM
Satisfactory. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on July 31, 2012, 11:49:15 AM
Today only a tiny little interim report:

Münzel-Kran_123 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_123.jpg)


The connection to the base of the crane house is run on an 8 mm guide tube. All the necessary cables should be conducted through.

Münzel-Kran_127 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_127.jpg)


Hamburger_Hafenkran_033 (fspg2)
(http://www.buntbahn.de/fotos/data/8180/2903Hamburger_Hafenkran_033.jpg)


All parts for the top duct were cut from 1mm brass sheet. The elongated holes in the base plate were made 0.5mm longer in order to get some play in the placement of the triangular supports. Furthermore the curves (radius = 0.25 mm) generated by the 0.5 mm cutter were filed with a small square file.

Münzel-Kran_124 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_124.jpg)


The 10/8mm guide tube (4.5 mm high) was soldered first, next came the small columns in pairs opposite one another. 2mm long soldering tin pieces (0.5 mm wire) were positioned at both sides of the triangular supports and brushed with soldering fluid. All parts were very tightly into each other. The hot flame let the solder flow into the cracks.

Münzel-Kran_128 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_128.jpg)
... scale of the picture about: 1:1 ...

Münzel-Kran_129 /b] (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_129.jpg)


Title: Re: Feldbahnmodule with ship
Post by: artizen on July 31, 2012, 04:41:45 PM
So pleased to see you updating on this forum as well as buntbahn. I struggle with my non-existent knowledge of German!

More exquisite detail work. This whole model is built like a Swiss watch.


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on July 31, 2012, 09:48:34 PM
Nice! I like how the triangular supports are keyed into the base plate for added strength.


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on August 06, 2012, 12:52:31 PM
@Ian
Up to a Swiss clock there are still missing a lot of mechanics :)

@Ray
At the beginning there were a few deliberations but they helped me with a faster installation finally.


The transverse nickel silver sheets which will carry the circular track were cutted yesterday. For this I used my  metal cutting machine (http://www.buntbahn.de/fotos/data/7443/2903Biegemaschine.jpg).
The sloping top corners I profiled with a 2mm saw blade on my Böhler buzz saw. Because all corners should get the same angle, the right sheet was glued on as a stop with double sided tape on the mobile saw bench.

Münzel-Kran_130 (fspg2)

(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_130.jpg)


Münzel-Kran_131 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_131.jpg)


The 8mm center column was grooved with a 0.8 mm cutter every 90 degrees 0.2 mm deep.


Münzel-Kran_132 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_132.jpg)


As soldering jig a Pertinax board served again.


Münzel-Kran_133 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_133.jpg)


Münzel-Kran_134 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_134.jpg)


Loosely put together all parts you can already recognize the similarity with the drawing.
   

Münzel-Kran_135 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_135.jpg)


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on August 06, 2012, 02:37:01 PM
I am reeling in stunned disbelief. That is amazingly sophisticated! -- Russ


Title: Re: Feldbahnmodule with ship
Post by: lab-dad on August 06, 2012, 03:37:50 PM
Those last few images are just simply amazing art!
Really beautiful mechanical masterpieces!
Will be a shame to cover them up!
-Marty


Title: Re: Feldbahnmodule with ship
Post by: Chuck Doan on August 06, 2012, 03:47:55 PM
Russ and Marty have said it all for me! Spectacular fabrications.


Title: Re: Feldbahnmodule with ship
Post by: artizen on August 06, 2012, 04:19:01 PM
 :o :o :o :o :o

Wonderful!


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on August 06, 2012, 11:16:26 PM
Marvelous!


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on August 11, 2012, 07:04:34 AM
Thanks guys.

Next to the crane, there are still many, many more small sites  ;)

Thus, all turnouts should be added with a drive and a switch.

Weiche_Abzweig_1 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Weiche_Abzweig_1.jpg)

For the turnout switch two parts were been casted.

Feldbahn_Stellbock_DIN9939_01 (fspg2)
(http://www.buntbahn.de/fotos/data/8231/2903Feldbahn_Stellbock_DIN9939_01.jpg)


Gussbaum_Stellbock_001 (fspg2)
(http://www.buntbahn.de/fotos/data/8231/2903Gussbaum_Stellbock_001.jpg)


Gussbaum_Stellbock_002 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Gussbaum_Stellbock_002.jpg)


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on August 28, 2012, 10:55:51 AM
For the turnout switch I need a small U-frame to connect the control rod with the adjustment weight.
A master pattern with subsequent casting would be too expensive.
So the router has to work a little bit longer.

Milled from 2mm sheet brass I got the required quantity of 16mm x  2mm x 2 mm profiles.


U-frame-2 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903U-Buegel-2.jpg)


For milling the second beam I have designed a template in which the profiles are processed.


U-frame (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903U-Buegel.gif)


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on August 30, 2012, 12:01:23 AM
The animated gif is very helpful in showing how you did it.


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on September 03, 2012, 01:44:23 PM
The U-bolt will be provided with a hole on the top to connect the pull rod certainly.
From 2mm sheet of brass a small drilling aid has been manufactured ...


Bohrhilfe_Buegel (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Bohrhilfe_Buegel.jpg)


...and was clamped vertically in a mini-vice. The U-bolt was inserted and secured with a 1mm rivet temporary. Using a small centering drill a 0.8 mm hole was drilled from above.
The 1.2 mm rod was turned off to 0.8 mm at one end and soldered into the drilled hole.


Feldbahn_Stellbock_DIN9939_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Feldbahn_Stellbock_DIN9939_02.gif)


Instead of drawings a few pictures now!

U-bolt-3 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903U-Buegel-3.jpg)


U-bolt-4 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903U-Buegel-4.jpg)


U-bolt-6 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903U-Buegel-6.jpg)


The first turnout switch is mounted to sample now  - present it remains only 8 more ☺

U-bolt-8 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903U-Buegel-8.jpg)


Title: Re: Feldbahnmodule with ship
Post by: lab-dad on September 03, 2012, 02:36:50 PM
All that beautiful precision machining and you went and left it out to get all rusty! ;)
Nice job!
Such a simple little thing............... ;D
-Marty


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on September 04, 2012, 01:47:33 AM
Most impressive. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Junior on September 04, 2012, 05:14:55 AM
Fantastic work and great weathering too  :o! I especially like the weathering of the ties.

Anders


Title: Re: Feldbahnmodule with ship
Post by: Chuck Doan on September 04, 2012, 08:21:12 AM
Beautiful work as usual!


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on September 30, 2012, 11:30:10 AM
@Marty, Russ, Anders, Chuck

Thanks for your friendly recognition!


Do you know that ...  a model part is half finished and waiting for the next soldering?  ;)

So it happend me with the stairs for the old shed. :'(

To recap, the steps were already drawn in Februar 2009 (http://www.buntbahn.de/modellbau/viewtopic.php?t=6691&postdays=0&postorder=asc&start=140)


Alter_Lagerschuppen_307 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Lagerschuppen_307.jpg)


The tread support I had soldered in a small solder gauge (http://www.buntbahn.de/fotos/showphoto.php?photo=58260&size=big&password=&sort=7&thecat=8054) in combination with the angle iron and two 0.5 mm rivets. The brass steps were finished ... also the ladder beams ... but nothing happend ...



Through the help of a friendly Buntbahner (http://translate.google.com/translate?sl=auto&tl=en&u=http%3A%2F%2Fwww.buntbahn.de%2Fmodellbau%2Fviewtopic.php%3Ft%3D10850%26postdays%3D0%26postorder%3Dasc%26start%3D0), I am equipped with a Resistance Soldering System– like this (https://www.americanbeautytools.com/site/models/rs).

Today I tested the new device.

First it was milled a new hard paper soldering jig and all parts were placed.

Alter_Lagerschuppen_305 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Lagerschuppen_305.jpg)


At those points which should be soldered small pieces of 0.5 mm tin-solder were placed and soldering fluid were added with a brush.

With the left brass electrode I held the stair step down, the carbon electrode was pressed against the solder wire, now the foot switch was pressed .... after a few seconds the solder melted. Through the capillary action the soldering fluid crept into the clefts. After I let loose the pedal I just waited and kept the carbon electrode still lightly until everything was fixed.
 
Alter_Lagerschuppen_306 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Lagerschuppen_306.jpg)


After half an hour and 28 solder points I could sandblast the stairs.


Alter_Lagerschuppen_308 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Lagerschuppen_308.jpg)


Alter_Lagerschuppen_309 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Lagerschuppen_309.jpg)


There is a huge difference beetwen the Resistance Soldering System and the soldering iron:

No long heating-up of the soldeing rod.
It is heated only the point at which the soldering flux and the solder is placed.
Older soldered joints remain cold.
Short or long breaks are not a problem, the unit is cold, as long as the foot pedal is not depressed.

I'm really excited by my new Resistance Soldering System. :)

Frithjof


Title: Re: Feldbahnmodule with ship
Post by: 5thwheel on September 30, 2012, 12:43:24 PM
I have been using American Beauty resistance soldering equipment for many years.  I find it very helpful when doing delicate parts. Still I do use a torch and soldering iron when needed.  I am very interested in the soldering (paper?) That you are using to jig up the ladder.  Tell us more about it and where one might find some.

Bill Hudson


Title: Re: Feldbahnmodule with ship
Post by: lab-dad on September 30, 2012, 04:01:25 PM
Those stairs are breathtaking!
I doubt if photographed in the right way ANYONE could tell it is a model.
Heck, I know if I was shown the photo above i could not tell it wasnt 1:1
I really need to invest in a resistance soldering tool.
-Marty


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on September 30, 2012, 05:15:56 PM
Nice! Did you mill the tread texture into the steps? Or is it photoetched?



Title: Re: Feldbahnmodule with ship
Post by: Frederic Testard on September 30, 2012, 11:10:19 PM
Fantastic stairs.


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on September 30, 2012, 11:49:37 PM
@Bill
I use Pertinax and Hardpaper (look for Paxolin) https://secure.wikimedia.org/wikipedia/en/wiki/Paxolin (in German: https://de.wikipedia.org/wiki/Hartpapier).
I buy remnants of laminated paper and Pertinax (about 3.00 € per kg) from a dealer for plastics.
You can´t use this material with a blowpipe. The flame will destroy the material.
It stinks and the fumes are not healthy!

@Marty
The resistance soldering equipment is the best purchase I did for my hobby.
My unit has been built by a friend. It is very similar like the American Beauty tools.
There is a discussion about self-building a resistance soldering tool at the German Buntbahnforum: http://www.buntbahn.de/modellbau/viewtopic.php?t=10850
Google translation: http://translate.google.com/translate?sl=auto&tl=en&u=http%3A%2F%2Fwww.buntbahn.de%2Fmodellbau%2Fviewtopic.php%3Ft%3D10850

@Ray
The texture is photoetched.

@Frederic
I am glad that you like the stairs!


Title: Re: Feldbahnmodule with ship
Post by: michael mott on October 02, 2012, 01:22:43 PM
Frithjof, Great work on the steps, reminds me of some that I made a while back.

Michael


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on October 06, 2012, 11:14:55 AM
@Michael
Thank you for your compliment!

It's just been great that I can solder a big part together with a small part very quickly, without fear that already soldered parts separated again.
I have cleared up in the last days (holiday thank) and and I found a lot of things which cry to have contact to my new resistance soldering equipment.

It goes on with the bridge module. The lifting mechanism of the bridge on the principle Hotopp (http://translate.google.com/translate?sl=auto&tl=en&u=http%3A%2F%2Fde.wikipedia.org%2Fwiki%2FLudwig_Hotopp)  (as shown here) (http://translate.google.com/translate?sl=auto&tl=en&u=http%3A%2F%2Fwww.buntbahn.de%2Fmodellbau%2Fviewtopic.php%3Fp%3D249055%26highlight%3Dhotopp%23249055) should be explained in detail as well as the closing mechanism of the swivel gate (http://www.autokaffee.com/DDD/Schwenk2.html) in model.


Modul-Montage_005 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Modul-Montage_005.jpg)



Modul-Montage_007 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Modul-Montage_007.jpg)


Although not operated with real water, some belowground functions shall be on view through a hole in the module box.


Modul-Montage_008 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Modul-Montage_008.jpg)


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on October 14, 2012, 01:34:04 AM
Hello,

I wrote that I am thrilled by the resistance soldering system, closely located parts next to the soldering points remain untouched.

I wanted to try more precisely.

Heber_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Heber_01.jpg)


For the visible part of the water lifter (explanation (http://www.autokaffee.com/DDD/Heber2.html)), I wanted to solder an auxiliary plate to another sheet.
Until now I had used always a metal angle for square alignment (of course, it has also withdrawn heat) - so I had to heat longer with the soldering iron - neighboring sites were cooled with toothpaste.

Now I was brave and took an old plastic triangel as a fence. With Tesakrepp everything was fixed .. and the resistance soldering system heated the right side ...


Heber_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Heber_02.jpg)


... and the left side kept cool ... :)

Heber_04 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Heber_04.jpg)


Heber_05 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Heber_05.jpg)


The water lifter could be viewed during the demolition of the old Lauenburg sluice in 2006 precisely.


(http://www.rondeshagen.com/Grafik/Kanal/Bau_Schleuse_LB/LB_Schleuse_Abriss/Abriss-15-01-06/IM000499-2006.jpg)
source: http://www.rondeshagen.com/Schleuse_in_%20Lauenburg.html


(http://www.rondeshagen.com/Grafik/Kanal/Bau_Schleuse_LB/LB_Schleuse_Abriss/Abriss-25-01-06/IM000541-2006.jpg)
source: http://www.rondeshagen.com/Schleuse_in_%20Lauenburg.html


At the photos from 1901 you can recognize the position of the water lifter under the old lift bridge of Lauenburg (more information klick here (http://translate.google.com/translate?sl=auto&tl=en&u=http%3A%2F%2Fwww.buntbahn.de%2Fmodellbau%2Fviewtopic.php%3Fp%3D249055%26highlight%3Dhotopp%23249055)).


Heber_08 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Heber_08.jpg)
Copyright: Lauenburger Elbschiffahrtsarchiv


Heber_09 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Heber_09.jpg)
Copyright: Lauenburger Elbschiffahrtsarchiv


By drawings (converted to scale 1:22.5) I could determine the sizes:

Heber_06 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Heber_06.jpg)
source:Hellmich


Heber_07 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Heber_07.jpg)
source: Hellmich


Now I look for an idea to turn a 6mm tube with a close radius, as shown in the photo below.
The sharp bend radius is already very tight. Tests with annealed copper wire and also with a filled brass tube could be bent at right angles (like here (http://translate.google.com/translate?sl=auto&tl=en&u=http%3A%2F%2Fwww.rc-show.com%2Fde%2Ftechnik%2Frohre-biegen%2Frohre-biegen.aspx)), however at this narrow radius 180Grad ...???
Next, I'll heat up a plastic rod and bend ... Let's see if it works.
Prototyping for two parts would be the last solution (because of cost).


Heber_10 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Heber_10.jpg)
Copyright: Lauenburger Elbschiffahrtsarchiv


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on October 14, 2012, 06:19:20 PM
Very interesting!


Title: Re: Feldbahnmodule with ship
Post by: Malachi Constant on October 14, 2012, 08:41:25 PM
(http://www.buntbahn.de/fotos/data/7452/2903Heber_02.jpg)

Almost everything in this thread complete blows my mind (mein kopf explodiert) ... all sorts of brilliant use of high tech equipment and techniques to produce fabulous models ...

Only in this photo do I see something that I can truly understand ... the use of scotch tape to produce a Rube Goldberg fixture.  It's very encouraging to see a modeling genius do at least one thing like (some of) the rest of us!  ;D

Outstanding modeling!  -- Dallas


Title: Re: Feldbahnmodule with ship
Post by: artizen on October 14, 2012, 09:50:12 PM
I use Lego to achieve the same result. This looks slightly more high-tech to me!


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on October 25, 2012, 06:39:16 PM
@Dallas
We all are cooking only with water ;)

With a 6.0mm ball cutter I will mill soon the shape of the elbow (right and wrong), each 3.0mm deep into two Teflon plates.


Heber_12 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Heber_12.jpg)


These two half-shells will be fixed with four pins in the correct position, so that I get a mold.


Heber_13 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Heber_13.jpg)


Teflon spray will be used as release agent. Thereafter, liquid resin will be filled in the mold. After curing I will separate the sprues (shown in yellow) and stick the flanges ....

Kruemmer_Flansch (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Kruemmer_Flansch.jpg)

I am curious if it will work  :?:



If it doesnt go, as I wants here (http://translate.google.com/translate?sl=auto&tl=en&u=http%3A%2F%2Fwww.rp-3d.de%2Fprototyping.html) might be a good alternative.

Krümmer_11 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Heber_11.jpg)





The light railway lift bridge was originally stored on two floats. They were lifted in shafts depending on water levels. At high tide (for example snowmelt) the bridge was pushed up to get a consisted overhead clearance of 4.50 m for the ships.


Schwimmer_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_01.png)


Through a hole in the module wall we´ll watch it later.


Schwimmer_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_02.gif)


The cover for the float are made of brass.


Schwimmer_03 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_03.jpg)


The stones of the shaft were milled in a 1.0 mm thick plywood plate 0.5 mm deep. The invisible area received only vertical joints at a distance of 4.74 mm, so that the plate can be bent better. With a inner diameter of 111.0 mm of the Plexiglas tube that measure is not enough. The plate will be bent more under hot water steam.


Schacht_Mauerabwicklung_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schacht_Mauerbwicklung_01.jpg)




Title: Re: Feldbahnmodule with ship
Post by: marc_reusser on October 29, 2012, 06:09:23 PM
Sigh,.....and you continue to be just as crazy as ever. ;D ;D ;D

As always, beautiful,fascinating, and educational.

Marc


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on November 03, 2012, 07:30:05 AM
Marc, thanks a lot for the compliment!

For the revision platform I have milled an auxiliary frame, attached to the outside of the Plexiglas tube. It will bear the wall elements later.


Schwimmer_04 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_04.jpg)


Schwimmer_05 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_05.jpg)


Schwimmer_06 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_06.jpg)


When I opened the dishwasher this morning, a lot of steam came towards me.... and at the same time a thought hit me.

I put the milled 1.0 mm plywood-wall unceremoniously into the machine and I waited about 20 minutes, what would happen.

The wood had sprung through the hot steam, but to the wrong direction - so that the stones were now outside.

However, I could bent the plywood quite easily to the opposite direction and introduced it into the plexiglass tube. Another tube, a few strips of wood and two clamps pressed the plate in the correct rounding.

Then I put everything in the oven. A bowl of boiling water was added as a moisturizer to it. At 75 degrees Celsius I let it in the oven for 20 minutes again.

The Plexiglas tube GS (http://translate.google.com/translate?sl=auto&tl=en&u=http%3A%2F%2Fwww.plexiglas-zentrale-bochum.de%2Fplexiglasgs) withstand heat up to 80 degrees Celsius.


Schacht_Mauerabwicklung_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schacht_Mauerabwicklung_02.jpg)



Currently I let everything cool down slowly. Tomorrow I´ll know the result.


Schacht_Mauerabwicklung_03 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schacht_Mauerabwicklung_03.jpg)


Schacht_Mauerabwicklung_04 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schacht_Mauerabwicklung_04.jpg)



Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on November 03, 2012, 08:22:33 AM
The light railway lift bridge was originally stored on two floats. They were lifted in shafts depending on water levels. At high tide (for example snowmelt) the bridge was pushed up to get a consisted overhead clearance of 4.50 m for the ships.

If the position of the railway bridge is variable by height, how did they handle the approach to the bridge? Did it have some kind of adjustable ramp at each end?



Title: Re: Feldbahnmodule with ship
Post by: Malachi Constant on November 03, 2012, 10:46:32 AM
It looks like a strange science experiment!  ;D  -- Dallas


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on November 04, 2012, 01:54:32 AM
I think this man is amazing. Let's see what the Mad Scientist has created. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on November 05, 2012, 04:05:34 PM
Quote
If the position of the railway bridge is variable by height, how did they handle the approach to the bridge? Did it have some kind of adjustable ramp at each end?

There was no ramp necessary such as: http://www.youtube.com/watch?v=cZrhuSE_ivA&feature=youtube_gdata_player   ;D

Both the sluice and the lift bridge were operated without electricity or diesel power.

It works very easily: only water power and two winches were used.


1: normal position - the float container are at the bottom - the light railway can use the bridge

(http://www.buntbahn.de/fotos/data/7452/2903lift-bridge-operation-principle_01.jpg)


2: lifted position - at high flood (in winter at snow melt) - the bridge can not be driven

(http://www.buntbahn.de/fotos/data/7452/2903lift-bridge-operation-principle_02.jpg)


3: lower position - With 4 weights (marked in red) - two with one winch per column - were lowered onto the bridge. The bridge is lowered despite high tide. The train can go. Then the weights are cranked up again. The bridge is lifted once more by the buoyancy of the floating container. (like position 2)

(http://www.buntbahn.de/fotos/data/7452/2903lift-bridge-operation-principle_03.jpg)


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on November 05, 2012, 07:28:00 PM
Ah, I see. Thanks.


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on November 11, 2012, 05:38:05 AM
A more exact addition:

Had a field train pass over the bridge, shotts and slides were put so that the water would flow out of the shafts. 4 weights expressed simultaneously (two per side / red) the bridge on its abutments and held her down, no matter what the water level was. In case of lockage, it proceeded in reverse order. Weights were cranked up (there were no electric drives - only water, compressed air and hand cranks), shotts and slide set and the water flows back into the shafts and lifted the bridge again. Such a process takes about 10 minutes. (Maybe electroseparators pumps had mastered the whole thing in about 2 minutes).  
This bridge served a match factory and a brick factory. In 1926, both companies had agreed to give up their trucks. They had a fear that the "heavy transport" (wood, bricks, tiles, and coal) would destroy the local roads. Thus, the bridge over the Elbe-Lübeck Canal (which was originally Elbe-Trave Canal in 1900)) was an important connexion between the main railway and the two companies. It works there about 500 workman and employees.  

The bridge was calculated originally for a load of 1 horse with 3 wagon (with about 7.8 tons) in 1901, but in everyday life the bridge soon became a locomotive and several wagons and a significantly higher weight (27 tons) was loaded. (See the two original attachments, only in German).  

About 90 freight cars from the main railway were loaded in goods (stone and brick) in 1949 by the brick factory and unloaded about 112 wagons with coal and machine parts. Together with the match factory there were even some 250 wagons with coal, which were transferred in 1950 to the light railway.


(http://buchhorsterwaldbahn.de/stuff/Interaktiver_Streckenplan/Buchhorster_Ziegeleibahn/Entdecke_die_alte_Trasse/Umschaufeln.jpg)

found: http://buchhorsterwaldbahn.de/stuff/Interaktiver_Streckenplan/Buchhorster_Ziegeleibahn/Entdecke_die_alte_Trasse/Umschaufeln.html

To this image I have a special affinity, it shows right in the picture my father in the 1950ger years.
War related material shortages also showed traces to the bridge.  The rusted and broken parts couldn´t repaired. The mechanical overload eventually led to a closure of the bridge in 1950.
After long negotiations with the city and the country, it was agreed to replace the old bridge with a new structure. The two companies had to bear he costs. Cheap credits were been provided by the public authorities.
As a further industrial development was desired, new users should contribute to the new bridge with a levy. However, this didn´t happened really. The new bridge was demolished in 1965 again - the truck was faster, cheaper, ...




The polymethyl methacrylate tube - Abbreviation PMMA (better known as acrylic glass or PLEXIGLAS ® (registered trademark of Röhm GmbH) - can be worked very well with a saw and cutter.
The plywood wall I used as a help to mark the cutting edge from the outside with a red felt pen. After that the plywood was removed and the tube attached to a drill stand.
With a sharp cutter the router separated the edges along the markings.


The Plexiglas GS can be worked wonderfully. However, it should be a vacuum cleaner nearby.


Schacht_Mauerabwicklung_07 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schacht_Mauerabwicklung_07.jpg)


The cross sections were made on the Böhler saw. Like here:

(http://www.buntbahn.de/fotos/data/7443/2903Boehlerkreissaege_mit_Hilfsanschlag.jpg)


The plexiglass tube only acts as a support for the outer circular wall sections. Because the interior is visible, the upper sector has been processed  accordingly.


Schacht_Mauerabwicklung_08 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schacht_Mauerabwicklung_08.jpg)


Into the vertical grooves of the tube a machined brass profile will be glued (at the picture it´s still loosely inserted).


Schacht_Fuehrungsschiene_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schacht_Fuehrungsschiene_02.jpg)


It serves as a guide rail for the rollers of the float.


Schacht_Fuehrungsschiene_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schacht_Fuehrungsschiene_01.jpg)





Title: Re: Feldbahnmodule with ship
Post by: marc_reusser on November 13, 2012, 04:41:22 PM
Wow. Your research, understanding and interpolation of the the construction and mechanics of the bridge are fascinating, and the history, photos, and documentation you provide is wonderful. The understanding of all this by us/me the reader, really allows for a much greater fascination, understanding , involvement and enjoyment of all the hard work and thought that you are putting into this build. Thank you.


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on November 24, 2012, 01:04:59 PM
Hi Marc,

Thank you for your kind words!

It's fun, not only to pursue modeling, but also to revive a bit of the history of my home again!


A stronger "corset" was drawn for the shaft in the meantime...


Schacht_Mauerabwicklung_09 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schacht_Mauerabwicklung_09.jpg)


Schacht_Mauerabwicklung_10 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schacht_Mauerabwicklung_10.jpg)


... and milled ...


Schacht_Mauerabwicklung_12 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schacht_Mauerabwicklung_12.jpg)


... and installed only as a trial.


Schacht_Mauerabwicklung_11 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schacht_Mauerabwicklung_11.jpg)


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on February 20, 2013, 01:56:42 PM
At the two following sketches of the float you can see two different versions:

Schwimmer_07(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_07.jpg)


Schwimmer_08 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_08.jpg)


Which version of the float was built in 1900 I could not find out really. At least the tower of the following drawing is never documented on any photo. However, good to see here is the jack. With this winch counterweights were dropped down to the bridge if a light railway should pass across at high flood.

Hubbruecke_Winde_01(fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Hubbruecke_Winde_01.jpg)

In the previous simulation of the shaft I came out of two embedded U-profiles for the lead roles in the masonry. Meanwhile I milled a new plexiglass tube with slots for four profiles. So I will get a safer guide.

Plexiglass_schlitzen_01(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Plexiglass_schlitzen_01.jpg)

With the help of a drawing and a rectangular plexiglass piece (instead of a geo-triangle) the four markers were transferred to the plexiglass tube.

Plexiglass_schlitzen_02(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Plexiglass_schlitzen_02.jpg)

Along these lines the four new slots were milled.

Plexiglass_schlitzen_03(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Plexiglass_schlitzen_03.jpg)


Plexiglass_schlitzen_05(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Plexiglass_schlitzen_05.jpg)


Schwimmer_09(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_09.jpg)


A colleague turned the domed lids of the float from brass.


Schwimmer_10(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_10.jpg)

Schwimmer_11(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_11.png)

The float inside has four supports and two rings of brass.


Schwimmer_14(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_14.png)

I milled four small holes into the underside for a safe connection. A MDF-plate works as a milling gauge.

Schwimmer_12(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_12.jpg)


Schwimmer_13(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_13.jpg)


Schwimmer_15(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_15.jpg)

... Resistance soldering is really great, I would not miss it anymore :-)

Schwimmer_16(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_16.jpg)


Schwimmer_17(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_17.jpg)


Until now I had assumed that the entire lid were made of riveted "pie segments." Discovered on the network prototype photos and drawings from the  ship canal lift Henrichenburg (http://architekturmuseum.ub.tu-berlin.de/index.php?set=1&p=79&Daten=151578) I had found such a construction. Here, however, the float had a diameter of 8.3 m.
I wanted to raise the brass rivets with a jig on the domed lid and .... ...now Volker helped with his reflections. He has kindly provided the cover for a tank car.

So the turned brass lid was pressed again into the MDF plate and I drilled four holes of 2mm. A round brass piece of 52mm x 10mm was equipped with congruent holes. Using four 2mm brass wire pieces both parts have been assembled.
Solder, soldering fluid.... and the resistance soldering device were allowed to show what it can do: I was very curious to see if the flame is not in as much material might be faster / better the parts added together.


Schwimmer_18(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_18.jpg)

There are two small videos  here (https://vimeo.com/58780473) and  here (https://vimeo.com/58781826). The flame has lost.
 
Then the lid was clamped on a lathe and the edge was rounded.


Schwimmer_19(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_19.jpg)


In order to receive an even riveting image the 0.3mm nickel silver plates were punche-marked with a V-Cutter 0.13 mm deep. A Pertinax pattern served again as a stop for the exact positioning of the plates.

Schwimmer_20(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_20.jpg)

In the next step the four panels were bent with the roller bending machine. Two victim plates served to get no kinks at the ends - as described here (http://translate.google.com/translate?sl=de&tl=en&u=http%3A%2F%2Fwww.buntbahn.de%2Fmodellbau%2Fviewtopic.php%3Fp%3D278445%26highlight%3Drollenbiegemaschine%23278445).

Schwimmer_21(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_21.jpg)

The curved panels were conducted at the rip fence of the rivets embossing machine along and the rivets were pressed with 1.3 mm head diameter.


Schwimmer_22 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_22.jpg)

Schwimmer_23(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_23.jpg)

Because of the comment of a fellow at Buntbahn forum I have bought a suction device - the quiet fan draws the vapors through the charcoal filter and provides for a better feel and probably for better air. In any case the bad smells are minimized.

Schwimmer_24(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_24.jpg)

Schwimmer_25 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_25.jpg)


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on February 20, 2013, 02:49:04 PM
Satisfactory. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on February 20, 2013, 11:10:35 PM
I really love watching this all come together!


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on February 21, 2013, 02:52:57 AM
Don't encourage him. His work is so good it is disconcerting! -- Russ


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on February 24, 2013, 02:23:04 PM
@Ray + Russ
Sometimes encouragement is very helpful :-)


The two floating container carried the bridge with two columns of four L-profiles.
On each side rolls were placed with 30 cm in diameter and about 2.5 cm in width.
They were conducted in corresponding U-profiles. Therefore the float glides smoothly in the shaft and does not hit the wall.


Schwimmer_27(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_27.jpg)

Four 8 x 8 x 3 mm brass sockets were equipped with four 0.5 mm L-shaped grooves which will serve for secure attachment of the supports to the float.

Schwimmer_26(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_26.jpg)


Schwimmer_28(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_28.jpg)


Title: Re: Feldbahnmodule with ship
Post by: marc_reusser on February 27, 2013, 04:06:34 AM
looks beautiful. Stunning attention to detail and craftsmanship (but nothing less is expected from you :) )

Curious, why use Nickel-Silver sheet for the float shell, instead of brass?

I wish I had more to say or offer. The build and sbs you are posting is completely enthralling...very educational...and so far above my skill level and capabilities, that it isn't even funny. :)





Title: Re: Feldbahnmodelle with ship
Post by: Barney on February 27, 2013, 03:08:48 PM
This is modelling with a difference with standards and techniques of the highest I and Im sure others have lernt a lot
Barney


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on February 28, 2013, 12:30:32 AM
@ Marc + Barney
Thanks for your words of praise. Each of us has his strengths. I'm always open-mouthed in front of your great designs, here I need to catch up!

1.   Nickel silver is firmer than brass. (0.3 mm nickel silver plate is comparable to a brass plate with 0.5 mm).
2.   Pressed rivets look simple rounder and cleaner in nickel silver.
3.   If paint is scraped, no yellow brass is lightning through.

Volker gave notice that the attachment of the supports maybe not modeled accordingly.

At the time of construction of the lift bridge in 1899, all pieces were riveted. The base soccets (picture No. 26) should have been welded - but that was not possible at this time. I have to agree with Volker.

Although there is a drawing, which shows a solution with a band profile around the float,


Schwimmer_07 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_07.jpg)


Schwimmer_29(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_29.jpg)

but on any photo, there was a indication like this. All plotted diameter show no peripheral profile band. Unfortunately I have no real detail drawings of this area... it's been a burden, if you count the rivets: wink:

A letter of 1948 describes the desolate status of the bridge  after WW2. Here the idea for my execution was given:


Schwimmer_32 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_32.jpg)

So the base and the columns were replaced after 1945 by the City Council ... at this time they could be riveted as well as welded ...


Schwimmer_30(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_30.jpg)


Slowly it comes out of the ground in the open pit, the supports will be cut on next weekend.


Schwimmer_31 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_31.jpg)



Title: Re: Feldbahnmodule with ship
Post by: fspg2 on March 02, 2013, 02:48:52 PM
To solder a few items together only, I draw up the two lower L-profiles in one sketch:


Schwimmer_37(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_37.jpg)


Schwimmer_36(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_36.jpg)


A 3mm brass sheet was fixed with double-adhesive film to a MDF board. Next I attached the plate to the milling machine.

First the holes were drilled (light green). Next I milled the dark green area as a pocket 2.5 mm deep.


Schwimmer_33(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_33.jpg)


After cutting the outer contour with a 1.5 mm-cutter (several passes in 0.8 mm steps) I got  the finished profiles (yellow and red) .


Schwimmer_34(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_34.jpg)


On the following  picture you can see the profiles assembled loosely. They fit neatly into each other thanks to CAD.


Schwimmer_35(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_35.jpg)


The next step will be the „cross“.


Schwimmer_38(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_38.jpg)


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on March 02, 2013, 08:20:01 PM
Holy cow, that is incredible milling! Such close tolerances on such small pieces!


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on March 04, 2013, 01:56:31 PM
@Ray
I'm always pleased when I see these results are produced by such a simple "cheese" milling machine.

Today only a small update:
Last weekend I finished the "cross" quickly. 3mm brass material was used as before. Initially I milled a pocket  0.5 mm deep to get the required height of 2.5 mm. Then the 2mm holes were drilled , a V-cutter did cut a groove of 0.1 mm deep and a 1mm milling cutter did the rest.

Schwimmer_39(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_39.jpg)

The used 1mm cutter produced 0.5 mm radii in the corners. To get square corners I lined up all parts to a 2mm wire and putted this unit to my mini vice. 


Schwimmer_40(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_40.jpg)


Schwimmer_41(fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_41.jpg)


Next will follow a jig for the screws.


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on March 04, 2013, 01:59:45 PM
Can you believe this guy? He must be a genius with an electron microscope to create that stuff. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Malachi Constant on March 04, 2013, 06:05:32 PM
Yeah, not only that ... but all the thought & planning that goes into this stuff.  Looking at the big things and breaking them down into every little bit ... and then figuring out the intricacies of each bit.  Amazing!  :o  -- Dallas


Title: Re: Feldbahnmodule with ship
Post by: lab-dad on March 04, 2013, 06:49:28 PM
Thanks for showing the "set-up" I am sure learning a lot from your posts!
-Marty


Title: Re: Feldbahnmodule with ship
Post by: marc_reusser on March 05, 2013, 01:18:39 AM
I am having modeling apoplexy.  :-X


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on March 17, 2013, 10:10:02 AM
@Russ, Dallas, Marty, Marc

Some parts are getting smaller as I get older. It´s probably my eyes.


The four guide rails in the shaft must be mounted exactly at 90 degrees.


Schwimmer_44 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_44.jpg)


Therefore I have milled two 1.5 mm brass plates and put both together. For aligning two 3mm brass plates were grooved at right angles additionaly.


Schwimmer_47 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_47.jpg)


Then all parts were assembled. They sit inside each other very tightly. Later I can take apart the pieces and use them again.


Schwimmer_45 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_45.jpg)


At this moment the guide rails will be inserted loosely. So they can still be removed if the shaft gets his color.


Schwimmer_46 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_46.jpg)


The following parts of the wall will be glued after the further guide rails are machined and assembled to the sample. So I will get clean transitions between the stones and the guide rail.



A little preview of what's next:

Schwimmer_43 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_43.jpg)


Schwimmer_42 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_42.jpg)


Title: Re: Feldbahnmodule with ship
Post by: Chuck Doan on March 19, 2013, 10:04:27 AM
Spectacular! Fun to watch.


Title: Re: Feldbahnmodule with ship
Post by: Franck Tavernier on March 19, 2013, 03:07:56 PM
A real piece of jewelery!  :P

Franck


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on April 08, 2013, 12:32:12 PM
@Chuck, Franck:  Thanks for your replies.

The round top seat for the checker plate cover of the float shaft consists of two machined brass rings.

Schwimmer_50 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_50.jpg)

Some boards will cover the inspection chamber later.

Schwimmer_48 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_48.gif)


Schwimmer_49 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_49.jpg)


Schwimmer_51 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_51.jpg)


Now only a few drawings. They are intended to show how it goes on next.

Schacht-Abdeckung_001 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schacht-Abdeckung_001.jpg)


Schacht-Abdeckung_002 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schacht-Abdeckung_002.jpg)


Schacht-Abdeckung_003_jpg (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schacht-Abdeckung_003_jpg.gif)


Title: Re: Feldbahnmodule with ship
Post by: marc_reusser on May 05, 2013, 05:38:55 PM
Cool. Now I am waiting to see you build those towers on each side!  ;D ;D


Title: Re: Feldbahnmodule with ship
Post by: Malachi Constant on May 05, 2013, 10:37:40 PM
Yes!  This does look interesting ... looking forward to more!  -- Dallas


Title: Re: Feldbahnmodule with ship
Post by: Franck Tavernier on May 05, 2013, 11:15:34 PM
Awesome ! 3D drawings are a good help for scratbuilding...

Franck


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on June 09, 2013, 06:16:59 AM
@ Marc, Dallas, Franck,
Thanks for your comments!

Originally I had the idea to raise the bridge with two small spindle drives of former digital scan backs (1991).


Plexiglass_schlitzen_05 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Plexiglass_schlitzen_05.jpg)


However, the stroke distance is only about 4cm - but I need 8cm.


Recently I received a few rods, ball cages, bearings and threaded rods from a colleague. They were installed into large TV zoom cameras (http://www.buntbahn.de/fotos/showphoto.php?photo=90672&size=big&password=&sort=2&thecat=7452) in the middle of 1980 years.


alte_Kamerafuehrungen (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903alte_Kamerafuehrungen.jpg)


These parts have exactly the right dimensions.


The two guides of the old digital scan back were replaced by the new longer rods meanwhile. In addition I have drilled the holes of 6mm to 8mm diameter and adjusted the guide rods with 2mm socket head screws, as well as the upper aluminum plate was milled for a new ball bearing. The bearings on the ball cages now have a lift height of about 9cm - more than I need!


Hubmechanismus_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubmechanismus_01.jpg)


Hubmechanismus_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubmechanismus_02.jpg)

Only the spindle pole needs to be shortened by a colleague.


Temporary attempts to operate the cylinder with pneumatic were unfortunately unsuccessful. Pneumatic certainly has its charm!
To raise and lower the lift cylinders uniformly and slowly, have been unsuccessful with compressed air.
I was able run quite uniform the hub (with 2kg load), but there was some jerkiness when lowering. No matter how I adjusted the valves, it was not satisfactory.
So I will pursue the spindle rod solution instead compressed air. You can follow a disussion (http://translate.google.com/translate?hl=&sl=auto&tl=en&u=http%3A%2F%2Fwww.buntbahn.de%2Fmodellbau%2Fviewtopic.php%3Ft%3D6691%26postdays%3D0%26postorder%3Dasc%26start%3D530) at bbf forum.


I hope to get the threaded rods shortened soon accordingly so that I can implement the following animation into the model.


Hubeinheit_Traeger_Montage_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_01.gif)

A 6 mm circular aluminum plate will be raised and lowered by the spindle unit. The float tank becomes seated on the edge of the aluminum plate grooves. So I have a uniform support. The small wheels on top will not have to endure great loads.


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on June 16, 2013, 12:48:03 AM
Today only a few pictures of the production of the 6mm aluminum plate. These will serve as a carrier for the lift cylinder.

Hubeinheit_Traeger_Montage_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_02.jpg)


Fixed up with Gudy 831 (http://translate.google.com/translate?hl=&sl=auto&tl=en&u=http%3A%2F%2Fwww.neschen.de%2Fgraphics%2Fschutz-und-aufziehfolien%2Fproduct%2F14-gudy-831) on to a MDF board, the 6mm aluminum plate got four 2mm holes . 2mm wire pins were plugged into those. Thereafter, recesses are milled for all the rods, which will pass through the plate later.

Hubeinheit_Traeger_Montage_03 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_03.jpg)


After that the plate was rotated to the backside. The four pins helped to put the plate to there position correctly.

Hubeinheit_Traeger_Montage_04 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_04.jpg)


Hubeinheit_Traeger_Montage_05 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_05.jpg)


Hubeinheit_Traeger_Montage_06 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_06.jpg)


Now all we need is the shortened spindle rod for final assembly.


Hubeinheit_Traeger_Montage_07 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_07.jpg)


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on June 16, 2013, 01:35:17 AM
Ho-hum, another example of a genius at work .... -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Gordon Ferguson on June 16, 2013, 02:15:57 AM
Ho-hum, another example of a genius at work .... -- Russ


Very true, but at least one of the holding screws is not straight ........ That makes me feel a little less overawed at the standard of craftsmanship and expertise


Title: Re: Feldbahnmodule with ship
Post by: Mr Potato Head on June 16, 2013, 01:30:33 PM
Normally I am on the opposite side of Russ's opinion , but What the F!@# who the hell are you some mad scientist?
MPH


Title: Re: Feldbahnmodule with ship
Post by: danpickard on June 16, 2013, 03:25:18 PM
Wonderful precision engineering.  Simply brilliant to be able to watch this entire project be created. 
Definitely the opposite end of the spectrum, when compared to the "usual" model railway approach to this mechanism, which might be more like a few scraps of MDF and some string pulleys  ;D

Cheers,
Dan


Title: Re: Feldbahnmodule with ship
Post by: artizen on June 16, 2013, 03:52:31 PM
Said it before - say it again - A...R...T   !!!!!!!


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on June 16, 2013, 11:19:12 PM
Brilliant work, as usual!

But I'm a bit distracted by those bearing cages, or whatever they are, which you borrowed from an old digital scanner. I keep wondering, how the heck did they get all those ball bearings in their places??



Title: Re: Feldbahnmodule with ship
Post by: michael mott on June 18, 2013, 07:42:58 AM
Quote
Very true, but at least one of the holding screws is not straight ........ That makes me feel a little less overawed at the standard of craftsmanship and expertise

Now Gordon! you have to realize that that screw was carefully placed at that angle to counteract the torques involved while trying to hold the beer can in the other hand..sheeesh I thought that was obvious!

Brilliant work on re purposing those linear bearings. Great 3D drawings as well.

Michael


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on June 18, 2013, 01:12:22 PM
Thank you for your interest and kind words! I think the whole thing is just simple craft and the best diversion from work - just hobby :-)

Something for everyone:

Hubeinheit_Traeger_Montage_05b (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_05b.gif)

Angled screw .... without screw .... straight screw :-)


Today I got back the spindle rods from my colleague – correct length now: 145mm.

Hubeinheit_Traeger_Montage_08 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_08.jpg)

It lacks the two lateral L-profiles at the image.




Title: Re: Feldbahnmodule with ship
Post by: fspg2 on June 25, 2013, 11:00:26 AM
Even if I could use two strong gear motors as drive for the slow-running reciprocating motion of the two spindles, ...

Hubeinheit_Motor_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Motor_01.jpg)


Hubeinheit_Traeger_Montage_09 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_09.gif)

... so I can´t imagine if both motors will run so uniform that the bridge will not tilt.



There are three solution approaches:


a) a continuous wave:

Only one motor that moves both spindles connected by a long shaft (distance at least approximately 110cm) combined with two angular gears can work.


b) stepper motor controller:

Otherwise, I have a few stepper motors and a control unit for a milling machine that can drive two stepper for the two X axes.
My existing stepper motor control (1/8 Step) came from my milling machine. Since there were step losses over and over a friend had built his own solution (with optocoupler card for galvanic isolation of PC + control). It´s works perfectly since a few years. The two X-axis are guided via the control unit (without belt). Once I had bought this router with two stepper motors for the two X-axis, because I didnt trust the drive belt in times past.
Whether the old control will work correctly at the bridge without step losses? ... maybe I´ll have a trial. At least it could be implemented with existing parts easily.


After a short discussion at bbf forum (http://translate.google.com/translate?hl=&sl=auto&tl=en&u=http%3A%2F%2Fwww.buntbahn.de%2Fmodellbau%2Fviewtopic.php%3Fp%3D294235%23294235) here my new favorite:

c) toothed belt drive:


Hubeinheit_Traeger_Montage_10 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_10.jpg)


Hubeinheit_Traeger_Montage_11 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_11.jpg)


The two belts should get another tensioner and guides certainly, so they dont sag at its length someday or become loose. On the other hand millions of color printers with their belt drives can not be wrong. :)



Title: Re: Feldbahnmodule with ship
Post by: lab-dad on June 25, 2013, 11:59:14 AM
There is also the "servo-link" style of chain.
Not sure of the strength limit or your need though.
Marty


Title: Re: Feldbahnmodule with ship
Post by: marc_reusser on July 08, 2013, 04:47:18 PM
Das ist aber ein Prachtstueck! incridible adaptation of parts, engineering and execution, and in the end it ends up looking like jewlery. Thank you too for the the SB images, and the great 3D GIF images.


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on July 14, 2013, 10:43:16 AM
Hi Marty, hi Marc,
Only a few steps forward. I cutted new longer aluminum L-sections to carry the bearing plates for the pulley on the same unit.

Hubeinheit_Traeger_Montage_12 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_12.jpg)


2mm deep pockets were cutted into MDF and the L-sections were placed...


Hubeinheit_Traeger_Montage_13 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_13.jpg)


...and 2mm holes were drilled next.


Hubeinheit_Traeger_Montage_14 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_14.jpg)


Two 6mm aluminum plates (shown in blue) are used as carriers for the two ball bearings.


Hubeinheit_Traeger_Montage_15 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_15.jpg)


Compared to the drawing, the four mounting screws were changed to 6mm (3mm instead). They are used for attachment on the underside of the module.


Hubeinheit_Traeger_Montage_16 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_16.jpg)


The round depression on the aluminum plate will locate the plexiglass tube. This is for the precise centering of the lift cylinder within the duct (as well as picture 09 (http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_09.gif) shows).

Hubeinheit_Traeger_Montage_17 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_17.jpg)


Hubeinheit_Traeger_Montage_18 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_18.jpg)


Hubeinheit_Traeger_Montage_20 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_20.jpg)


A final look at the bottom of the module. The pulley and the belt will be freely accessible.


Hubeinheit_Traeger_Montage_19 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_19.jpg)



Title: Re: Feldbahnmodule with ship
Post by: finescalerr on July 14, 2013, 12:32:39 PM
It looks just like the rendering! -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Hauk on July 14, 2013, 03:24:48 PM
We want video!!!


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on July 14, 2013, 10:19:29 PM
As always, truly amazing work!


Title: Re: Feldbahnmodule with ship
Post by: kneighbarger on August 16, 2013, 11:56:29 AM
Absolutely amazing work.....
Ken


Title: Re: Feldbahnmodule with ship
Post by: chester on August 16, 2013, 06:13:03 PM
Like Marc said, it looks like jewelry. Fascinating/fantastic.


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on October 06, 2013, 02:22:21 PM
@Russ
It looks just like the rendering! So it should be :-)

@Hauk
Two videos you can see in the following.

@Ray, Ken, chester
Thanks for your comments!


The computer for my miling machine has failed for three weeks ... my lathe had a problem also: the main switch was broken ...

…but still ... I 'm a little further now .


Since I wanted to use a few existing long drive belts, I have chosen a small detour for the drive unit :


Hubeinheit_Traeger_Montage_021 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_021.jpg)


Hubeinheit_Traeger_Montage_022 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_022.jpg)


Hubeinheit_Traeger_Montage_023 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_023.jpg)


The motor drive has failed the first test. He was too weak in lower speed range.

A stronger LINAK motor was purchased with flanged gearbox.

Hubeinheit_Traeger_Montage_024 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_024.jpg)

A few new drawings were made with CAD.


Hubeinheit_Traeger_Montage_025 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_025.jpg)



Hubeinheit_Traeger_Montage_029 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_029.jpg)


Hubeinheit_Traeger_Montage_30 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_30.jpg)


Meanwhile the water jack has been printed: SLS-Verfahren (http://de.wikipedia.org/wiki/Lasersintern) Print .



Heber_11 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Heber_11.jpg)


Heber_14 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Heber_14.jpg)


The tube has a diameter of 6.0 mm. The visible Hexagon nuts have a height of only 0.35 mm!
The tube is connected loosely for the picture.


Heber_15 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Heber_15.jpg)

The recognizable roughness is expedient to an old rusted model. The tube will be smoothed with fine sandpaper later.


The two lifting units are installed now .

Hubeinheit_Traeger_Montage_32 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_32.jpg)


At the bottom of the module (door leaf) I have mouted the drivebelts and the new motor unit.

Hubeinheit_Traeger_Montage_31 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_31.jpg)


On a little video you can see the first lifting test. I regulated the motor beetwen 2 – 10 volts.


See for yourself Video (http://vimeo.com/74580500)!

Thus, the lifting mechanism will not destroyed itself, I have attached two micro switches on the two support units .
Once a switch is triggered, the motor stops and can be moved in the opposite direction only. Similarities with Fulgurex railway switch drive are wanted.


Hubeinheit_Traeger_Montage_33 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_33.jpg)


At 12 volts lifting takes about 24 seconds. When I place the slider to about 1 volt it moves over 8.5 minutes. In the original a raising or lowering tooks about 10 minutes.
The only thing that bothers me right now is the engine noise as soon as I fix about 5 volts (76 seconds) . The module acts as a resonator.


Hubeinheit_Traeger_Montage_34 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_34.jpg)


Meanwhile, I've wired the limit switches.


Hubeinheit_Traeger_Montage_37 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_37.jpg)


The switches of the two lifting units are connected in series.

At the first unit I glued the brass nut with the round aluminum plate and pinned it with three brass pins .
That was not such a good idea, because the spindle could be turned much harder only. Probably the spindle jammed against the two parallel guides.

For the second lift unit I milled a 3mm groove in the two parts (brass nut , aluminum plate). The shaft of the brass nut was turned off by 0.3 mm. The spindle has a little free space now.


Hubeinheit_Traeger_Montage_36 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_36.jpg)


Two brass square pieces serve as a tappet .


Hubeinheit_Traeger_Montage_35 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_35.jpg)



At the end a brass cover plate and a snap ring will secure everything.


Hubeinheit_Traeger_Montage_39 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubeinheit_Traeger_Montage_39.jpg)


The result: an equally smooth transition over the whole way (hand-turned).

The first lifting unit will be rebuilt in the same way soon.


A second Video (http://vimeo.com/76227275) shows the lifting at 7 volts. The wooden board is established only provisionally to get a taste of the future bridge.

lifting_at_7_Volt (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903lifting_at_7_Volt.jpg)

Frithjof


Title: Re: Feldbahnmodule with ship
Post by: Hauk on October 06, 2013, 02:40:27 PM
Sorry  about your problems, but great to see your progress!


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on October 07, 2013, 01:48:34 AM
What a relief to know you're not perfect. I was about to jump off a cliff. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: lab-dad on October 07, 2013, 06:10:13 AM
Looking great!
I hope my motor does not have problems as yours did!

As far as the noise; try finding some self adhesive butyl rubber.
It is used in roofing repairs and automobile insulation.

-Marty


Title: Re: Feldbahnmodule with ship
Post by: NE Brownstone on October 07, 2013, 10:12:26 AM
I like the lead screw nut key seat solution.  No need for trying to broach an internal key way.

I hope all of this will be viewable in the finished model.  It would be such a waste of awesomeness to be hidden.  Most people these days have no clue what quality machine work is all about, much less the skill required to accomplish things like this. 

A+++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on July 13, 2014, 01:58:10 PM
Thanks for your kind words.

Once again some days have passed since  I had nailed the roof battens to my old warehouse (http://translate.google.com/translate?hl=&sl=auto&tl=en&u=http%3A%2F%2Fwww.buntbahn.de%2Fmodellbau%2Fviewtopic.php%3Ft%3D6691%26postdays%3D0%26postorder%3Dasc%26highlight%3Dlagerhaus%26start%3D270)

An original roofing tile I got from my neighbor. It is preserved for posterity remain in scale 1:22,5.


Doppelfalzziegel_02 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Doppelfalzziegel_02.jpg)


Doppelfalzziegel_06 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Doppelfalzziegel_06.jpg)


The roofing tile was drawn by Volker.


Doppelfalzziegel_07 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Doppelfalzziegel_07.jpg)


Afterwards I have covered the roof, but only in CAD.


Dachgerippe_01 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Dachgerippe_01.jpg)


Dachgerippe_02 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Dachgerippe_02.jpg)


Dachgerippe_03 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Dachgerippe_03.jpg)


Dachgerippe_04 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Dachgerippe_04.jpg)


I just now need an idea how I can produce 1300 bricks for the roof. Maybe it can be an attractive load too.

Injection moulding would be the best way, but the cost of form creation will be around 3 - 4k € - unfortunately a little bit too high.  Additional each individual brick will be cost about 10 - 20 cents.
Merging multiple tiles and printing out as a group and creating a form from it, this could be one way to get faster and maybe a little cheaper to get the aim.
The results shown in various forums of example Shapeways, I don´t like the surface structure. In addition, the minimum thicknesses are far too thick.

Volker (Hydrostat) had recently achieved great results printing of his phone.

Now a few bricks will be printed by the same procedure. Afterwards I will get trying white metal castings. Problematic from the perspective of the founder is the thin material thicknesses – it is be partly only 0.4 mm. Let's see what comes out.

White metal has the advantage of greater weight compared to plastic and certainly a good aging resistance.



Update to the lift bridge:

A friendly forum colleague looked at the Provincial Archives in Schleswig (norther part of Germany) for the missing graphics of the old lift bridge. He found out that all the missing construction drawings from 1899/1900 are still in Lauenburg - and not in Schleswig, as I had been told.
So I asked again in my previous hometown.

This time I had luck!!! They told me they could not promise anything, but ......


A few days ago I received several e-mails from the Water and Nautical Department with exactly those drawings which were missing for the construction of the lift bridge. Again, my special thanks to the staff member which scanned the old plans very quickly and sent me them as PDF's! Without their help, I would still hope ....

It was a little bit like Christmas and birthday together.


I hadn´t quite given up the hope to get a few more details about the mechanical design ... that's why I had made nothing on the lifting bridge even for a few months. I wouldn´t like to start with my construction maybe I could find out later that the original was quite different.


The drive is working, what is missing are the five bridge segments.


Meanwhile I have scaled the drawings to 1:22.5 and they were plotted. So I have a additional help to determine the dimensions of the various angles and profiles.


Hubbruecke_Anschlussbruecken_ (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Hubbruecke_Anschlussbruecken_.jpg)
Copyright: WSA-Lauenburg/Elbe


Hubbruecke_beweglicher_Brueckenteil_1 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Hubbruecke_beweglicher_Brueckenteil_1.jpg)
Copyright: WSA-Lauenburg/Elbe


Up to now I could only guess many things from the old photos – but now with the construction drawings from 1899/1900 I can imagine that it will take a few years until I will soldered together all gusset plates, angles and rivets .... that's what happens when you count the rivets.




Most I love the drawings from the bridge portal and the winch.


Hubbruecke_Mappe_1 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Hubbruecke_Mappe_1.jpg)
Copyright: WSA-Lauenburg/Elbe


Since the blueprints were archived in a large portfolio for drawings, they couldn´t be scanned. A small camera helped.


Hubbruecke_Portal_1 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Hubbruecke_Portal_1.jpg)
Copyright: WSA-Lauenburg/Elbe


The blueprints are trimmed in black and white and scaled to 1:22.5 with photoshop. If the proportions are disturbed, so I still have a lot of dimensions in the drawings.

Hubbruecke_Portal_2 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Hubbruecke_Portal_2.jpg)
Copyright: WSA-Lauenburg/Elbe


The function of the four counterweights (with 500 Kg weight each) is now clear, they oppressed down the bridge.
Also I can detect the course of the individual ropes accurately...

I am always thrilled that I got this drawings!

Hubbruecke_Winde_1 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Hubbruecke_Winde_1.jpg)
Copyright: WSA-Lauenburg/Elbe


Hubbruecke_Winde_2 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Hubbruecke_Winde_2.jpg)
Copyright: WSA-Lauenburg/Elbe



In addition, I received a few drawings of  the sluice gate … oh, a lot of rivets are there….


Stemmtor_1 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Stemmtor_1.jpg)
Copyright: WSA-Lauenburg/Elbe


Stemmtor_2 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Stemmtor_2.jpg)
Copyright: WSA-Lauenburg/Elbe


Stemmtor_3 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Stemmtor_3.jpg)
Copyright: WSA-Lauenburg/Elbe


Stemmtor_Details (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Stemmtor_Details.jpg)
Copyright: WSA-Lauenburg/Elbe


On the small-800pixels pictures you can not see a lot of things really  - in 1:22.5, the parts are quite big - there is still much to do!

For me I´m happy to go with a new commitment to the implementation of the many small challenges.



I'll start with a small, but important bridge detail:

... the two pendulum pillars that supported the three eastern port bridges in the curve.

First an excerpt was taken from the orignal design plans (1:22.5) and saved as a BMP.

Hubbrueckentraeger (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Hubbrueckentraeger.jpg)
Copyright: WSA-Lauenburg/Elbe


This file has been used as a background image for the CAD drawing. After that, the gusset plates and L-profiles were drawn…


Nebenbrueckentraeger_002 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Nebenbrueckentraeger_002.gif)


image (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903image.jpg)


Nebenbrueckentraeger_004 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Nebenbrueckentraeger_004.jpg)


... and the conversion in two milling data for the front and back follows.


Nebenbrueckentraeger_005 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Nebenbrueckentraeger_005.jpg)


The nickel silver sheet has four 2-mm holes in the corners to get the second page congruent. The sheet was glued with Gudy 831 film (http://translate.google.com/translate?hl=&sl=auto&tl=en&u=http%3A%2F%2Fwww.neschen.de%2Fgraphics%2Fschutz-und-aufziehfolien%2Fproduct%2F14-gudy-831) to the MDF board every time.
So the 0.1 mm V-cutter could reach the same depth everywhere.

Nebenbrueckentraeger_006 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Nebenbrueckentraeger_006.jpg)


On Friday evening I was able to mill out the parts and press the first 288 rivets.

Nebenbrueckentraeger_007
(fspg2)(http://www.buntbahn.de/fotos/data/7452/2903Nebenbrueckentraeger_007.jpg)


The plates have been slightly distorted by the pressing – so they have to be addressed a little.


Nebenbrueckentraeger_008 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Nebenbrueckentraeger_008.jpg)


Sorry for the information flood :) Even though I should have killed you with the amount of the new drawings, so perhaps you can imagine my excitement.


Title: Re: Feldbahnmodule with ship
Post by: artizen on July 13, 2014, 05:52:06 PM
Excellent!


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on July 14, 2014, 12:29:16 AM
Congrats on getting the additional information you were needing! Looks like you will have plenty of work to keep you busy on this project for a long time.

I'll be curious to see how the tiles come out.



Title: Re: Feldbahnmodule with ship
Post by: finescalerr on July 14, 2014, 01:30:38 AM
I love to see how you approach a model from research to conception to CAD to production. I wish more people could appreciate what you do. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on July 21, 2014, 01:29:30 PM
Meanwhile, the western part of the bridge is created on the computer.


westl_-Nebenbruecke_Montage_001 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903westl_-Nebenbruecke_Montage_001.gif)


I started with the horizontal section. The first longitudinal beam (I-profile 16mm x 6mm) was drawn. Afterthen the side view was placed.

westl_-Nebenbruecke_Montage_004 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903westl_-Nebenbruecke_Montage_004.gif)

The cross beams and braces followed.

westl_Nebenbruecke_Montage_007 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903westl_Nebenbruecke_Montage_007.jpg)


I cut the first beams and planks from beech square strips (10mm x 20mm) with my little Böhler-saw. With a rough-toothed wood saw blade without crossed teeth I got very clean and smooth surfaces. In the first pas I had chosen all dimensions slightly thicker (about 1-2 tenths of a mm) and worked in the second step with the final dimensions.

I let the 5,3 mm x 8mm transom about 2 cm longer than I need.


A milled Pertinax template helps to drill 1mm holes. They are working for attaching the the side handrail supports and wooden beams to the I-section.


westl_Nebenbruecke_Montage_009 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903westl_Nebenbruecke_Montage_009.jpg)


Always four lumbers were processed at the same time. The result at the end: 26 small beams.


westl_Nebenbruecke_Montage_010 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903westl_Nebenbruecke_Montage_010.jpg)


westl_Nebenbruecke_Montage_011 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903westl_Nebenbruecke_Montage_011.jpg)


In the next step 1mm wire pieces were plugged into the central holes. So the beams couldn´t move during contour milling on both ends.


westl_Nebenbruecke_Montage_012 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903westl_Nebenbruecke_Montage_012.jpg)


westl_Nebenbruecke_Montage_013 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903westl_Nebenbruecke_Montage_013.jpg)


westl_Nebenbruecke_Montage_014 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903westl_Nebenbruecke_Montage_014.jpg)


westl_Nebenbruecke_Montage_015 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903westl_Nebenbruecke_Montage_015.jpg)


westl_Nebenbruecke_Montage_016 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903westl_Nebenbruecke_Montage_016.jpg)


westl_-Nebenbruecke_Montage_018 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903westl_-Nebenbruecke_Montage_018.gif)


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on July 21, 2014, 01:59:09 PM
Your work is intimidating. Most satisfactory. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Peter_T1958 on July 21, 2014, 02:15:24 PM
I truly envy you, in a positive sense of course! All this represents a huge pool of accumulated knowledge in engineering - hats off! 

(http://i240.photobucket.com/albums/ff181/Peter_T1958/klose_zps9aac5366.jpg~original) (http://s240.photobucket.com/user/Peter_T1958/media/klose_zps9aac5366.jpg.html)
Peter


Title: Re: Feldbahnmodule with ship
Post by: Hauk on July 21, 2014, 03:44:03 PM
So glad that you are posting again!
Your work is a great inspiration.


Title: Re: Feldbahnmodule with ship
Post by: lab-dad on July 22, 2014, 06:00:46 AM
Those contours on the beams are beautiful!
And of course the machining makes me feel very inadequate.....

Amazing how things were made functional and appealing "back in the days"
It is so true form follows function.
I can see how the profile would allow rainwater to drip off and not settle into the end grain.

I like the railing without the mesh too.

-Marty


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on July 26, 2014, 12:40:19 PM
@Russ, Peter, Hauk, Marty
I am pleased that you like my posts!  :)  Indeed I hope a few more guys will have benefit from it.


I´m looking for I-profile 6mm x 16mm.


westl_Nebenbruecke_Montage_008 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903westl_Nebenbruecke_Montage_008.jpg)


Nobody can supply in this dimension. Therefore I`l put it together from 3 parts.


Langtraeger_I-Profil-16x6-Haasler (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Langtraeger_I-Profil-16x6-Haasler.jpg)


The profiles for the bridge are ordered here: click (http://translate.google.com/translate?depth=1&hl=en&rurl=translate.google.com&tl=en&u=http://www.hassler-profile.li/)  

They will be made from 6mm x 2mm square profile, centrally grooved and thereafter both webs will be edited on a milling machine (with inclined table). The bar is adjusted in height that the total level of 16mm is achieved.


Today I got a delivery from the caster.

Volker had let print the roof tiles as prototype to get white metal castings of them.

Have a look to the result:


Doppelfalzziegel_008 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Doppelfalzziegel_008.jpg)


The parts are not cleaned and plastered. I put them on the roof battens only to see if the size fits correctly.


Doppelfalzziegel_011 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Doppelfalzziegel_011.jpg)


Doppelfalzziegel_012 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Doppelfalzziegel_012.jpg)










Title: Re: Feldbahnmodule with ship
Post by: artizen on July 26, 2014, 05:19:17 PM
Just when you think it couldn't get any better you go ahead and cast roof tiles where most of the detail is hidden underneath!

Stunning. This work should end up in a museum to show everyone how it should be done!


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on July 26, 2014, 07:11:55 PM
Amazing detail in those tiles!


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on July 27, 2014, 12:39:38 PM
Perfect as usual.

It may be a heavy roof.

Russ


Title: Re: Feldbahnmodule with ship
Post by: BKLN on July 28, 2014, 11:43:52 AM
Du hast doch echt einen an der (Dach-) Pfanne, Volker!

Absolutely amazing work! Are those white metal castings to be used for the actual model or are they serving as masters for casting in another material?



Title: Re: Feldbahnmodule with ship
Post by: Franck Tavernier on July 31, 2014, 05:36:58 AM
Impressive precision and beauty, as always!

Congratulations,

Franck


Title: Re: Feldbahnmodule with ship
Post by: Chuck Doan on July 31, 2014, 07:20:54 PM
Thanks for the update! Just amazing work at all levels.


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on August 26, 2014, 01:21:24 PM
Thanks to all of you - Volker earns a big compliment.

@BKLN  They will serve as masters for casting in white metal or Resin.



The crosspiece of I-beams were center punched and riveted from the backside.


westl_Nebenbruecke_Montage_022 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903westl_Nebenbruecke_Montage_022.jpg)


For easy positioning of the angle profiles, slots were milled (0.1 mm deep) into the sheet.
The MS58 brass material can be milled very painless. The rivets would emerged better with Ms63 certainly.
After sandblasting you will not see the difference.

westl_Nebenbruecke_Montage_023 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903westl_Nebenbruecke_Montage_023.jpg)


Holes were drilled into the legs accordingly for fixing the 5,0mm x 3,5mm fastening angles.

westl_Nebenbruecke_Montage_024 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903westl_Nebenbruecke_Montage_024.jpg)


westl_Nebenbruecke_Montage_025 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903westl_Nebenbruecke_Montage_025.jpg)


As drilling aid a 3.2 mm deep groove in a Pertinax plate served. A 6.0mm x 2.0mm U-profile has been put under the profile. A Scotch masking tape held everything in place.
The two hundred 1.0 mm holes could be drilled from the opposite side likewise. However I just wanted to make sure that the drill wouldnt run away on the inclined surfaces.


westl_Nebenbruecke_Montage_026 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903westl_Nebenbruecke_Montage_026.jpg)


To prepare the mounting bracket (wooden beams on the I-beams) two 50cm long 5mm x 5mm brass L-profiles were used.
The profiles were fitted (leg to leg) in a 1.2 mm wide and 4.5 mm deep groove at the MDF board.


westl_Nebenbruecke_Montage_030 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903westl_Nebenbruecke_Montage_030.jpg)


In two passes all the holes were drilled. The distance between the individual angular parts is 9.0mm. A small stop served for accurate positioning for the second leg side.


westl_Nebenbruecke_Montage_027 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903westl_Nebenbruecke_Montage_027.jpg)


Then I cutted the profiles into 5-strip on my metal cutting machine (similar here)  (http://www.buntbahn.de/fotos/data/7443/2903Blech_schneiden.jpg) to get  a 3.5mm width shank.


westl_Nebenbruecke_Montage_028 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903westl_Nebenbruecke_Montage_028.jpg)


Finally all angles were separated. Now they have a length of about 8mm.
This angles will be soldered with two rivets to the I-profile. Afterthan the rivets will be cutted and rounded.
The bilateral overhang will cropped with the Böhler saw later.


westl_Nebenbruecke_Montage_029 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903westl_Nebenbruecke_Montage_029.jpg)


There are only small steps, but the job comes first.


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on August 26, 2014, 01:33:39 PM
Your latest progress lives up to your usual horrible and depressing standards, Frithjof. Seriously, every time you post something it inspires me. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Chuck Doan on August 26, 2014, 02:19:58 PM
Astounding. I mean really.


Title: Re: Feldbahnmodule with ship
Post by: Gordon Ferguson on August 26, 2014, 04:10:09 PM
So each of these perfect pieces is 8mm long, with 3 x 1mm holes accurately positioned  :o

Makes me feel a bit of a stone age man, fiddling and whittling with little bits of plastic.

The whole process and execution is superb, wish I had my time over to learn at least some of your skills


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on August 30, 2014, 01:40:49 PM
As always, very impressive and fascinating work!


Title: Re: Feldbahnmodule with ship
Post by: Hydrostat on September 05, 2014, 11:17:08 AM
Okay, again hijacking Frithjof's thread.

Before production start for the white metal roof tiles we had to ensure that they are easily to color. Frithjof gave me the first castings (some of them will serve as master form for the series) to test that.

The tiles were burnished with a blackening and a copperizing fluid from a tiffany supplier. This is the blackened version:

(http://www.buntbahn.de/fotos/data/9000/5715IMG_7947b.jpg)

And that's the copperized one:

(http://www.buntbahn.de/fotos/data/9000/5715IMG_7948b.jpg)

In both ways the surface afterwards assumes water based color (gouache). I made that fast and dirty with a brush. For comparison: left hand is the blackened, right hand the copperized item. I used exactly the same paint application and shade for both pieces!

(http://www.buntbahn.de/fotos/data/9000/5715IMG_7951b.jpg)

The roofage might look like that later on. Admittedly the color has enough film strength, but it tends to get shiny when you rub it. Frithjof will have to test a bit with matte lacquer or some fixative when the roof is mounted and colored.

(http://www.buntbahn.de/fotos/data/9000/5715IMG_7956b.jpg)

(http://www.buntbahn.de/fotos/data/9000/5715IMG_7959b.jpg)

And the tile beside the tile.

(http://www.buntbahn.de/fotos/data/9000/5715IMG_7953b.jpg)

Cheers,
Volker


Title: Re: Feldbahnmodule with ship
Post by: BKLN on September 05, 2014, 01:10:15 PM
Very nice!


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on September 05, 2014, 02:36:29 PM
Interesting.

Are the prototype tiles painted red, or made of red material? It looks dark gray or black in the crevices and only red on the surface, but maybe the black is just accumulated crud.




Title: Re: Feldbahnmodule with ship
Post by: Hydrostat on September 06, 2014, 01:56:31 AM
Interesting. Are the prototype tiles painted red, or made of red material? It looks dark gray or black in the crevices and only red on the surface, but maybe the black is just accumulated crud.

Ray,

they are made from red clay. The dark spots are accumulated crud from air pollution. This is an old tile which surely has seen the coal fired heating era.

Cheers,
Volker


Title: Re: Feldbahnmodule with ship
Post by: Chuck Doan on September 08, 2014, 10:46:31 PM
Beautifully made and finished.


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on August 20, 2015, 03:09:00 AM
Today it goes on with the swing bridge piers.

For more information about Pendulum pillars look here (http://translate.google.com/translate?depth=1&hl=en&rurl=translate.google.com&sl=auto&tl=en&u=https://de.wikipedia.org/wiki/Pendelpfeilerbr%25C3%25BCcke)!


Pendel-Pfeiler_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Pendel-Pfeiler_01.jpg)
Copyright: WSA-Lauenburg/Elbe


Both pillar consists of each 22 angle profiles and 12 gussets.

From 3x3mm brass L-profile I cutted the required number on length.
The profiles have rivets in both flanks. To get this all congruent, I cut small auxiliary gauges from pertinax.


Pendel-Pfeiler_ankoernen (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Pendel-Pfeiler_ankoernen.jpg)


The flanks have an interior length of 2.6mm and a thickness of 0.4mm.
Two profiles will be placed into the gauge – flank against flank - for centrepunch.
Since I have no 0.8mm cutter with 2,6mm cut-length, the grooves were milled with an 1.2mm milling cutter into the pertinax plate.


Pendel-Pfeiler_ankoernen_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Pendel-Pfeiler_ankoernen_02.jpg)


The 0.4mm gap will be filled with  0.4 mm metal strips, so nothing will wobble.
In addition, the inserted profiles were fixed with adhesive tape.


Pendel-Pfeiler_ankoernen_03 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Pendel-Pfeiler_ankoernen_03.jpg)


The profiles are made of brass MS58, this can be milled wonderful - but to push rivets makes no joy!
Therefore all profiles were annealed at the points where the rivets could be seen.


Pendel-Pfeiler_ausgluehen (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Pendel-Pfeiler_ausgluehen.jpg)


For my embossing machine I habe corresponding punches.


Punzen_Nietenpraegen_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7434/2903Punzen_Nietenpraegen_01.jpg)


Pendel-Pfeiler_Nieten-druecken_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Pendel-Pfeiler_Nieten-druecken_01.jpg)


Pendel-Pfeiler_Nieten-druecken_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Pendel-Pfeiler_Nieten-druecken_02.jpg)


From Pertinax an assembly aid was milled .


Pendel-Pfeiler_Montagehife_01_ (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Pendel-Pfeiler_Montagehife_01_.jpg)


As I inserted the riveted profiles in the assembly jig, I noted an fault. I had cut the diagonal struts side inverted.

This I could easily change, as I would have countered the file in Sheetcam and then re-milled only the appropriate level with the milling data for the diagonal profiles. For new alignment on the milling machine the four corner holes had been used. So I had to drill four holes, insert 2 mm pins and position the existing Pertinax plate on it .... milling - ready ......!

However, in order to get the gusset plates in position new passer pieces would be needed.


That's why I cut a new assembly jig, so I can solder together the complete pendulum pillar-halves in one step.


Pendel-Pfeiler_Montagehife_04_ (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Pendel-Pfeiler_Montagehife_04_.jpg)


Here, the two diagonal struts (with one flank down) and the four outer profiles were cutted 0.8mm deeper into the Pertinax plate. The gusset plates were given a 0.4mm recess.
So I can solder four congruent parts very fast.
I am glad that the new idea and its implementation fit again. The profiles and the gusset plates sit neatly in the recesses.
Now the parts need solder! : D

Frithjof


Title: Re: Feldbahnmodule with ship
Post by: Allan G on August 20, 2015, 09:10:56 AM
Your work is great!!! Allan


Title: Re: Feldbahnmodule with ship
Post by: Hauk on August 20, 2015, 10:18:20 AM
So glad you are back!
You never fail to inspire.


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on August 20, 2015, 11:50:00 AM
Most satisfactory! -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on August 20, 2015, 11:33:30 PM
It's always a pleasure to see your modeling posts!


Title: Re: Feldbahnmodule with ship
Post by: 1-32 on August 22, 2015, 04:16:35 AM
very cool frithjof
great colour match with the roof tiles volker texture is a good match also
kind regards kim


Title: Re: Feldbahnmodule with ship
Post by: Bill Gill on August 22, 2015, 05:35:56 AM
Beautiful work!


Title: Re: Feldbahnmodule with ship
Post by: Barney on August 23, 2015, 08:17:55 AM
Outstanding Brass work
Barney


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on August 23, 2015, 03:01:21 PM
@Allan, Hauk, Russ, Ray, Kim, Bill and Barney: Thank for your approval :)

The first of the two pendulum pillars were finished today.

For this I had cut a few pertinax gauges. They should help me in aligning the upper L-profiles.


Pendel-Pfeiler_Montagehife_05_ (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Pendel-Pfeiler_Montagehife_05_.jpg)


Pendel-Pfeiler_Montagehife_06_ (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Pendel-Pfeiler_Montagehife_06_.jpg)


The excess solder was removed largely with a small triangular scraper and a preparation tool / Glasradierer (like this (https://www.krantz-online.de/en/online-shop/___product/503/___showCat/72/___pageid/16/preparation_tool_-_glasradierer.html)). The sandblasting gun did the rest.


Pendel-Pfeiler_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Pendel-Pfeiler_02.jpg)


The two equal halves I putted together. The 0.4mm thick nickel silver plate served as a conduit.


Pendel-Pfeiler_03 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Pendel-Pfeiler_03.jpg)


Both parts were pressed together easily. The overhanging L-profiles were cutted with the Böhler-saw.


Pendel-Pfeiler_04 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Pendel-Pfeiler_04.jpg)


The similarity with the drawing is wanted.

Pendel-Pfeiler_05 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Pendel-Pfeiler_05.jpg)



Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on August 23, 2015, 08:45:52 PM
Such marvelous miniature engineering!


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on August 24, 2015, 01:03:59 AM
Gosh. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Hauk on August 24, 2015, 04:15:02 AM

(http://www.buntbahn.de/fotos/data/7452/2903Pendel-Pfeiler_02.jpg)


The two equal halves I putted together. The 0.4mm thick nickel silver plate served as a conduit.

(http://www.buntbahn.de/fotos/data/7452/2903Pendel-Pfeiler_03.jpg)


Bulletproof modelling!


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on September 08, 2015, 04:18:05 AM
@Ray, Russ, Hauk: Thanks - slowly I'm quite embarrassed.

I have been asked to give an overview about my activities at buntbahn forum - perhaps it is also of interest here?

Eight years ago I started with my project, even more intensively and sometimes less. Job and family comes first. But there ist no date I have to be ready!
It makes me fun, the individual steps to go through (such as research, drawing and design, milling, soldering and construction, try out and if it doesn't work to try it again,...). There is never a dull moment.

It follows an overview of the projects associated with the topic "Feldbahn modules with ship"

a. the old platform (http://www.buntbahn.de/modellbau/viewtopic.php?t=6691&postdays=0&postorder=asc&highlight=alte+rampe&start=70) Here still the turnouts and the greening are missing.

b. the lift bridge (http://www.buntbahn.de/modellbau/viewtopic.php?p=249054&highlight=hubbr%FCcke#249054) It works the mechanical drive - I am currently on the pendulum pillars. Now both pillars are completed.

c. the old shed (http://www.buntbahn.de/modellbau/viewtopic.php?t=6691&postdays=0&postorder=asc&highlight=alte+waage&start=300) See below!

d. the truck scale (http://www.buntbahn.de/modellbau/viewtopic.php?t=6691&postdays=0&postorder=asc&highlight=alte+rampe&start=130) The roof could be covered with the existing roof tiles by Volker now.

e. the old port crane (http://www.buntbahn.de/modellbau/viewtopic.php?t=6691&postdays=0&postorder=asc&start=470) He waits for the next use of soldering.)


The front wall of the old fire station (http://www.buntbahn.de/modellbau/viewtopic.php?p=284820&highlight=feuerwache#284820) was milled in scale 1:22.5. – I stopped working on it!
The 1:24 ladder (https://www.google.de/search?q=1:24+Feuerwehr++drehleiter+yat+ming&client=safari&rls=en&biw=1469&bih=1090&tbm=isch&tbo=u&source=univ&sa=X&ved=0CCAQsARqFQoTCJjknLfq2McCFcfbLAodW1ILMQ) looks just too puny in comparison. I only know in scale 1:22.5 Opel Blitz as LF8 (http://www.mo-miniatur.com/Opel-Blitz-Feuerwehr-LF-8-Weissenhorn), which fits into the 60th years.

Clicking on the blue marked letters let appear the German pages of Buntbahn. You can translate it with Google Translator.


Grundriss_FMmS_2 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Grundriss_FMmS_2.gif)


Grundriss_Module_bislang-fertig (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Grundriss_Module_bislang-fertig.jpg)


Always, if I have a little time, I look at the parts and then any of the parts gains. :wink:

Currently I'm on the bridge superstructure - also if the old shed asked to get some bricks.



Once Volker announced the first casting of the roof ridge brick with a picture, ...I was just a bit appalled by the unmasking of this macro photo.


Firstziegel_00 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Firstziegel_00.jpg)
(Image by Volker)


He told me that you wouldn´t see the levels of pressure with the naked eye.

Recently I got the roof ridge bricks.

He's right, on a quick comparison photo (it´s still a magnification!) you can collate an unedited brick behind the front brick easily sandblasted.


Firstziegel_01 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Firstziegel_01.jpg)


Firstziegel_02 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Firstziegel_02.jpg)


Let's see how the parts look burnished and treated with red color, just as Volker did it before here (http://www.finescalerr.com/smf/index.php?topic=1424.210)




Title: Re: Feldbahnmodule with ship
Post by: Bill Gill on September 08, 2015, 05:30:33 AM
It is good to see the diagram of your overall plan to understand where each of the models will be located. The roof tiles look very good after you did a little cleaning up.


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on September 08, 2015, 12:41:46 PM
Not only do the new parts look terrific but I love the concept of the entire layout. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: lab-dad on September 08, 2015, 04:40:04 PM
I spent my lunch hour over at the German forum.
Im only part way through.
Definitely time well spent!!!!!
Looking forward to spending more time there!
Marty


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on October 19, 2015, 12:45:40 PM
That's what you get when you counts rivets - or only stones... and you doesnt know the overall dimensions of the original!

When I started with the my project "Feldbahn modules with ship" in mid-2007 I did the first drawings for the bridgeheads (http://www.buntbahn.de/modellbau/viewtopic.php?t=6691&postdays=0&postorder=asc&start=20). I walked out of dimensions which I had measured on a stone of a demolished old house.
Helmut milled the MDF-plates with the joints (http://www.buntbahn.de/fotos/data/7452/2903Helmut_beim_Fugen_saeubern.jpg) according to my DXF drawing.

All parts fit together, the two bridgeheads were glued and the toothed quoins were trimmed in the joints with a thin sawblade. Like here:: click (http://www.buntbahn.de/fotos/data/8054/2903Alter_Lagerschuppen_122.jpg). Finally everything was primed gray.

So far so good!

Brueckenkoepfe (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Brueckenkoepfe.jpg)


As I put the bridgehead on a drawing of the original bridge elements (scaled to 1:22,5)  I noted the estimated dimensions are not correct. The width is about 10mm too wide.

I'll make the parts just new!
To scale down the entire sketch doesnt work because the stones have to be changed slightly different in height and width.

Now I have changed the individual size of all different stones, so that the width of the bridge head becomes 10mm smaller.

Brueckenkopf_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Brueckenkopf_02.jpg)


Currently the bridgehead looks more prototypical.

Brueckenkopf_05 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Brueckenkopf_05.jpg)


The wall joint with 0.5mm thickness is included into the stone size.
Just to mill the outer contour with a 1.5mm router, I drew a new layer. It has a gap of 0.65mm. (0.75mm ist the correct worth, but it´s more easier to put the tooth of the stoneedges together.
The nooks have been pre-drilled with a 0.5mm drill. Thus, the corner radius has been reduced from 0.75mm to 0.25mm. The plates fit together without extra work at the corners.


Brueckenkopf_06 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Brueckenkopf_06.jpg)


Brueckenkopf_07 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Brueckenkopf_07.jpg)

This is the DXF file passed to Sheetcam.

Brueckenkopf_08 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Brueckenkopf_08.jpg)


Three and a half hours later, plates for one bridgehead were finished.

Brueckenkopf_09 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Brueckenkopf_09.jpg)


At German buntbahn forum I was asked for the dimensions overall the modules:

Module_Abmessungen (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Module_Abmessungen.jpg)



Title: Re: Feldbahnmodule with ship
Post by: finescalerr on October 20, 2015, 01:24:38 AM
That should be a wonderful module. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on October 20, 2015, 03:23:21 AM
@Russ  Maybe you are right :)

Here a small update from last night.

Wood glue and screw clamps, sandpaper and a 0.5mm saw blade helped in assembling the first parts.

The toothed quoins I had let protrude approximately 0.5mm. Similarly, you can see here on the picture of the old only loose assembled bridgehead: click (http://www.buntbahn.de/fotos/data/7452/2903Brueckenkopf_gefraest_5.jpg)

After drying of the glue the entire block has been laid flat on a sandpaper (200 grain) and abraded with two, three movements to the brick surface. After that the 0.5mm saw blade cut free the joints at the corners,

Brueckenkopf_16 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Brueckenkopf_16.jpg)

sandpaper (600 grain) smoothed the complete surfaces and a brass brush cleaned the joints from dust.


Brueckenkopf_14 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Brueckenkopf_14.JPG)

Frithjof


Title: Re: Feldbahnmodule with ship
Post by: lab-dad on October 20, 2015, 05:39:19 AM
That looks solid to me!
I wish I had one of those cnc routers!... :-[
Thanks for posting - always an inspiration!
-Marty


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on October 21, 2015, 09:08:38 PM
That turned out great! Can't even see the joint.


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on October 31, 2015, 12:56:04 PM
Uwe, a nice colleague of Buntbahn forum tendered to print some needed parts in 3D.
 
At this  German forum (http://www.buntbahn.de/modellbau/viewtopic.php?t=6691&postdays=0&postorder=asc&start=670) he describes how he did it.


It was a great joy as I got a package from him recently.

I smoothed all parts with sandpaper (grain size1000) then the sandblaster was used. It tooks about 5 minutes per part.

Brueckenkopf_18 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Brueckenkopf_18.jpg)
top left = roughly smoothed with sandpaper 1000grain, top right = sandblasted addition, bottom right = unmachined casting


Brueckenkopf_17 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Brueckenkopf_17.jpg)

Next the parts will be primed gray, by the way larger pores will become sealed. I´ll see how they look like, possibly sandpaper and sandblasting gun will needed again.

Frithjof


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on October 31, 2015, 08:47:47 PM
Looks great!


Title: Re: Feldbahnmodule with ship
Post by: 1-32 on November 01, 2015, 02:42:26 AM
hi friithjof.
are those stone cappings 3d printing.just very clean and convincing.
regards kim


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on November 01, 2015, 04:29:08 AM
Hi Kim,

those parts are castings. Uwe has printed two adverse half shells with his 3D printer.

The following pictures may demonstrate the processing method (taken by Uwe):

STL-file
(http://www.buntbahn.de/fotos/data/9033/4389Frithjof-BK-3D-01.jpg)


two half shells for left and right capping
(http://www.buntbahn.de/fotos/data/9033/4389DSCN9547.JPG)


ready for casting
(http://www.buntbahn.de/fotos/data/9033/4389DSCN9548.JPG)


half shells with cast
(http://www.buntbahn.de/fotos/data/9033/4389DSCN9586.JPG)


castings before clean up
(http://www.buntbahn.de/fotos/data/9033/4389Br_ckenKopf01.jpg)



Title: Re: Feldbahnmodule with ship
Post by: lab-dad on November 01, 2015, 12:59:56 PM
How do you fill the molds?
I can not see plaster flowing into the molds.
Marty


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on November 01, 2015, 01:01:51 PM
I love this blend of traditional and hi-tech and the results speak for themselves. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: 1-32 on November 01, 2015, 09:35:09 PM

3d printing to make the molds and you can use any material for the finish-nice


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on December 02, 2015, 03:49:45 PM
A little update again after a long time.

Many small riveted angles and profiles have to be made for the four connecting bridges.

Hubbruecke_Anschlussbruecken_ (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Hubbruecke_Anschlussbruecken_.jpg)
Copyright: WSA-Lauenburg/Elbe


oestliche_Bruecken (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903oestliche_Bruecken.jpg)

Either I could
(a) drill all small profiles and fill them with genuine rivets or (a lot of work)
(b) press rivets or (The profiles must be annealed before!)
(c) build a master pattern and cast it or
(d) print a master pattern and cast them too.

For the crossbeam and lower shelf I requested a foundry. I hope that they can print and cast the partly only 0.4mm thick sections!


Knoten_A-Gussbaum-neu_001 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Knoten_A-Gussbaum-neu_001.jpg)


The blue selection indicates the finished part. The lateral parts will be cut off.
 

Knoten_A-Gussbaum-neu_002 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Knoten_A-Gussbaum-neu_002.jpg)


U-Profil_6x3x0_5_56_5mm_Gussbaum_002 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903U-Profil_6x3x0_5_56_5mm_Gussbaum_002.jpg)


U-Profil_6x3x0_5_56_5mm_Gussbaum_003 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903U-Profil_6x3x0_5_56_5mm_Gussbaum_003.jpg)


I had made the longitudinal beams and the mounting bracket for the wooden cross beams some time ago (http://www.finescalerr.com/smf/index.php?topic=1424.210).
The drilled holes have a diameter of 1.0 mm. But the purchased 1.0 mm rivets have a diameter of 0.94 mm only.
After positioning the first angles with the rivets on the long beams, an exact alignment of the angles were not given. The tolerance in the holes was clearly noticeable.
Since I had purchased about 300 rivets, I will use them, especially as manufacturing new better rivets would take until early next year.


Loetlehre_Winkel_oben_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Loetlehre_Winkel_oben_01.jpg)


But now I want cause an exact result with minimal effort.
So, again a small gauge was drawn and machined.


Loetlehre_Winkel_oben_05 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Loetlehre_Winkel_oben_05.jpg)


Loetlehre_Winkel_oben_06 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Loetlehre_Winkel_oben_06.jpg)


Loetlehre_Winkel_oben_07 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Loetlehre_Winkel_oben_07.jpg)


Loetlehre_Winkel_oben_08 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Loetlehre_Winkel_oben_08.jpg)


Loetlehre_Winkel_oben_09 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Loetlehre_Winkel_oben_09.jpg)


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on December 02, 2015, 08:40:52 PM
Well done!


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on December 13, 2015, 09:48:18 AM
Two weeks ago I was still assumed that I would use the existing rivets...
Quote
... especially as manufacturing new better rivets would take until early next year.

Then I got good news by Manfred (a colleague at Buntbahn forum) that he was still able to make my desire rivets very quickly.

So, I have soldered the new custom-made rivets and the angle profiles with the first longitudinal beams.


The protude angle profiles should be sawn off with my BÖHLER saw, but...

Langtraeger_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Langtraeger_01.jpg)

the height-adjustable blade was not sufficient up (in despite highest position).

So I milled a gauge from beech wood where I could insert the longitudinal beams overhead.


Langtraeger_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Langtraeger_02.jpg)

At a guidance I pushed this gauge past the saw blade and separated the overhanging parts from both sides without hurting the long carrier with the saw blade.

Langtraeger_03 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Langtraeger_03.jpg)


Langtraeger_04 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Langtraeger_04.jpg)


I was not very happy with my sand blast cabinet. Continuously the compressor came on to generate the required pressure (ejector concept). In the long time the noise was very annoying.
At Buntbahn I saw a note on an alternate product from Austria: here (http://www.microsofttranslator.com/bv.aspx?from=&to=en&a=http%3A%2F%2Fwww.logiblast.at%2FSeiten%2FSMART-Cab.php)

Now the complete air volume is used for the radiation and not 80% for the suction of the blasting media.
A pressure of approximately 2 atmospheres is sufficient for the purposes of our hobby!

As the package arrived yesterday, I immediately had to sandblast one part.

Langtraeger_05 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Langtraeger_05.jpg)

The silky shiny surface is achieved by glass beads.


Langtraeger_06 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Langtraeger_06.jpg)

My conclusion: Even if I must refill the reservoir with glass beads (or aluminium oxide) every 5 minutes, the result is much better than I had reached it with the old sand blasting cabinet.
But above all, I have less noise pollution now.
Through the use of glass beads I have an almost complete removal of solder residue with a lower pressure also.
I have not regretted the purchase... so far ;-)


Title: Re: Feldbahnmodule with ship
Post by: Bill Gill on December 13, 2015, 10:58:24 AM
Beautiful workmanship.


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on December 13, 2015, 01:51:20 PM
Most satisfactory! -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on December 13, 2015, 02:30:49 PM
Beautiful workmanship.

Agreed! 


Title: Re: Feldbahnmodule with ship
Post by: Chuck Doan on December 13, 2015, 11:02:07 PM
Hard to believe it could get better...but it did!


Title: Re: Feldbahnmodule with ship
Post by: Hauk on December 14, 2015, 03:57:40 PM
I was not very happy with my sand blast cabinet. Continuously the compressor came on to generate the required pressure (ejector concept). In the long time the noise was very annoying.
At Buntbahn I saw a note on an alternate product from Austria: here (http://www.microsofttranslator.com/bv.aspx?from=&to=en&a=http%3A%2F%2Fwww.logiblast.at%2FSeiten%2FSMART-Cab.php)

Now the complete air volume is used for the radiation and not 80% for the suction of the blasting media.
A pressure of approximately 2 atmospheres is sufficient for the purposes of our hobby!


Looks like a very interesting setup for blasting!

But you still need an external compressor with the setup?


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on December 18, 2015, 02:34:41 PM
Thanks for your approving!

@Hauk
You are right, I need an external compressor!


The three eastern connecting bridges are arranged at an angle to each other.

Before I will cut off and rounding the bottom protruding rivet shafts with a hollow cutter I still want to adjust the last gussets at the transitions of the three bridges. These are at an angle arranged.

I milled into a 70cm x 30cm MDF board grooves and I placed the respective longitudinal beams into it. The abutting edges I have tailored on the Böhler-saw. For this purpose the saw blade was been tilted by 7 angular degree and I cut away the long carrier. This was carried out in several stages, so as not to cut off to much of the material at once.


Langtraeger_07 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Langtraeger_07.jpg)


Langtraeger_08 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Langtraeger_08.jpg)


Langtraeger_09 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Langtraeger_09.jpg)


Langtraeger_10 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Langtraeger_10.jpg)


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on December 19, 2015, 01:54:07 AM
The model matches the drawing so precisely it's frightening. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Allan G on December 19, 2015, 09:58:17 AM
I agree with Russ!!!!!!!!!!! Allan


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on December 26, 2015, 03:39:14 PM
The gusset plates that hold the crossmembers should be printed in wax and then remelted in brass.
Have a look at the master form as 3D printing:
 
Knoten_A-Gussbaum-neu_003 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Knoten_A-Gussbaum-neu_003.jpg)

Only with a magnifying glass small stairs were visible on the rivets. Two small areas I have smoothed with a sandpaper file (1000 grit). Then the glass beads came into play again. Viewed with a magnifying glass you can imagine the step levels only a little bit yet.
Thus processed, I'll send back this master form to the foundry. They will create a silicone mold and made several casts. The size of shrinkage I had included with 1.5% previously.
At the end the red-bordered area should be width of 20mm.
Unfortunately, I have to wait to the end of January for the finished parts, since the caster is very well utilized.

After adjusting the angle of the longitudinal beams (of the three eastern connection bridges), a few jigs were milled.


Langtraeger_Montagelehre_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Langtraeger_Montagelehre_01.jpg)


With the help of these synthetic resin bonded paper gauges I will be able to mount the gusset plates, crossbeams and connecting profiles precisely.


Langtraeger_Montagelehre_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Langtraeger_Montagelehre_02.jpg)


Langtraeger_Montagelehre_03 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Langtraeger_Montagelehre_03.jpg)


Meanwhile, the protruding rivets have been reduced to 0.6mm height.
For this purpose I have set the saw blade parallel to the inner angle of the longitudinal beam
(adjusted vertically that the blade doesn´t touch the bridge, but only cut off the 1mm shafts of the rivets).


Nieten-kuerzen_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Nieten-kuerzen_01.jpg)


This supernatants will be rounded with a 1.0mm hollow cutter.
Such milling cutter you´ll get here for example as „Finierfräser“ in different diameters.: click (http://www.goldschmiedebedarf.de/search.php?queryFromSuggest=&goldschmiedebedarf_de=channel&query=FINIERFRAESER).

There is one flaw: The rivet head has a diameter of 1.2mm - the shaft only 1.0mm ..... so I'm going to live.
Otherwise I would have use 1.2mm solder wire pieces and must be rounded at both ends.


The first crossbeam I have cut from 6mm x3mm U-profile.
Using a Pertinax gauge I drilled holes for the rivets be soldered.
Originally I wanted get the crossmember by casting.
Two reasons against:
a) the price per each finished casting (15 pieces) would have amounted to approximately € 16.00,
b) with a length of 56mm, I was not sure if all the parts would have really the identical dimensions after casting.
Now I have costs of 2.00 € per piece (16 rivets and brass profile) + effort, which is not really expected at hobby.

Quertraeger_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Quertraeger_01.jpg)


The 24 M2 screws (for attaching the Pertinax gauges to the longitudinal beams) had to be shortened by about 3mm. For this I had put a brass tube as auxiliary stop on the bolt and fixed it with a nut. With a thin cutting disk then the bolts were brought to the same length and could be mounted.

Schrauben_kuerzen (fspg2)
(http://www.buntbahn.de/fotos/data/7443/2903Schrauben_kuerzen.jpg)


The recesses for the nuts have been milled tightly so that I need no further wrench during assembly.
 
Langtraeger_11 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Langtraeger_11.jpg)


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on May 03, 2016, 10:54:59 AM

Currently I am still waiting for some castings for the bridge.

A small excercise in between came just right! In my search on the web for old workshop equipment I found this old workbench (the dimensions  are: 151cm width, 82 cm depth and 97 cm height)  - for my old shed (klick here (http://www.buntbahn.de/fotos/showgallery.php?cat=8054&si=&page=2&sort=7&perpage=80&password=&ppuser=2903&stype=)) a little bit too large (and also a bit overpriced) ...

Alte Werkbank_ 151 cm breit x 82 cm tief und 97 cm
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Werkstatttisch_01.jpg)
found at: http://www.ebay.de/itm/alte-antike-Werkbank-Werktisch-Arbeitstisch-Eisentisch-Metall-VINTAGE-/311170890958

So a reduction in scale 1:22,5 was constructed, based on the photos and the known dimensions...

Alter_Werkstatttisch_02 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Werkstatttisch_02.jpg)


... the parts were milled in brass....

Alter_Werkstatttisch_03 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Werkstatttisch_03.jpg)


The four legs are from 2.5mm brass round profile. The ends were drilled on the lathe with a 2mm pilot drill. So it looks like tubes  (if one considers the workbench from below)

Alter_Werkstatttisch_04 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Werkstatttisch_04.jpg)

Gauges were made from Pertinax. With their help I can solder the little angle plates rectangular.

On the following screen the parts are assembled loosely.

Alter_Werkstatttisch_05 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Werkstatttisch_05.jpg)

Overall, I needed about 1h for drawing and 2.5h for milling and about 35min for solderimg.


Alter_Werkstatttisch_06 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Werkstatttisch_06.jpg)


The upper edges of the worktop have to become more blunt before the next steps can follow.


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on May 03, 2016, 12:57:55 PM
Acceptable. Please proceed. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on May 03, 2016, 09:32:46 PM
Masterful craftsmanship, as usual!


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on June 25, 2016, 02:19:04 PM

Today a small update only.

The master pattern I could survey in last December already. Small grades I removed with fine sandpaper and my sandblaster. Next the caster reproduced it in a silicone mold.
I´m sad to say but the first cast I got was waste. The material thickness of 0.45 mm and the rivet heads were poured clean - unfortunately, however, the 24mm long gusset plate were curved over the whole length. Even with light hammer strokes I couldn´t reach a satisfying result with a test piece.

So it was agreed with the foundry to return everything and made a new attempt with another silicone material. In addition, the casting tree got a third runner in the middle.
Recently I got the new casts. Although small differences in the twenty castings were present, I could use all the parts.

Knoten_A-Gussbaum-neu_003 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Knoten_A-Gussbaum-neu_003.jpg)

Masterform - red mark is required

Knoten_A-Gussbaum-neu_004 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Knoten_A-Gussbaum-neu_004.jpg)

First the sprue webs were detached using a cutting disk.

Knoten_A-Gussbaum-neu_005 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Knoten_A-Gussbaum-neu_005.jpg)

Then I cleaned the edges with a sandpaper file.

Knoten_A-Gussbaum-neu_006 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Knoten_A-Gussbaum-neu_006.gif)

a) Mastermodel with 101.5% size for silicone casting
b) cast from the series (with the third runner) (100% size)
c) sprues are separated
d) left supernatant separated (with Böhler disk saw)
e) + f) front and back  side (both lateral protrusions separated)

Since I need two different rivet arrangements for the left and right side and didn´t want to invest in two masterforms, my master pattern got rivets on the front and on the back.

Knoten_A-Gussbaum-neu_007 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Knoten_A-Gussbaum-neu_007.jpg)

Each redundant rivets were milled either on the front or on the back.



Title: Re: Feldbahnmodule with ship
Post by: finescalerr on June 26, 2016, 12:55:31 AM
Superb. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on July 03, 2016, 06:31:13 AM
Thanks, Russ :-)

Hold the parts in hand, would have been feasible for a few castings. For 20 parts I drawn and cut two small "Pertinax shoes".

Knoten_A-Gussbaum-neu_008 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Knoten_A-Gussbaum-neu_008.gif)


This allowed me to free the gusset plates of the supernumerary rivets quickly. A 1.0mm cutter was set several times lower in height. The shoe with the casting was moved by hand on the flat surface of the cross table until the rivet heads no longer remained. Slight scratch marks of the router will be covered by the soldered diagonal braces later.

Knoten_A-Gussbaum-neu_009 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Knoten_A-Gussbaum-neu_009.jpg)



Another small step was a small auxiliary device which organized the longitudinal beam at an angle so that the „Finier“cutter can rounding the rivet heads vertically from above.

Halter_Finierfraeser_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Halter_Fiinierfraeser_01.jpg)


Halter_Finierfraeser_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Halter_Fiinierfraeser_02.jpg)


The slots in the base board located the five carriers.

Halter_Finierfraeser_03 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Halter_Fiinierfraeser_03.jpg)


Halter_Fiinierfraeser_04 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Halter_Fiinierfraeser_04.jpg)


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on July 03, 2016, 12:39:06 PM
I love that cutter! -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on July 04, 2016, 11:56:18 PM
This is just incredible engineering!


Title: Re: Feldbahnmodule with ship
Post by: Allan G on July 05, 2016, 09:19:20 PM
Wow!!! Wow!!!.....Allan


Title: Re: Feldbahnmodule with ship
Post by: Hydrostat on July 06, 2016, 12:22:52 AM
Frithjof,

which speed did you chose with the cutter? I know they work well with hand tools but wasn't aware they fit for machining, too.

Volker


Title: Re: Feldbahnmodule with ship
Post by: Bill Gill on July 06, 2016, 05:23:40 AM
Your level of design and execution is so far beyond anything I could conceive of that I can only look on in awe. All your fabrication is precise and meticulous and 'gorgeous', if such a term is appropriate for a bridge.


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on July 06, 2016, 11:21:39 AM
@ Russ, Ray, Allan, Bill  Thanks for your recognition

@Volker
 
Quote
Which speed did you chose with the cutter? I know they work well with hand tools but what not aware They fit for machining, too.

Yesterday I got new „Finier“cutter (TwinCut). Now the results are much more better.

The „Finier“cutter is described  here  (https://www.goldschmiedebedarf.de/product_info.php?products_id=25470&language=en).

recommended speed: 2500-7000 rpm
speed range: max. 20,000 rpm

I used the drill stand and the Pertinax gauge only for vertical alignment. For accurately positioning I´m using a headband magnifier!

Halter_Finierfraeser_05 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Halter_Finierfraeser_05.jpg)

The engine is not running - the chuck I rotate with my left hand - felt 10 RPM. With my right hand I can regulate the height varies slightly.


Halter_Finierfraeser_06 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Halter_Finierfraeser_06.jpg)


Halter_Finierfraeser_07 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Halter_Finierfraeser_07.jpg)

Halter_Finierfraeser_08 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Halter_Finierfraeser_08.jpg)


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on July 29, 2016, 02:01:27 AM
The 3x6mm U crossbeams had got  1mm holes  (http://www.buntbahn.de/fotos/showphoto.php?photo=103312&password=&sort=7&thecat=7452) already. My first attempt hard-soldering the rivets was not satisfactory. Although I used 0.5mm silver hard-solder wire sparingly, it was still too much.


Beng_Loetpaste_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Beng_Loetpaste_01.jpg)
left with 0.5mm silver solder wire  -  right with brazing paste


A friendly model builders gave me a great tip: brazing paste (http://www.bengs-modellbau.de/werkzeug/loetzubehoer/silberlotpaste-zum-hartloeten)
So I put 1.5mm long rivets into the holes (a real game of nerves ... using 5 rivets .... 2 rivets landed somewhere around the room) ... and coated all with the brazing paste from the back. Then the flame fixed it in no time. The protruding shanks I separated at my small Böhler saw and I smoothed all surfaces on a sandpaper board..


Beng_Loetpaste_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Beng_Loetpaste_02.jpg)
above with 0.5mm silver solder wire  -  below with brazing paste


The first long beams were combined with the casted gusset plates and the small vertical angels of brass.


Knoten_A-Gussbaum-neu_010 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Knoten_A-Gussbaum-neu_010.jpg)


The diagonal braces were center marked in a small Pertinax gauge (similar here (http://www.buntbahn.de/fotos/showphoto.php?photo=101780&size=big&password=&sort=2&thecat=7452)). So I can press the rivets positioned accurately.
Previously 3x3mm brass profiles were annealed with the flame. Thereby they were soft, otherwise the rivet heads could have been forced out.
At the first bridge I soldered four diagonal struts .... indeed, I need a third hand.
The solder tweezer came not as good to the right position. So I'm going to build new angled soldering tips.


Knoten_A-Gussbaum-neu_011 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Knoten_A-Gussbaum-neu_011.jpg)


Knoten_A-Gussbaum-neu_012 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Knoten_A-Gussbaum-neu_012.jpg)


Knoten_A-Gussbaum-neu_013 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Knoten_A-Gussbaum-neu_013.jpg)


Knoten_A-Gussbaum-neu_014_ (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Knoten_A-Gussbaum-neu_014_.jpg)
Ansicht von unten

Coming a little bit faster to the target assembling the next 20 diagonal braces, I milled two small auxiliary gauges (again from pertinax).
The profiles got 1mm holes in the center.  It was soldered with an 1.3mm rivet (shaft 1mm) and an 0.4 mm shim . Now the profiles joint in an exact angle of 57.49 degrees.


Knoten_A-Gussbaum-neu_015 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Knoten_A-Gussbaum-neu_015.jpg)


Knoten_A-Gussbaum-neu_016 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Knoten_A-Gussbaum-neu_016.jpg)
diagonal braces view from bottom side






Title: Re: Feldbahnmodule with ship
Post by: Hauk on July 29, 2016, 05:43:43 AM
Inspirational and educational as usual!
Incredible work.


Title: Re: Feldbahnmodule with ship
Post by: lab-dad on July 29, 2016, 05:44:10 AM
A hundred years from now modelers will be referencing your work and trying to achieve the same results but falling way short.
Always a pleasure to witness such precision.
The brazing paste is a good tip too!

-Marty


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on July 29, 2016, 12:20:02 PM
I agree with Marty. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on July 29, 2016, 10:12:37 PM
Marvelous precision and a joy to follow along!


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on August 17, 2016, 03:13:17 PM
@ Hauk, Marty, Russ, Ray
I am pleased that you like it :)

Up to now I was concerned with the 4 subbridges, but now the beams of the main bridge shall be prepared.

Traeger_Montage_20 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Traeger_Montage_20.png)


Since the original drawings were photographed very wavy, you can see mistakes especially at the top end.

Hubbruecke_Portal_1 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Hubbruecke_Portal_1.jpg)
Copyright: WSA-Lauenburg/Elbe


Traeger_Montage_Grundskizze_frontal_1 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Traeger_Montage_Grundskizze_frontal_1.jpg)
Copyright: WSA-Lauenburg/Elbe

With Photoshop I could compensate some inaccuracies in the vertical and horizontal scaling individually. The original dimensions of the drawing have been converted to 1:22.5, then compared with the dimensions of the copy and adjusted if necessary .
In this way prepared I composed the drawings in 3 levels.

Traeger_Montage_Grundskizze_3D_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Traeger_Montage_Grundskizze_3D_01.jpg)


Traeger_Montage_Grundskizze_3D_06 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Traeger_Montage_Grundskizze_3D_06.jpg)


Traeger_Montage_Grundskizze_3D_05 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Traeger_Montage_Grundskizze_3D_05.jpg)

The blue intermediate layer characterize the position of each angle section.


Traeger_Montage_05 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Traeger_Montage_05.jpg)

The blue lines mark the location of the corner profiles.

Traeger_Montage_06 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Traeger_Montage_06.jpg)


In the following animation the procedure can be seen:

Traeger_Montage_00 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Traeger_Montage_00.gif)


Traeger_Montage_15 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Traeger_Montage_15.jpg)


Traeger_Montage_17 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Traeger_Montage_17.jpg)


The holes in the sheets and profile angles will pick up rivets later. I think it will give more stability - even if I have a lot more effort.

At the drawings I have read the dimensions of the ground and the upper edges of the two outer corner profile bends, also the height between the levels. Then I converted it to 1:22,5.


Traeger_Montage_21 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Traeger_Montage_21.jpg)

By the help of a 3D sketch I connected the respective vertices. The four corner angle (red) I extruded in the height.

Traeger_Montage_22 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Traeger_Montage_22.jpg)




Title: Re: Feldbahnmodule with ship
Post by: finescalerr on August 18, 2016, 12:58:29 AM
Impressive. It would take me six months to figure out how to interpret those drawings and I'd probably still do it wrong! -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on August 20, 2016, 12:40:58 AM
I agree, very impressive, and quite interesting! Also, I really enjoy your animated drawings! Very helpful for seeing how you plan to assemble things.



Title: Re: Feldbahnmodule with ship
Post by: Hauk on September 03, 2016, 11:07:10 AM
This project will go down in history as one of the most fantastic modeling projects ever!
You just have to love it.


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on September 07, 2016, 11:39:58 AM
@Russ
Six month are very quick - indeed I needed more than one year  ;)  Thereby I discussed with Volker and other guys of Buntbahn forum.

@Ray
Such animations you can get with Photoshop timeline for example.

@Hauk
Thanks for the kind words  :)  In Germany we are saying: "We all are cooking with water only".  ;)

Although it is not really clear until now, how the angles of the corner profiles were made out with the prototype of 1900, I will use a milled and folded 0.4mm brass frame for the base. This ensures that all four sockets quickly obtain the same dimensions.

Bodenrahmen_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Bodenrahmen_01.gif)


Brass MS58 can be milled better, but I have used MS63. Most dealers sells MS58plates from 0.5mm thickness only. MS63 is more soft and can be bent better. I milled with addition of cutting oil.

Bodenrahmen_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Bodenrahmen_02.jpg)


I annealed the sheets before bending. This ensures that the edges didn´t break (depending on the rolling direction).

Bodenrahmen_03 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Bodenrahmen_03.jpg)


In several steps the angle were bent. Thereby oblique grooves -  sawn in a beech wood slat - helps to bent the profiles.
From stage to stage the angle was inclined more and more until the result was reached. A brass block and a plastic mallet helped during bending.


Bodenrahmen_04 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Bodenrahmen_04.jpg)


Triangles made from 1.5mm brass MS58 serves as base feet.


Bodenrahmen_05 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Bodenrahmen_05.jpg)


Bodenrahmen_06 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Bodenrahmen_06.jpg)

This 16 feet and the four frames are only a small step until the completion of the bridge – As you know, the way is the goal . Certainly it will take a few years until I'm done .

Currently I´m drawing the top girders of the bridge.


Oberhaupt_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Oberhaupt_01.jpg)


Oberhaupt_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Oberhaupt_02.jpg)


Oberhaupt_03 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Oberhaupt_03.jpg)



Traeger_Montage_32 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Traeger_Montage_32.jpg)




Title: Re: Feldbahnmodule with ship
Post by: finescalerr on September 07, 2016, 12:26:26 PM
I have the feeling Frithjof knows what he is doing .... -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Bill Gill on September 07, 2016, 02:28:22 PM
More excellent work!


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on September 07, 2016, 10:03:56 PM
More excellent work!

Indeed!


Title: Re: Feldbahnmodule with ship
Post by: Hauk on September 08, 2016, 01:17:08 AM

Brass MS58 can be milled better, but I have used MS63. Most dealers sells MS58plates from 0.5mm thickness only. MS63 is more soft and can be bent better. I milled with addition of cutting oil.

May I ask where you buy your brass? And do you have a good source for milling bits?
And again, thanks for the inspiration & information.

By the way, did you consider etching the 0,4mm? With half-etched folding lines the 0,4mm brass folds up nicely. I have etched 0,5mm parts with good results.


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on September 17, 2016, 11:24:09 AM
@Hauk

Sorry for my late reply, I was on a business trip.

May I ask where you buy your brass?

My address for brass and nickel silver is: http://www.wilmsmetall.de

For modeler they have a special edition (mostly dimensions: 200mm x 300mm): http://www.wilmsmetall.de/static/download/Extrablatt_Modellbauer.pdf. The price is sometimes a little bit cheaper.

If you needs more different material thickness have a look here: http://www.zaenker-dittrich.de/messing-bleche.php.  I got this link from a colleague at Buntbahn forum shortly.

And do you have a good source for milling bits?

A lot of milling bits I'm ordering on this adress: http://www.as-toolstore.de. The quality ist quite enough for most requirements.

With milling bits from Hoffmann Group (more expensive) you can get a longer lifetime. I'm often using:  https://www.hoffmann-group.com/DE/de/hom/Monozerspanung/VHM-Fräser/VHM-Mini-Fräser-TiAlN/p/201842-0,5 (https://www.hoffmann-group.com/DE/de/hom/Monozerspanung/VHM-Fräser/VHM-Mini-Fräser-TiAlN/p/201842-0,5)
 On the right side you can choose the size (Größe wählen).

The length of the 0.5mm cutter is only 2,3mm (instead 5mm to 7,5mm from as-toolestore). More than 30 hours I'm using the milling bits from type number: 201842 - without lost of their sharpness. My feed rate for example with a 0.5mm cutter is: 100-120mm/min  -  20000-26000 rpm  -  milling depth is half of the cutter diameter maximum.


And again, thanks for the inspiration & information.

Thanks, I hope you'll follow my thread in future as well. :)


By the way, did you consider etching the 0,4mm? With half-etched folding lines the 0,4mm brass folds up nicely. I have etched 0,5mm parts with good results.

Yes, I did!   I know etching helps a lot to save time ;)  But I don't like the edges. A L-profile or U-profile have sharp edges. An etched profile will get a radius.


Title: Re: Feldbahnmodule with ship
Post by: Hauk on September 17, 2016, 03:07:36 PM
@Hauk

Sorry for my late reply, I was on a business trip.



No problem!
Thanks a lot for the links, a lot of very useful stuff!


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on October 03, 2016, 01:49:28 PM
For the 4 crossbeams I need U-profiles with dimensions of 13.5mm x 4.0mm x 200mm.
The relevant dealers sells either 12mm x 4.0mm or 15mm x 4.0mm.

Although I would have milled the U-profiles of a 4.0 mm flat profile, then the inner surfaces of the lateral flanks would not have become slightly conical, but only parallel.
A manufacturer could fabricate the profiles - in desired dimensions, however the setting costs for the machine are considerably – much more than the profiles themselves.

So I ordered four 15mm profiles with 250mm length.

In an MDF board I milled a groove (250mm long and 15.0mm wide).
The four profiles were laid into the recess. On each end 2 holes (3mm) were drilled. Small screws holds the profiles determined, while an 1.5mm router separats the parts in the middle.

Quertraeger_trennen_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Quertraeger_trennen_01.jpg)


The result are a 4x2 curved L-profiles (the braching was out).


Quertraeger_trennen_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Quertraeger_trennen_02.jpg)


Two half profiles shall soldered together – so I´ll get a height of 13.5 mm.

In addition I have milled small "shoes" of brass. That will keep the two halves in position when soldering.

Quertraeger_trennen_03 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Quertraeger_trennen_03.jpg)


Quertraeger_trennen_04 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Quertraeger_trennen_04.jpg)


Quertraeger_trennen_05 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Quertraeger_trennen_05.jpg)


Soon I will solder – hard or soft... I will test it.

 
At the tower beams I drawed a little bit further.

Profile by profile are drawn as single files. So its easier to position the holes for rivets or the center marks.

Traeger_Montage_36 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Traeger_Montage_36.jpg)


Traeger_Montage_39 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Traeger_Montage_39.jpg)


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on October 03, 2016, 04:07:48 PM
I've never seen anyone do that with brass. Incredible. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on October 03, 2016, 10:57:09 PM
I never cease to be amazed at how much effort you put into making this, and making sure it's exactly right!


Title: Re: Feldbahnmodule with ship
Post by: lab-dad on October 04, 2016, 05:59:43 AM
I look forward to seeing the soldering - before you clean it up!
Torch or iron?
-Mj


Title: Re: Feldbahnmodule with ship
Post by: Hauk on October 04, 2016, 07:39:36 AM
For the 4 crossbeams I need U-profiles with dimensions of 13.5mm x 4.0mm x 200mm.
The relevant dealers sells either 12mm x 4.0mm or 15mm x 4.0mm.

Crazy stuff. In a good way, of course.
A great inspiration to get some milling done myself.


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on October 12, 2016, 11:46:54 PM
Thanks a lot  :)

Present I am drawing the head of bridge support:


Oberhaupt_05 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Oberhaupt_05.gif)


Oberhaupt_06 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Oberhaupt_06.jpg)

The four weights that push down the bridge were raised and lowered by a winch.
The winch has four separate areas on its pulley for the ropes of the four weights.


Winde_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Winde_01.jpg)
Copyright: WSA-Lauenburg/Elbe


Winde_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Winde_02.jpg)
Copyright: WSA-Lauenburg/Elbe


Winde_03 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Winde_03.jpg)
Copyright: WSA-Lauenburg/Elbe


On the drawings I can see three pulleys (on the left side) leading the ropes down to the winch only. I´m missing the fourth pulley.


Oberhaupt_04 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Oberhaupt_04.jpg)
Copyright: WSA-Lauenburg/Elbe


The horizontal pulley (right side) I haven´t drawn yet!

Copyright: Lauenburger Elbschiffahrtsarchiv (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Hubbr_cke_LEA-261_mitte.jpg)
Feldbahn-Hubbrücke - Mittelteil


Title: Re: Feldbahnmodule with ship
Post by: 1-32 on October 13, 2016, 02:45:14 AM
love the color renderings.
cheers


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on October 14, 2016, 12:12:12 AM
Cool!


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on October 21, 2016, 07:09:05 AM
A small supplement to the functional sequence:

By default the bridge was lowered permanently.
At normal water level a minimum overhead clearance of 4.5m were given.
Also the light railway could pass the bridge and it had´nt take the other into consideration.
The floats are not floated on, and thus did not raise the bridge also because there was not water inside the two shafts at that time. The bridge rested by their weight and via the attached connecting float supports on the two carriers safely.
.

Only at a higher water level (f.e. snow melt floot) water streamed into the two shafts and lifted the bridge up to about 2.0m (circa 89mm in the model).

All moving vessels had always priority in traffic on the Elbe-Trave-Canal (later Elbe-Lübeck-Canal)!

Wanted a light railway to pass the obstacle and the ship traffic allowed it a worker lowered the four weights with a hand crank.
The buoyancy of the floats was calculated that the relatively low weight of four weights (each 500Kg) sufficient to press down the bridge, no matter how high the water level was in the shafts.
Also gate valves were closed so no additional water could flow into the shaft. Overflowing water was drained away through pipes.

Later the weights were uplifted by a worker again. The bridge was lifted by the residual water in the shafts and water comming from the canal after opening the gate valves.


As driving I will take an underfloor engine. The four ropes comming from the motor drive will be wounded over the pulley of the winch triple-fold.

Depending on direction of rotation the lifting or lowering of weights will take place. They weigh about 60 grams each. Whether that is enough for a smooth operation I´ll check on a test rack.


Antrieb-Seilwinde_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Antrieb-Seilwinde_01.jpg)
schematic diagram

Antrieb-Seilwinde_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Antrieb-Seilwinde_02.jpg)
schematic diagram


At the same time the hand crank shall move.
The pulley has a diameter of 10mm -  almost three rope revolutions would wound onto the roll (89mm way).
At a model gear ratio of 1/8 * 1/5 = 1/40  I would have to crank 120 times until the weights are raised or lowered.
So the motor drive has really turn slowly or I would have to crank by hand!
Lifting or lowering the original bridge itself took about 10 minutes.

The model drive is already working. I can make a choise between 24 seconds - 8.5 minutes. See here (http://www.buntbahn.de/modellbau/viewtopic.php?t=6691&postdays=0&postorder=asc&highlight=hubbr%FCcke&start=560) und as video (https://vimeo.com/76227275).



Meanwhile I have drawn to the winch a little bit -  in time two gears are missing only.


Winde-18 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Winde-18.jpg)


Winde-19 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Winde-19.jpg)


Winde-20 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Winde-20.jpg)


Zahnrad_43mm_136Z (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Zahnrad_43mm_136Z.jpg)


Zahnrad_43mm_136Z-02 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Zahnrad_43mm_136Z-02.jpg)


I´ll continue the construction if I know the real diameter of the individual gears I can buy.


Now I need an idea where I can get gears with module 0.3 or 0.4.
The upper table contains the converted dimensions of the original gears and the bottom I found at a dealer I trus.

Zahnrad_Tabelle (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Zahnrad_Tabelle.jpg)

I would like to use purchased parts (brass) and rework this a bit.

So far I have found diameter of 36mm with 120 teeth (module 0, 3) – in Germany.

Does anyone have experience with printed gears?

Which materials are helpfull?

Are there any problems with the surface roughness?


Title: Re: Feldbahnmodule with ship
Post by: 1-32 on October 22, 2016, 03:37:40 PM
hi Frithjof.
your modelling is so different to my efforts but i still like it.
you are basically a model engineer but differ from the lath art of the past.yourself  Volker and Helmut are mastering software to produce your rivet perfect models.
cheers kim


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on October 23, 2016, 12:17:54 PM
Hi Kim,

Thank you very much for your praise :-)

Today I soldered together the half profiles for the crossbeams.

Although I originally wanted to braze the parts, the first carrier was soldered soft. Until now it keeps together.


Quertraeger_trennen_06 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Quertraeger_trennen_06.jpg)


The surfaces were trimed with sandpaper first and afterwards with the sandblaster.

Quertraeger_trennen_06-Ausschnitt (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Quertraeger_trennen_06-Ausschnitt.jpg)

The still visible joint I will fill in with solder. Next four 3x3mm L-profiles will "riveted" to the beam. That would have sufficient stability to give.


Quertraeger_trennen_07 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Quertraeger_trennen_07.jpg)



Also the remaining gears for the winch were drawn.

An animation shows the function already.


Winde_Animation_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Winde_Animation_01.gif)



I'm still not quite sure how the four weights were built in the original.


Gewichte_05 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Gewichte_05.jpg)


I suspect that they consisted of three parts.

How they were connected to each other? In the middle area there was a continuous rod certainly... but how can I imagine the red dotted connections?


Gewichte_06 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Gewichte_06.png)


Gewichte_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Gewichte_01.jpg)


Gewichte_04 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Gewichte_04.jpg)


Title: Re: Feldbahnmodule with ship
Post by: EZnKY on October 23, 2016, 08:23:56 PM
Wouldn't the central vertical rod be enough to "connect" them together?  (Along with gravity of course!) 

What if the short vertical lines you've circled in red are just concealed alignment pins to keep the three sections from rotating around the vertical rod? 


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on November 03, 2016, 12:46:01 AM
Eric, you are right!

Now I have translocated the rotation prevention inside the weights, they are no longer visible from the outside.

Also I have modified the red fastening fitting for the cables.


Gewichte_15 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Gewichte_15.jpg)


They were arranged pairwise ...


Gewichte_16 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Gewichte_16.jpg)


... and milled from a 2.0mm MS58-sheet.


Gewichte_12 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Gewichte_12.jpg)


At the same time small filler pieces were milled. They keep safely the two legs over the drilling and milling process in the MDF gauge.


Gewichte_13 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Gewichte_13.jpg)


The two parts have been inserted together vertically into a milled groove of a MDF board. Then I milled two holes with a 0.8mm drill. In these holes I put 0.8mm wires. So I got an additional attachment of the two parts during separation with a 1.0mm router.


Gewichte_14 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Gewichte_14.jpg)


Small filthines at the edges will be slightly smoothed - with naked eyes they are barely visible.


The four weights have been milled also. As material served a brass profile (15.0mm x 5.0mm). The corners were rounded with a 1.0mm ovolo cutter - while simultaneously brought to a width of 14.2mm.


Gewichte_07 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Gewichte_07.jpg)


Gewichte_08 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Gewichte_08.jpg)


The weights were manufactured of three separate elements originally. The edges were chamfered. First I have scratched the joints with a 0.25mm blade 0.5mm deep from all sides. Thereafter the parts were pressed in MDF grooves and processed at the same area with a 90 degree V-cutter. The corners must be reworked with a small file.


Gewichte_09 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Gewichte_09.jpg)


The bevels on the lower section are cutted with the help of my the small circular saw. To ensure that all angles were equal I had cut to two small gauges from MDF.


Gewichte_11 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Gewichte_11.jpg)


Gewichte_10 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Gewichte_10.jpg)


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on November 03, 2016, 01:27:21 AM
I am constantly in awe of the precision you achieve in milling such small details.


Title: Re: Feldbahnmodule with ship
Post by: mspaw on November 03, 2016, 07:23:55 PM
Im blown away. Thanks so much for sharing and please, please keep it up.

-Michael


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on November 06, 2016, 06:28:52 AM
@Ray
Thanks, but it´s only a "cheese milling machine". May be it´ll be much more precise with a massive machine.

@ Michael
I´d be glad to.

The four weights are lifted or lowered at the same time from one winch.

Comming from the large pulley on the winch ...

Seilrolle_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Seilrolle_02.jpg)

the individual steel ropes run through various small pulleys (diameter 10.0mm).


Rollenmontage_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Rollenmontage_02.jpg)


Seilfuehrung_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Seilfuehrung_01.jpg)


I have milled the roll holders from a 12.0mm x 10.0mm MS58-square rod.

First the two 1.2mm holes were drilled.

Into the third 3.0mm hole a rod will be inserted later. This will hold the brass part accurately in position into the gauge while milling.


Rollenhalter_03 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Rollenhalter_03.jpg)


Seilfuehrung_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Seilfuehrung_02.jpg)


Afterthen a small pocket was milled into Pertinax and the brass block was putted inside.

 
Rollenhalter_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Rollenhalter_02.jpg)

Another hole was drilled to allow a small screw to fix all.

Next the above red marked area was milled with a 1.0mm cutter in steps of 0.5mm.
 
Rollenmontage_06 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Rollenmontage_06.jpg)


Rollenmontage_07 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Rollenmontage_07.jpg)


Rollenmontage_08 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Rollenmontage_08.jpg)


Rollenmontage_09 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Rollenmontage_09.jpg)


Rollenmontage_10 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Rollenmontage_10.jpg)

Now I have both, 3-roll holders and such for one role.
In the next step the parts will be separated from the brass rod, so that I´ll get the green-marked roll holder.


Rollenhalter_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Rollenhalter_01.jpg)


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on November 06, 2016, 12:54:35 PM
That should suffice. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: mspaw on November 06, 2016, 06:29:28 PM
Outta curiosity, What type milling bits are you using for your brass work? Ive worked in mainly acrylic, RenShape and aluminum. I gather brass is a dream to mill so I really should give it a try. Also any recommendations would be most appreciated.

-Michael


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on November 13, 2016, 05:44:42 AM
@Michael
Please have a look here (http://www.finescalerr.com/smf/index.php?topic=1424.285) to my post from September 17, 2016. Maybe your questions will be answered there. If not, let me know.

You wouldn´t believe how time-consuming is the making of the small parts.
For example, I needed for drawing, creation of milling files and the milling of the small plates for the roll holders finally two hours.
Cutting out from cardboard would have been faster, but it hadn´t made me happy  ;-)


Rollenmontage_11 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Rollenmontage_11.jpg)



The axle holders were fixed in an MDF teaching with 1.0mm wire sections and given the lack of 1.0mm holes.


Rollenmontage_12 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Rollenmontage_12.jpg)



For the pulleys with the required dimensions of 10.0mm x 2.2mm and a shaft hole of 1.2mm I made a find here: klick (http://www.modellbauschrauben.de/shop_detail.php?gruppid=58)


The width of these rope pulleys is  only 1.9mm instead of the required 2.2 mm - the axle hole has 2.0mm instead of 1.2mm.


So a 2.0mm MS58 rod was drilled out (1.2mm) and small segments were glued centrally into the 2.0mm axle hole (see lying role).

Now the role is located properly in the center and is running smoothly.


A quick photo was taken on the windowsill with overcast sky.


Rollenmontage_14 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Rollenmontage_14.jpg)


Rollenmontage_13 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Rollenmontage_13.jpg)


Title: Re: Feldbahnmodule with ship
Post by: Allan G on November 13, 2016, 11:00:33 AM
I'm not sure there are words to describe this incredible "art".  Allan


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on November 13, 2016, 01:56:30 PM
I agree with Allan. I also must compliment your professional quality photography. Most satisfactory. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on November 13, 2016, 08:35:08 PM
Ditto to the previous comments!



Title: Re: Feldbahnmodule with ship
Post by: mspaw on November 14, 2016, 09:19:43 AM
Its very satisfying just watching the process unfold. Thanks for  sharing with us!


Title: Re: Feldbahnmodule with ship
Post by: nk on November 27, 2016, 12:21:28 PM
This is an amazingly professional build. Well beyond being a hobby. I am deeply impressed at your micro engineering.


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on November 28, 2016, 06:28:36 AM
Thanks to all of you – now im going red in my face ;-)

The upper metal end of the sluice walls will arise from 10.0mm x 8.0mm brass profile .


Metallkante_1_25mm_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Metallkante_1_25mm_01.jpg)


For test purposes I profiled Ureol rods and the brass profiles afterwards.

Metallkante_1_25mm_03 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Metallkante_1_25mm_03.jpg)


In a MDF gauge (8.0mm deep) the bars were tightly inserted and milled with a 3.0mm router - first the green and blue marker.
Later the 1.25mm quarter round cutter rounded the red zone.


Metallkante_1_25mm_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Metallkante_1_25mm_02.jpg)


I got a link for small gears from a colleague of Buntbahn forum: click (http://shop.kkpmo.com/index.php?language=en&cat=c27_M0-3-Spurgear-Gears-Pinions-M0-3---Gearwheels---Pinion---Spurgear.html&listing_sort=&listing_count=96&cPath=21_27&=)

Unlike other vendors you can choose many gear diameter and also the diameter of the shaft and the thickness. I got the ordered parts within one week!

Although I couldn´t get my wanted pairing with the corresponding number of teeth (21.0mm with 60 teeth and 4.2mm with 12 teeth), I have selected two gears with which I received the same hole distance of axles.
Now I have 19.8mm (64teeth) + 5.4mm (16teeth) with modulus of 0.3.
The original dimensions converted to 1: 22.5 needed modulus of about 0.35.



Winde_21 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Winde_21.jpg)


The larger gear was fixed in a hard paper gauge and both sides were deepened in the central region at 0.7 mm. So I could save a lot of weight   :)


Winde_22 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Winde_22.jpg)


Winde_23 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Winde_23.jpg)


First "rehearsal" - the hole spacing is correct. Although the diameter and the gear ratio (now 1: 4 instead of 1: 5) are not exactly, I will be able to stand it.

Winde_24 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Winde_24.jpg)


Title: Re: Feldbahnmodule with ship
Post by: lab-dad on November 29, 2016, 07:03:52 AM
Where is the spoked gear coming from?
Or are you going to modify a solid one?

Great gear site - thanks!

-Marty


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on November 29, 2016, 12:20:04 PM
Hi Marty,

Initially I purposed to let make the large gear with wire EDM from 3mm MS58. Only the 2.0mm center hole and the outer contour should be eroded with the wire.

After I had made very good experience with the gear provider, I remembered the note at Buntbahn forum that also special diameter up to 45mm would be possible.
My last night query was made today in positive views.
However, even 45mm material must be ordered ... but that should be there on Wednesday and then two gears should be manufactured (just to be on the safe side one more, if I make a mistake during further processing!).

The price is very interesting - around a quarter of the cost over a wire EDM.

Like the last gear I will do all following cuttings with the help of a hard paper gauge.


Zahnrad_136-Zaehne (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Zahnrad_136-Zaehne.gif)



Today I got two small pulleys from a friendly precision mechanic master.
For this purpose he had honed a small lathetool.
So clean I wouldn´t have done ... not yet, maybe I can learn that too.
The grinding of cutting tools maybe an art in itself, I only saw it at youtube.


Seilrolle_03 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Seilrolle_03.jpg)

The central webs from the right pulley are high as the edges.
Let's see if the ropes (they are running up in a slight angle) are not jumping into the neighboring chamber.



Title: Re: Feldbahnmodule with ship
Post by: SandiaPaul on November 30, 2016, 05:33:33 AM
I have been following this right from the start. Your techniques are excellent and thus the results!
Look forward to more, thanks for taking the time to post it!

Paul


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on January 15, 2017, 04:43:35 AM
Paul,
Thanks for your praise :)

After a few parts of the wall were milled a second time (I actually thought I had it already milled long, long time ago .....), they were painted grey with  a hard brush and various gray acrylic colours. So they paint reached to the joints of the wall.
All 25 individual wall parts dried one day. Afterthen they were smoothed slightly at the surface with 400 sandpaper and then sucked off.

Like the walls in former times all parts were painted with Plaka No. 25. For this I used a rubber roll, shown here (http://www.buntbahn.de/fotos/showphoto.php?photo=51094&size=big&password=&sort=7&thecat=7452).


The paint was applied to a glass plate and then rolled out thinly with the rubber roller. Then I rolled over the masonry several times. Each time only a bit of color were taken, so the wall joints couldn´t fill up.

After half of the wall parts were painted red, I arranged it to the module for a first blocking rehearsal.


Modul-Montage_009 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Modul-Montage_009.jpg)


Meanwhile all parts of the walls are coated red, except a small part on the left part.

The connection on the left of the staircase is curved slightly in length and a little bit transversal in the height.

Mauer_rund_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Mauer_rund_01.jpg)
Copyright: Lauenburger Elbschiffahrtsarchiv

Mauer_rund_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Mauer_rund_02.jpg)
Copyrigth: Slg_Frenzel/Oppermann


For this wall I used 1.0mm waterproof glued plywood. The upper edge consists of ureol blocks.

Here already the loosely assembled parts:


Mauer_rund_03 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Mauer_rund_03.jpg)


Mauer_rund_04 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Mauer_rund_04.jpg)


Slowly the left wall of the sluice gateway grows in appearance.


Spanten_Wand_schraeg-01 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Spanten_Wand_schraeg-01.jpg)

So I cut the frames for the "round" wall and mounted it.

Modul-Montage_011 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Modul-Montage_011.jpg)
So far the Uriol- (calcareous sandstone) blocks in the picture are arranged loosely.


All the parts were pasted with waterproof wood glue and reinforced with remains of poplar plywood and various bars from the back.
With a 90 degree angle iron the alignment of the walls was thereby constantly controlled.


Modul-Montage_010 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Modul-Montage_010.jpg)


Title: Re: Feldbahnmodule with ship
Post by: Bill Gill on January 15, 2017, 07:22:49 AM
Many materials, many techniques, one remarkable result!


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on January 15, 2017, 02:55:57 PM
The techniques are creative and professional and their implementation outstanding. All in all, rather adequate. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on January 15, 2017, 07:56:06 PM
It's great to see it all coming together.



Title: Re: Feldbahnmodule with ship
Post by: fspg2 on January 24, 2017, 12:37:42 PM
With Photoshop I created a floot marker.


Pegel_5_2mm_breit (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Pegel_5_2mm_breit.jpg)

 
For trial I printed it out on plain paper and attached it to the wall tentatively.


Modul-Montage_014 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Modul-Montage_014.jpg)


As font I used  "Leipzig Fraktur", but that pleased me not really. The figures are to small in height to recognize from afar.
The next test I'm going to print that floot marker to high-gloss photo paper (290gr.)  Then I´ll proceed with superglue - as Volker shows here  (http://www.finescalerr.com/smf/index.php?topic=2257.120).


Modul-Montage_016 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Modul-Montage_016.jpg)


The large corner UREOL-"calcareous sandstones" I have mutually mounted on two 8.0mm brass tubes and glued with superglue.

Modul-Montage_012 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Modul-Montage_012.jpg)


Stone by stone I checked the accuracy of fit in the sidewall.
Before they were finally glued to the two walls, I smoothed the visible surfaces with sandpaper. Then the sandblaster went into action to roughen the surface evenly.


Modul-Montage_013 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Modul-Montage_013.jpg)


To position the western bridgehead I put it on a print in scale 1:22.5. This shows the location of the lateral „mounds“.


Modul-Montage_017 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Modul-Montage_017.jpg)


Modul-Montage_018 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Modul-Montage_018.jpg)


At the following picture you can see the old bridge from 1901 und a new one from the beginnig of the 1950s.


Hubruecke_1901-1965 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Hubruecke_1901-1965.jpg)
Copyright: Lauenburger Elbschiffahrtsarchiv


This was necessary because the old bridge of 1901 could not longer satisfying the requirements.
Also you can see that the new lift bridge has 10 (instead of 11) fields only.


Hubbruecke_Archiv_0-3 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Hubbruecke_Archiv_0-3.jpg)
Clipping of archive from 1942


The old bridge was closed for traffic in April at beginning1950s.


Offers were invited for a new construction.


Angebot_Neubau_01_04_1950 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Angebot_Neubau_01_04_1950.jpg)
Clipping of archive from 1950

The funding were advanced by the city as a loan to the participating companies. The match factory in Lauenburg and the brickyard Basedow were previously the only users of this bridge. It was hoped to attract other industrial companies for the shared use of the new bridge - but without success. The truck won and took possession of all transport tasks done faster, without having to reload the goods.


Die_Bruecke_30_08_79 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Die_Bruecke_30_08_79.jpg)
Slg:Hellmich


This bridge was already demolished 15 years later again. The Lauenburger Schiffer club had tried in vain to acquire this bridge.


08_Hubbruecke_1964 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/290308_Hubbruecke_1964.jpg)
Slg:Hellmich


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on January 25, 2017, 01:22:19 AM
This build is so interesting, I'll be sorry to see it end when you finally get it finished!


Title: Re: Feldbahnmodule with ship
Post by: Bill Gill on January 25, 2017, 07:19:59 AM
This is a wonderful project to follow.


Title: Re: Feldbahnmodule with ship
Post by: nk on January 29, 2017, 12:35:50 PM
I love all the research that has goneon to make the build a reality. And the quality of the build itself is seriously impressive


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on March 01, 2017, 02:57:09 PM
@Ray
I think this projekt will never be finish up. There are a lot of little parts I´ll recreate ;-)

@ Bill and nk
thanks, I’m glad you like it


Long time ago a friend cutted the first UREOL- stones with his precision saw.

Sandstein_Ecke_006 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Sandstein_Ecke_006.jpg)

Unfortunately I had made a mistake.


The cornerstones of the floodgates were made with the same length and width as the front cornerstones. The height was right, but they were about 10mm too short and too small....
So they had to be remake.

5cm strips were cut from an Ureol residues block with a big circular saw.
The surfaces I smoothed with my milling machine and one edge was blunted with an 8mm-quarter round cutter.

The front sides I smoothed with a grinding wheel.


Sandstein_Ecke_007 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Sandstein_Ecke_007.jpg)


As the saw blade to my Böhler-saw is too small, I had to saw the Ureol blocks from two sides.
For this I had fixed a MDF plate with clamps on the saw table right-angled.


Sandstein_Ecke_008 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Sandstein_Ecke_008.jpg)


Sandstein_Ecke_009 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Sandstein_Ecke_009.jpg)


All parts I smoothed again with the grinding wheel, as you could see a slight edge in the middle and and partly saw blade marks.

Sandstein_Ecke_010 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Sandstein_Ecke_010.jpg)


On the following picture you can compare the new bricks and the old one. They are only loosely laid.

Sandstein_Ecke_011 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Sandstein_Ecke_011.jpg)

Now the stones must be cut to the correct length and width before I can glue it.

Sandstein_Ecke_013 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Sandstein_Ecke_013.jpg)


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on March 22, 2017, 12:36:24 PM
After I had brought the UREOL "limestone sandstone" at the sluice gates to the right dimensions and had chamfered the edges,

Sandstein_Ecke_014 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Sandstein_Ecke_014.jpg)

they were glued.

Sandstein_Ecke_16 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Sandstein_Ecke_16.jpg)

The border edge on the left side I adjusted to the same level of the right plate.

Mauer_rund_05 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Mauer_rund_05.jpg)

For this I planned a remain UREOL part to 10mm height with the help of a 16mm cutter.
The outer contour were milled with an 1.5mm cutter.

Mauer_rund_08 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Mauer_rund_08.jpg)

The milling cutter was inclined by 12° for the oblique edge. The UREOL part was guided along a gauge (with the same inner rounding).

Kante_fraesen_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Kante_fraesen_01.jpg)

Mauer_rund_06 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Mauer_rund_06.jpg)

Mauer_rund_07 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Mauer_rund_07.jpg)


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on March 22, 2017, 12:50:29 PM
Perfect. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on April 01, 2017, 03:29:51 AM
Recently I bought some new furnishings in 1: 22.5 from Manufaktur FT click here (http://www.manufaktur-ft.de/epages/63860341.sf/de_DE/?ObjectPath=/Shops/63860341/Categories/Category1/Schraenke_und_Co). 

All parts are made of cardboard.

If one doesn´t put up the parts directly in the foreground or you look through a window only, the board character doesn´t catch your eye.

I will put one of the high desks into my old storage shed with the open rear wall.


However, a part of metal and wood I would prefer.

Stehpult_04 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Stehpult_04.jpg)


As a little finger exercise in between I drew this high desk...

Stehpult_01 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Stehpult_01.jpg)

... and milled the first parts of nickel silver and brass.


Stehpult_02 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Stehpult_02.jpg)


Stehpult_03 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Stehpult_03.jpg)

Unfortunately I had break because my milling spindle motor went on strike ..... well, he has worked about 3,000 hours in the last 12 years. And I only had to replace the coals three times.


The unrolling for the box I folded using a square rod and a thin nickel siver plate. The edges were grooved with a 91° V-cutter previously.


Stehpult_05 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Stehpult_05.jpg)


After I tried to repair the milling motor (I cleaned and oiled the inner parts), I wanted to know if I could save him or not?

In addition I drawed a gauge for mounting the lectern box and milled it from 5.0mm Pertinax.

The old Kress milling motor sounded not good, ... the coals are fine ... I suspect that a bearing is defective.

So far the engine has participated well, maybe he senses so that I will get a new milling machine soon - a Frieda (http://www.rc-network.de/forum/showthread.php/547293-Fräse-quot-Frieda-quot).


But the result is ok:

Stehpult_06 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Stehpult_06.jpg)


Stehpult_07 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Stehpult_07.jpg)

Next step will follow soon – I ordered a new Kress 1050 FMT 1.


Title: Re: Feldbahnmodule with ship
Post by: Bill Gill on April 01, 2017, 06:10:42 AM
Nice! I hope your new milling machine understands what great work will be expected of him :)


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on April 01, 2017, 12:28:16 PM
Ho-hum, perfection as usual. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on April 01, 2017, 09:16:11 PM
Fantastic work as usual. Too bad about the dying mill, but at least you'll be getting a shiny new one. I hope it gives you many good years of service.



Title: Re: Feldbahnmodule with ship
Post by: Sami on April 03, 2017, 09:57:56 AM
Perfect work !


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on April 10, 2017, 02:11:00 AM
After a new milling motor was commissioned, I could mill out two jigs from Pertinax.


Stehpult_08 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Stehpult_08.jpg)


Stehpult_09 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Stehpult_09.jpg)


Stehpult_10 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Stehpult_10.jpg)



Next, the cover plate for the high desk came into line.

Stehpult_15 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Stehpult_15.jpg)


Only for one single pedestal desk I would never even bothered to do it with the Pertinax teachings, but for a small series already.


Stehpult_13 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Stehpult_13.jpg)

So a new milling file was created.

Stehpult_14 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Stehpult_14.jpg)


Into a 0.3 mm nickel silver plate four 2.0mm holes were drilled first. Afterthen 0.15mm deep grooves for the bending edge were milled with a V-cutter. The plate had been glued with Gudy 870 on the MDF board.

Stehpult_11 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Stehpult_11.gif)


Then the sheet was dissolved from the wooden board using a thin cutter blade. I removed the remnants of the adhesive film. Now the second side was provided with Gudy 870.
Into the previously drilled four holes I put brass pins to align the back of the nickel silver plate. Then the bending edges and the external contours were milled.


Stehpult_12 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Stehpult_12.jpg)

After that I bent the sheets with the help of two brass profiles, into which I saw 0.3mm wide slots.


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on April 10, 2017, 12:04:40 PM
That is so sophisticated I think I'm getting a headache! -- ssuR


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on April 12, 2017, 12:05:23 AM
These methods are so far beyond me, yet still fascinating to see!


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on April 14, 2017, 12:58:09 PM
Russ, Ray - Thanks :)

Today, the first high desk was soldered - the Pertinax gauge helped. Then I cutted off the overhanging legs.

Stehpult_17 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Stehpult_17.jpg)


The pertinax teaching has been aligned to the saw table and secured with crepe tape. The saw blade was slowly moved from bottom to top while sawn off the excess L-profiles.

Stehpult_18 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Stehpult_18.jpg)


Stehpult_19 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Stehpult_19.jpg)

The foreman noticed immediately that there were a few parts still missing: the cover plate, the wooden boards on the lower shelf and the button on the drawer.

Stehpult_20 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Stehpult_20.jpg)


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on April 24, 2017, 11:38:13 PM
In search of other equipment and furnishing for my old shed, I came across an old work barrow on the webside of Paul Petau. However, he offered this only in scale 1: 43.5. Look here (http://web271.webgo24-server4.de/Gambio/gx2/Anlagenzubehoer/Werkstattwagen-2--Bausatz-mit-Holzbeplankung--ohne-Ladegut-Nr--239.html).
So I draw a little bit  and cut the first parts on my small circular saw.


Alter_Transtportwagen_01 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transtportwagen_01.jpg)


Alter_Transtportwagen_02 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transtportwagen_02.jpg)


Existing limewood cutting boards were cut to 9.4 mm width and 1.0 mm thickness.

Alter_Transtportwagen_03 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transtportwagen_03.jpg)


Always 9 boards were glued on both sides to an 0.2 mm nickel silver plate.
So I got a material thickness of 2.2mm.

Alter_Transtportwagen_09 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transtportwagen_09.jpg)

The correct wide caused the circular saw again. So that the wood doesn´t frazzled, it was secured with tape previously.
 
Alter_Transtportwagen_04 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transtportwagen_04.jpg)


With the milling machine a 1.5mm deep slot was cuttet in MDF and the boards got 0.8mm holes in two rows.

Alter_Transtportwagen_05 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transtportwagen_05.jpg)


Alter_Transtportwagen_06 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transtportwagen_06.jpg)

The milled brass frame received the same holes. 

Alter_Transtportwagen_08 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transtportwagen_08.jpg)


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on April 25, 2017, 12:23:15 AM
Nice. I like the idea of sandwiching some metal between the planks to give it strength, without detracting from the appearance.



Title: Re: Feldbahnmodule with ship
Post by: finescalerr on April 25, 2017, 12:54:42 AM
Beautiful fabrication. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Bill Gill on April 25, 2017, 06:45:38 AM
Nicely planned and constructed. The model will look really good and not be too fragile.


Title: Re: Feldbahnmodule with ship
Post by: lab-dad on April 27, 2017, 05:52:15 AM
Great!
I assume you will make the wheels?
Looking forward to seeing that process!!!!

-Marty


Title: Re: Feldbahnmodule with ship
Post by: LesTindall on April 27, 2017, 01:18:30 PM
Yes, I'm particularly interested in how you do the wheels. I have a project on the go which uses similar wheels.

Les


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on April 28, 2017, 04:13:09 PM
Thanks for your interest ☺

Now I´ll go on with the wheels. They have a diameter of 26.5mm.

Alter_Transtportwagen_10 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transtportwagen_10.jpg)

With Sheetcam the milling file (.tap) was created.

Alter_Transtportwagen_11 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transtportwagen_11.gif)


Each two wheel halves were cut from 2.0mm brass sheet.

Alter_Transtportwagen_12 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transtportwagen_12.jpg)


Alter_Transtportwagen_13 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transtportwagen_13.jpg)


The two wheel halves were soldered together. Then I smoothed the tread with sandpaper on my lathe. The first iron wheel is burnished already.


Alter_Transtportwagen_14 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transtportwagen_14.jpg)


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on April 28, 2017, 07:51:43 PM
Wow! Just...wow!


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on April 29, 2017, 01:15:12 AM
Ditto. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: 1-32 on April 29, 2017, 03:45:38 AM
love the trolley cheers


Title: Re: Feldbahnmodule with ship
Post by: lab-dad on May 01, 2017, 11:48:05 AM
Nice!
CNC makes it (look) easy!
Marty


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on May 05, 2017, 01:12:03 PM

Today only a small update.

Thus, the last parts for the old transport trolley were milled and the first frame soldered.


Alter_Transportwagen_15 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transtportwagen_15.jpg)



Alter_Transportwagen_17 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transtportwagen_17.jpg)


Alter_Transportwagen_18 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transtportwagen_18.jpg)


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on May 06, 2017, 01:15:14 AM
That is just beautiful. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Bill Gill on May 06, 2017, 04:08:01 PM
I agree with Russ: Beautiful!


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on May 06, 2017, 10:22:45 PM
Yep, definitely beautiful!


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on May 08, 2017, 12:26:12 AM
Russ, Bill, Ray: Thanks for your commendation.

Currently there are only small steps that I can tell about.


The front axle has been soldered together. Small rectangular Pertinax blocks helped for this.
Both laterals received two 0.8 mm holes and were pinned with small rivets.
(A 0.8mm wire was no longer in my junk box, so the rivets.)


Alter_Transportwagen_19 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_19.jpg)


The rivet heads I grinded on a sandpaper file.


Alter_Transportwagen_20 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_20.jpg)



The remaining wheel halves were soldered together.
To smooth the outer surfaces of the tires, I've screwed it into a gauge ....

Alter_Transportwagen_21 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_21.jpg)


... and the lathe did the rest.

Alter_Transportwagen_22 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_22.jpg)


Now a first rehearsal on four wheels.

Alter_Transportwagen_23 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_23.jpg)


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on May 08, 2017, 12:47:12 AM
Wow!


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on May 08, 2017, 12:04:58 PM
Now I know your secret for doing such perfect work: You talk the lathe into doing everything for you but you take all the credit! -- ssuR


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on May 16, 2017, 01:05:49 AM
@Russ  Please don´t tell anyone  ;)


I must confess, on the website of Paul I discoverd a  smaler transport trolley (http://web271.webgo24-server4.de/Gambio/gx2/Anlagenzubehoer/Sonstiges/Transportwagen-1--1x-Nr--223-430.html). I liked it so much that I had to build it in scale 1:22.5.

First it was drawn a little bit:

Alter_Transportwagen_klein_01 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_klein_01.jpg)


Alter_Transportwagen_klein_03 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_klein_03.jpg)


Alter_Transportwagen_klein_04 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_klein_04.jpg)


The workshop wagons will be build as welded version. Made of 2.0mm and 1.5mm brass sheets, the side bolsters and the axle bearings were milled.

Alter_Transportwagen_klein_05 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_klein_05.jpg)


Alter_Transportwagen_klein_07 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_klein_07.jpg)


Synthetic resin bonded paper gauges facilitate the installation of the crossbars.

Alter_Transportwagen_klein_08 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_klein_08.jpg)


Alter_Transportwagen_klein_10 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_klein_10.jpg)


The foreman must always complain about - of course he immediately noticed that the wheel is slightly oversized.

Alter_Transportwagen_klein_09 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_klein_09.jpg)


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on May 16, 2017, 01:18:03 AM
Either you never sleep or you have learned how to create beautiful parts very efficiently. It would take me a month to make just one part ... and it would look a lot worse than yours. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Bill Gill on May 16, 2017, 05:28:32 AM
Another terrific start! Maybe a little filing can resize the wheel :)


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on May 16, 2017, 09:58:23 PM
You're a wizard of miniature fabrication!



Title: Re: Feldbahnmodule with ship
Post by: fspg2 on May 23, 2017, 01:35:43 PM
Russ, Bill, Ray - Thanks!  :)


See how the Pertinax gauges looks after four trolleys were soldered.


Alter_Transportwagen_klein_11 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_klein_11.jpg)


On the next image you can see in front left one unit before sandblasting, the other three frames are blasted.


Alter_Transportwagen_klein_12 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_klein_12.jpg)


At the old trolley the shaft is still missing.


Deichsel_01 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Deichsel_01.jpg)


For the cross-connection I have milled a little gauge with an 1.5mm ball cutter.


Deichsel_quer_bohren_01 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Deichsel_quer_bohren_01.gif)


Deichsel_quer_bohren_02 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Deichsel_quer_bohren_02.jpg)


In the vice both oblique holes were placed vertically by the help of a second gauge.


Deichsel_quer_bohren_03 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Deichsel_quer_bohren_03.jpg)


In order that the rod doesn´t rotate during drilling the second hole, the rod was fixed inside with adhesive tape and additionally secured with an 1.5 mm round bar.


Deichsel_quer_bohren_04 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Deichsel_quer_bohren_04.jpg)


The two long shaft halves were "sharpened" in a hard paper gauge.


Deichsel_quer_bohren_05 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Deichsel_quer_bohren_05.jpg)


Deichsel_quer_bohren_06 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Deichsel_quer_bohren_06.jpg)


Title: Re: Feldbahnmodule with ship
Post by: Bill Gill on May 23, 2017, 04:10:54 PM
It's pleasing and inspiring to see the consistently high quality of your work.


Title: Re: Feldbahnmodule with ship
Post by: 1-32 on May 24, 2017, 12:41:32 AM
as always a great series of photos of lovely work.
cheers kim


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on May 24, 2017, 01:22:09 AM
It is easy for us to see the perfection of your work but we usually forget to mention the intelligence and talent that goes into the planning, design, and jigs. I think all of us would agree your work is adequate. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on May 25, 2017, 12:26:57 AM
Marvelous work!


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on May 25, 2017, 12:04:30 PM
@ Bill, Kim, Russ, Ray   
You make me quite confuse, with so much praise - all this is no witching :-)

It goes on, but only a little für time reasons. 

I milled the wheel discs for the little trolleys and soldered it together.

Alter_Transportwagen_klein_13 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_klein_13.jpg)


Alter_Transportwagen_klein_14 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_klein_14.jpg)


Alter_Transportwagen_klein_15 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_klein_15.jpg)


To smooth the running surface, I will build a small gauge from an 8.0mm aluminum or brass rod. Here it´s already drawn:

Alter_Transportwagen_klein_16 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_klein_16.gif)



To get equal shafts for the large trolley, I also milled a small gauge from 1.0mm brass sheet.
Deichsel_quer_bohren_07 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Deichsel_quer_bohren_07.jpg)


Deichsel_quer_bohren_08 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Deichsel_quer_bohren_08.jpg)


Deichsel_quer_bohren_09 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Deichsel_quer_bohren_09.jpg)


Deichsel_quer_bohren_10 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Deichsel_quer_bohren_10.jpg)


Title: Re: Feldbahnmodule with ship
Post by: Gordon Ferguson on May 28, 2017, 11:35:00 AM
I always love seeing new posts on this thread , the ideas and execution of them is a wonder to behold .

In many ways I wish I had my time again to be able learn the skills and techniques demonstrated on every page so I hope you will forgive for posting this picture ........ It's only posted due my sense of humour and to demonstrate a completly opposite approach

It's plastic , it's made using only hand tools ......... Scalpel, dividers , sanding sticks, the only power tool used was an electric drill at the end just to do a final truing up ......... Overall dia 19mm / about 3/4 inch

Used this master to cast up copies in resin

(http://i232.photobucket.com/albums/ee275/gfadvance/Andrew%20Barclay%20Narrow%20Gauge%20Loco/image_zpsufawphls.jpeg)


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on May 28, 2017, 12:20:22 PM
Satisfactory nonetheless. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Bill Gill on May 28, 2017, 03:05:36 PM
Gordon, your skills and models are excellent. The choice of materials and tools take nothing from that.


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on May 29, 2017, 12:18:12 AM
Excellent work, Gordon!


Title: Re: Feldbahnmodule with ship
Post by: Allan G on May 29, 2017, 08:58:44 AM
"INCREDIBLE".....Allan


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on June 01, 2017, 02:11:30 PM
Gordon, I´m enthused about your skills - it looks great :)


The shafts of the larger trolleys should be hard-soldered.
For this I had  put the prepared 1.5mm wires into the milled gauge and coated it with brazing paste from Bengs and placed everything on my ceramic soldering plate.
Micro flame on it ....the paste swelled a little, turned gray and gray ... but didn´t want to be silvery and connect themselves to the brass rods.
I suspected that my brass gauge took away too much heat - so a new jig was milled (with larger cutouts around the solder joints) ... with the same result.

Then the gauge was raised slightly .... lo and behold, now it worked as usual. So the solder plate had played a trick on me.


Alter_Transportwagen_26 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_26.jpg)


Also the same soldering jig served as a fence for the saw - here the tip was separated ....


Alter_Transportwagen_24 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_24.jpg)

... and the edge was rounded with an 1.5mm ball cutter.

Alter_Transportwagen_25 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_25.jpg)


The first old trolley is almost ready .... he must be grown old a little.

Alter_Transportwagen_27 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_27.jpg)


For the small trolley I had milled the steering roller holder -  made of 0.5 mm nickel silver.

Alter_Transportwagen_klein_17 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_klein_17.jpg)


The other small bearings were milled – they are waiting for the assembly.

Alter_Transportwagen_klein_18 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_klein_18.jpg)


Title: Re: Feldbahnmodule with ship
Post by: eTraxx on June 01, 2017, 05:10:14 PM
Geeze. Watching the world class work in the thread is both wonderful and depressing ... ha.


Title: Re: Feldbahnmodule with ship
Post by: Bill Gill on June 01, 2017, 06:21:14 PM
Frithjof, following along your construction by looking through your lens rather than over your shoulder is a very enjoyable and educational experience.


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on June 01, 2017, 10:13:42 PM
I'm loving it!


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on June 02, 2017, 01:11:39 AM
"World class" is no exaggeration. (The same applies to a few others here.) -- Russ


Title: Re: Feldbahnmodule with ship
Post by: nk on June 04, 2017, 11:10:57 AM
This is incredible stuff. WOW


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on June 11, 2017, 10:58:19 AM
Thanks to all  :)

Meanwhile, I have build a gauge to smooth the tread of the small wheels.
Just as here (http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_klein_16.gif) being planned, it worked:
From an 8.0 mm aluminum rod material was removed by turning to 7.0mm in the front region, an 0.8mm and a 2.5mm hole was centered recess drilled.
The 0.8mm hole was drilled with an 1.0mm tap.
Four 1.5mm holes at a distance of 2.3 mm (calculated from the middle) were drilled also. From hole to hole the rod was rotated 90 °.


Alter_Transportwagen_klein_19 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_klein_19.jpg)


Alter_Transportwagen_klein_20 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_klein_20.jpg)


Into two of the outer holes 1.5 mm brass pins are inserted. An 1.0mm screw fixed all centrally.
After that I was able to turn the outer surfaces.

Alter_Transportwagen_klein_21 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_klein_21.jpg)


Alter_Transportwagen_klein_22 (fspg2)
(http://www.buntbahn.de/fotos/data/8054/2903Alter_Transportwagen_klein_22.jpg)


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on June 11, 2017, 12:58:29 PM
Another adequate development. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on February 14, 2018, 02:27:14 PM
The last few months, I didn´t handle on model building.
I had another construction site.
A new milling machine was purchased as a pre-assembled part set.
I had reported at the Buntbahn Forum about it. Post from 2017/07/06 click (http://www.buntbahn.de/modellbau/viewtopic.php?t=6691&postdays=0&postorder=asc&start=800) Please us Google translation, if you want.

Soon I will continue to build my models ☺


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on February 14, 2018, 08:27:09 PM
Good to hear you will be resuming model work soon!


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on February 15, 2018, 01:32:19 PM
I was wondering where you were .... -- Russ


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on April 15, 2018, 01:20:29 AM
At the moment I am using the milling-free time to draw what has remained lying around, so that the milling machine will soon get something to do again.
It has already passed a few days, where I had last worked on the old port crane. (  Contribution from 2012/08/06  (http://www.finescalerr.com/smf/index.php?topic=1424.105) )


From the boom of the old Münzel crane, unfortunately, I have only a few photos, which can only guess the rough dimensions.

Muenzel-Kran_051 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_051.jpg)
Münzel-Kran_Lauenburg (Copyright W.Hinsch-LEA)


Muenzelkran_Lbg_2k (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzelkran_Lbg_2k.jpg)
Münzel-Kran_Lauenburg (Copyright W.Hinsch-LEA)


Muenzel_Kran_LEA_03 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel_Kran_LEA_03.jpg)
Münzel-Kran_Lauenburg (Copyright W.Hinsch-LEA)

The search on the Web revealed a few images of old harbor cranes that revealed a few more details, e.g. hier (https://www.hamburger-fotoarchiv.de/bilder_hafen/frames/frames_2_465_061_29_fruchtschuppen_magdeburger_hafen.html). A wonderful archive of historical pictures!

So I'll try to construct the job as best I can.

Muenzel-Kran_136 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_136.jpg)

I borrowed the black background sketch in the above picture in the German eisenbahn magazin 82/3 and scaled it to 1: 22.5.

Muenzel-Kran_137 (fspg2)
(http://www.buntbahn.de/fotos/data/8181/2903Muenzel-Kran_137.jpg)


Title: Re: Feldbahnmodule with ship
Post by: 1-32 on April 16, 2018, 10:53:23 PM
hi Frithjof.
how are you I went through the photo reference on Hamburg I really enjoyed it cheers Kim.


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on April 18, 2018, 06:12:30 PM
Nice. I like the look of that crane. It will make an interesting model.


Title: Re: Feldbahnmodule with ship
Post by: Franck Tavernier on April 29, 2018, 03:02:09 AM
Hi Frithjof,

Crazy stuff!

What is the brand of lathe that you use? Proxxon?

Franck



Title: Re: Feldbahnmodule with ship
Post by: Lawton Maner on April 29, 2018, 04:20:45 AM
Brilliant work as usual.

The photos on the site where you introduced the new milling machine need no translation.  They are very easy to follow and illustrate how you do things quite well.   

Can you please tell us who is the manufacturer of the new milling machine?


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on May 03, 2018, 02:29:46 PM
@ Kim & @ Ray
Cranes have always been my favorite - especially the old ones

@Franck
My lathe came from this company: click (https://www.paulimot.de/drehmaschinen/mit-vario-antrieb/186/drehbank/drehmaschine-pm190-v-mit-frequenzgesteuertem-deutschen-motor)

@Lawton
The manufacturer of the my new milling machine P1: EMS-Möderl (http://www.ems-moederl.de/index.html)



About 1 1/2 years ago I searched for large gears for the winch (https://www.finescalerr.com/smf/index.php?topic=1424.300) of the lifting bridge (post #314). 

Winde-21 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Winde-21.jpg)

I got from Karl Heinz a reference to a Polish company (https://shop.kkpmo.com/index.php?language=en&cat=c21_Zahnraeder-und-Triebe-Zahnraeder-und-Triebe.html&XTCsid=4b2954cbdd400e735e84242bdf75797e&cPath=21&=&XTCsid=4b2954cbdd400e735e84242bdf75797e) that Cogwheels produces gears to order. Within a few days I had several neatly made small parts lying in front of me - and at a super price!

Winde_21 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Winde_21.jpg)


The production of the large wheel with 43.43mm diameter has been postponed several times. First, no material was available in the required diameter, then the new machine, which should make the production was not set up ... on my last request, I got unfortunately no answer.
Then by chance I came to a 3D print of this gear, but in plastic.
It worked with the existing smaller brass gears. However, I was not sure how the plastic would endure a permanent load on the fairly small teeth. So the parts remained lying in the box once. ;) ;)

After my positive brass casting experience with Shapeways, I then dared - today came the highly polished part of the post.

In the comparison with the plastic part can be seen in the brass version of the gear tips slight rounding. I suspect that the hand polishing has broken the tips a bit.
Since the gears mesh well, I assume a safe operation on the finished winch.

Zahnrad_136-Zaehne_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Zahnrad_136-Zaehne_02.jpg)


Title: Re: Feldbahnmodule with ship
Post by: Lawton Maner on May 04, 2018, 11:00:16 AM
Thanks for the link to the mill.
Another question.  Which CAD software do you use?


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on May 18, 2018, 08:08:29 AM
Hi Lawton,
it´s Inventor®: please look here (https://www.autodesk.com/education/free-software/inventor-professional)


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on July 29, 2018, 02:04:37 PM
There are already so many construction sites here ...... so let's start another one now  ;)

My field railway tracks are also supposed to get gravel.

Steigung_14_06_08_1 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Steigung_14_06_08_1.jpg)

Of course, I can distribute the gravel between the rails with the tried and true method with a spoon and brush ....

Some time ago I found an image of a small hand-held gravel cart from the field railway museum Glossen (unfortunately I can not upload the prototype photo because I do not know the source anymore), it became imitated in 1: 22.5.


Feldbahn_Schotterwagen (fspg2)
(http://www.buntbahn.de/fotos/data/9406/2903Feldbahn_Schotterwagen.gif)


Feldbahn-Schotterwagen_01 (fspg2)
(http://www.buntbahn.de/fotos/data/9406/2903Feldbahn-Schotterwagen_01.jpg)


Feldbahn-Schotterwagen_07 (fspg2)
(http://www.buntbahn.de/fotos/data/9406/2903Feldbahn-Schotterwagen_07.jpg)


Feldbahn-Schotterwagen_08 (fspg2)
(http://www.buntbahn.de/fotos/data/9406/2903Feldbahn-Schotterwagen_08.jpg)


The funnel was drawn as an unrolling ...


Feldbahn-Schotterwagen_09 (fspg2)
(http://www.buntbahn.de/fotos/data/9406/2903Feldbahn-Schotterwagen_09.jpg)


Feldbahn-Schotterwagen_10 (fspg2)
(http://www.buntbahn.de/fotos/data/9406/2903Feldbahn-Schotterwagen_10.jpg)


... and created a milling file.

The material I used is 0.3mm nickel silver sheet.

Here the colored lines mean:
Red = V-groove cutter 0.1mm tip with 0.15mm depth - bending edge
Green = V-groove cutter 0.1mm tip with 0.4mm depth - 45 ° edge
Blue = 1.2mm cutter with 0.5mm depth - edge with 90 °


Feldbahn-Schotterwagen_11 (fspg2)
(http://www.buntbahn.de/fotos/data/9406/2903Feldbahn-Schotterwagen_11.jpg)

Milling took 15 minutes - with two changes of milling cutter.


Feldbahn-Schotterwagen_12 (fspg2)
(http://www.buntbahn.de/fotos/data/9406/2903Feldbahn-Schotterwagen_12.jpg)


In addition, small assembly jigs were milled out of 5.0mm Pertinax.


Feldbahn-Schotterwagen_13 (fspg2)
(http://www.buntbahn.de/fotos/data/9406/2903Feldbahn-Schotterwagen_13.jpg)


Feldbahn-Schotterwagen_14 (fspg2)
(http://www.buntbahn.de/fotos/data/9406/2903Feldbahn-Schotterwagen_14.jpg)


Feldbahn-Schotterwagen_15 (fspg2)
(http://www.buntbahn.de/fotos/data/9406/2903Feldbahn-Schotterwagen_15.jpg)


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on July 29, 2018, 09:08:47 PM
I know I should be excited by the gravel car but, for some reason, the feldbahn tracks really got my attention. Please show more of the layout. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on July 30, 2018, 12:35:38 PM
Very cool!


Title: Re: Feldbahnmodule with ship
Post by: Bill Gill on July 30, 2018, 12:59:19 PM
Very good progress, excellent work. You didn't lose any skills even though you had to stop modeling for awhile.
All the metal work impresses me a lot!


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on December 16, 2018, 03:46:29 PM

It's been a while since I wrote (28.11.2016 (http://www.finescalerr.com/smf/index.php?topic=1424.300)):

Quote
The upper metal end of the sluice walls will arise from 10.0mm x 8.0mm brass profile.


Since then, the brass profiles slumbered half finished milled in a small box deep in a drawer and came only at cleaning up again to light.   

Recently, the last upper curves were milled at the edges with a 1.25mm quarter-end mill.
Then the small Böhler-saw was used and brought 45° miter to  the first profiles.

Thereafter, three 1.0mm holes were drilled vertically at the ends and in the center to precisely align everything with small pins on the MDF masonry and also to secure everything in gluing later.


Metallkante_1_25mm_04 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Metallkante_1_25mm_04.jpg)


Metallkante_1_25mm_05 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Metallkante_1_25mm_05.jpg)


Gradually, the parts are positioned on the upper edges of the lock walls on a trial basis.


Metallkante_1_25mm_06 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Metallkante_1_25mm_06.jpg)


Metallkante_1_25mm_07 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Metallkante_1_25mm_07.jpg)


Metallkante_1_25mm_08 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Metallkante_1_25mm_08.jpg)



Meanwhile, all brass profiles for the upper left edge are mitred ...


Metallkante_1_25mm_09 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Metallkante_1_25mm_09.jpg)


Metallkante_1_25mm_10 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Metallkante_1_25mm_10.jpg)


Metallkante_1_25mm_11 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Metallkante_1_25mm_11.jpg)


... and tentatively placed.

A small milled subframe helped to solder the small brass profiles around the ladder.


Metallkante_1_25mm_12 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Metallkante_1_25mm_12.jpg)


Metallkante_1_25mm_13 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Metallkante_1_25mm_13.jpg)


Metallkante_1_25mm_14 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Metallkante_1_25mm_14.jpg)


Metallkante_1_25mm_15 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Metallkante_1_25mm_15.jpg)


Next, the round edge will be profiled from a 10mm brass plate.

For this, the order for each surface milling passes was set in the CAD program.

Metallkante_1_25mm_16 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Metallkante_1_25mm_16.jpg)


Metallkante_1_25mm_17 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Metallkante_1_25mm_17.jpg)


Metallkante_1_25mm_18 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Metallkante_1_25mm_18.jpg)


Metallkante_1_25mm_19 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Metallkante_1_25mm_19.jpg)

Now the mill machine has to come into action.

Frithjof


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on December 16, 2018, 08:59:13 PM
As always, it is a pleasure to follow along with your progress on this project!


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on December 17, 2018, 01:17:14 PM
The precision and execution are beyond comprehension. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on December 17, 2018, 03:44:06 PM
Thanks for your consent.

It took less than an hour for the milling machine to mill the round metal edge.


Metallkante_1_25mm_20 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Metallkante_1_25mm_20.jpg)


Metallkante_1_25mm_21 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Metallkante_1_25mm_21.jpg)


Title: Re: Feldbahnmodule with ship
Post by: nalmeida on December 18, 2018, 05:47:28 AM
Wonderful work, I also do a lot of machining and I really appreciate all your posts. I do not post much but I find all your work amazing.


Title: Re: Feldbahnmodule with ship
Post by: Hydrostat on December 18, 2018, 06:10:22 AM
How are you going to achieve the butt joints?


Title: Re: Feldbahnmodule with ship
Post by: Bill Gill on December 18, 2018, 06:46:07 AM
Always enjoy seeing your work.


Title: Re: Feldbahnmodule with ship
Post by: Barney on December 18, 2018, 04:05:06 PM
Amazing just amazing - such precision
Barney


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on December 30, 2018, 05:13:16 AM
@Volker
I can´t give a clear answer to that. On all the pictures I know, I´m not been able to see any clear joints.... except here:

Crop_Schleuse_Lbg_22_07_1959 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Crop_Schleuse_Lbg_22_07_1959.jpg)
Slg:Hellmich

The photo is from 1959 and shows another area of the lock.


I will not solder all the brass profiles to each other so that the wood and brass parts can "move" when the temperature changes.



Now the first metal edges were placed on the wall.

Previously I have glued into the holes 1.0mm brass wire with shaft-hub joint-adhesive and sanded the tops smooth.
On the bottom the wire stopped about 5 mm long for precise assembly.
The parts were blasted and blackened.


Metallkante_1,25mm_23 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Metallkante_1_25mm_23.jpg)


Metallkante_1,25mm_24 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Metallkante_1_25mm_24.jpg)



Something to the ladders:

In July 2011, I had milled a gauge from Pertinax to build the two ladders for the locks walls.

what´s that? (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903was_wird_das.jpg)


The 1.0 x 2.0 mm thick model spars are 20.0 cm (17 steps) and 28.0 cm (24 steps) long and 20.28 mm wide. The soldering gauge heIps for clean aligned stairs.

Leiter_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Leiter_01.jpg)



After the protruding rungs outwards on both sides were cutted with an 0.3mm saw blade on my Böhler-saw (http://www.kaleas.de//kaleas.cgi?action=show&sessionID=67169088129424133767169088&lang=de&page=shop-produktliste.html&cat=32&subcat=3220&catname=S%E4gen,%20Fr%E4sen&arcode=x)
(similar to how here (http://www.buntbahn.de/fotos/data/8054/2903Alter_Lagerschuppen_028.jpg)), I had smoothed the outside with a sandpaper file.

Leiter_03 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Leiter_03.jpg)

Afterthen the two ladders were sandblasted.

Leiter_04 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Leiter_04.jpg)

Four 1.0 mm holes in the wall pick up the pins at the ends of the brackets.

Leiter_05 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Leiter_05.jpg)


Now I would like to thank all of you for your participation - but especially at Russ for the opportunity to write here in this great forum!

Have a good start for 2019!


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on December 30, 2018, 02:26:19 PM
Everything looks perfect. I find no room for improvement. Satisfactory. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on December 31, 2018, 12:04:17 AM
Once again a well-made jig proves its worth!


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on January 03, 2019, 03:25:37 PM
I could do only a little "earthworks" the last days.

So I installed the mooring (http://www.buntbahn.de/modellbau/viewtopic.php?t=6691&postdays=0&postorder=asc&start=310) first and glued the top metal edges.

A few plywood boards were installed for reinforcement.

For soundproofing, I had filled up all voids with cellulose insulation (https://www.google.com/search?q=D%C3%A4mmstoff+Zellulose&client=safari&rls=en&source=lnms&tbm=isch&sa=X&ved=0ahUKEwiXstCZudLfAhXNjqQKHZWaCvoQ_AUIDygC&biw=1530&bih=1089#imgrc=qAo88dijSM4FlM:) still present.


Metallkante_1_25mm_028 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Metallkante_1_25mm_028.jpg)


Metallkante_1_25mm_025 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Metallkante_1_25mm_025.jpg)


Metallkante_1_25mm_026 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Metallkante_1_25mm_026.jpg)


Title: Re: Feldbahnmodule with ship
Post by: 1-32 on January 04, 2019, 02:29:00 PM
great, what is the sound insulation for?


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on January 05, 2019, 02:36:01 PM
Hello Kim,

Below the module is the drive motor for the lifting bridge.
Have a look here (http://www.finescalerr.com/smf/index.php?topic=1424.180).
I hope that the module no longer serves as a resonator due to the insulation.

It continued with the area to the right and left of the western bridgehead.

Modul-Montage_017 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Modul-Montage_017.jpg)


Several strips of Styrodur were cut to a 60 ° miter and glued together with waterproof wood glue.
After drying, they were further cut into shape with a craft knife.


As already shown on 13.06.2008 (http://www.buntbahn.de/modellbau/viewtopic.php?t=6691&postdays=0&postorder=asc&start=70), the terrain was marked covered with Molto Holz Universal Spachtel Plus  (https://www.molto.de/produkt/holz-universal-spachtel-plus/).

After drying, a hard surface results, which remains slightly flexible and unlike gypsum does not break.


Modul-Montage_019 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Modul-Montage_019.jpg)


The plywood wall plate left below the stairs was glued and fixed with Tesakrepp and aluminum weights to dry.


Modul-Montage_020 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Modul-Montage_020.jpg)


Modul-Montage_021 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Modul-Montage_021.jpg)


Modul-Montage_022 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Modul-Montage_022.jpg)


Modul-Montage_024 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Modul-Montage_024.jpg)


Modul-Montage_025 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Modul-Montage_025.jpg)


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on January 05, 2019, 02:38:06 PM
Impressive. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on January 09, 2019, 01:03:07 AM
After about 10 minutes of drawing work and 6 minutes of milling time, I could glue these four parts together.

You might think that I want to build a small banquette ...

Modul-Montage_28 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Modul-Montage_28.jpg)

... maybe with a little too big legs ....

Modul-Montage_29 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Modul-Montage_29.jpg)

... in principle, it's a kind of desk, but it should be used only twice.

Modul-Montage_26 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Modul-Montage_26.jpg)


Each of the sandstone pedestals (from about 1950 it was concrete) of the two bridgeheads had a small pipe in the upper area.


Modul-Montage_27 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Modul-Montage_27.jpg)


When it rained, the water collected in the recessed center of the pedestal and then could drain through the small tube.

To get both holes at the same angle, this little "bench" helped.


Modul-Montage_30 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Modul-Montage_30.jpg)


Modul-Montage_31 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Modul-Montage_31.jpg)


For better hold the two 1.8mm brass tubes while sandblasting, I pulled them onto a 0.3mm brass wire.


Modul-Montage_32 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Modul-Montage_32.jpg)


Then they were mounted with a new UV adhesive.


Modul-Montage_33 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Modul-Montage_33.jpg)


Modul-Montage_34 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Modul-Montage_34.jpg)


Modul-Montage_35 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Modul-Montage_35.jpg)


Title: Re: Feldbahnmodule with ship
Post by: Hauk on January 09, 2019, 09:35:08 AM
I can´t tell you how much I enjoy this thread!

Would love to see a picture with all the different bits and pieces arranged according to your master plan.

Thanks for sharing!


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on January 09, 2019, 01:27:04 PM
Good idea, Havard. Glad I thought of it! -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Hydrostat on January 09, 2019, 01:54:26 PM
Frithjof,

it is only presumption; I'm no building engineer: To me it rather looks like the tube served to drain the area behind the brick wall. On the one hand the angle doesn't look that steep at the picture and on the other hand draining that area in front of the wall would have meant to shape the surface toward the inlet of the tube. I'd rather expect a maybe somewhat inclined surface draining water towards the front, especially according to the amount of water on such a small surface?

About the UV adhesive: how does it harden - there's only that tiny seam between tube and block?

Cheers,
Volker


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on January 10, 2019, 10:32:01 AM

@Hauk @Russ
Sorry, at the moment I cann´t serve with a current overview photo, because most of my small individual projects are packed in various boxes.
To get a small impression, I can only refer to thread No.16 currently: click: 08.09.2015 (http://www.finescalerr.com/smf/index.php?topic=1424.225)

@Volker
Unfortunately, when I started this project in 2007, I couldn't look at the bridgehead anymore because it has already been demolished a year before.

But I could talk to an architect who told me that this thin pipe was used to drain the water from the sandstone plinth.
In addition, there was a depression between the two supports of the bridge, in which the water could collect and flow from there into the small drainage pipe.

Quote
On the one hand the angle doesn't look that steep at the picture
You are right ???

Meanwhile, I have created a recess with a small grinding wheel.
As it really looked, I can only guess. Unfortunately, there is no photo of it.

Modul-Montage_36 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Modul-Montage_36.jpg)


Quote
About the UV adhesive: how does it harden - there's only that tiny seam between tube and block?

I got to know this UV-glue (https://www.fischer.de/de-de/produkte/ganz-ohne-werkzeug/reparieren/uv-kleber/545866-uv-kleber) through a modelmaker.
After the glue is applied, the small tube was still movable for a few secunds. Only when the small supplied UV lamp is activated for 5-15 seconds, the splice hardens. Without UV light, it takes about 15 minutes to harden.
It can be used very well for the assembly of model glass (glass or plastic). If the UV light is used, the glue will not effloresce. You just have to be very sparing with the amount of glue. It is best to wear it with a small needle or thin metal rod.


Title: Re: Feldbahnmodule with ship
Post by: Lawton Maner on January 10, 2019, 11:46:47 AM
The adhesive uses the same technique that your dentist uses to build up a filling now that many people feel the amalgam of silver and mercury is dangerous.  Unlike the amalgam, this can be built up on a surface rather then having to be dovetailed into the tooth in order to hold it in place.  This adhesive is often advertised on late night television. 


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on January 10, 2019, 02:25:21 PM
This post is pretty boring in comparison with the interesting stuff above ... but thanks for the link to your drawing. Now I can see how everything will fit together. I really like your diorama. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on January 14, 2019, 03:01:47 AM
As the title of this thread suggests, at some point a ship must appear.

At the stairs a small metal boat swims, as it was used next to many river Elbe ships..

I imagine a small dinghy, as you can see here (http://medienarchiv.baw.de/utils/ajaxhelper/?CISOROOT=wsv&CISOPTR=2496&action=2&DMSCALE=30&DMWIDTH=512&DMHEIGHT=337&DMX=512&DMY=512&DMTEXT=&DMROTATE=0) on a historic photo of the Bundesanstalt für Wasserbau (Federal Institute of Hydraulic Engineering) (http://medienarchiv.baw.de/cdm/ref/collection/wsv/id/2496).

After all, I want to give back the red Lego ship to my grandson.

Modul-Montage_37 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Modul-Montage_37.jpg)


However, I miss the dimensions and more detailed photos currently.



Some time ago I received from a modeler colleague some great drawings of old port barges, in some cases even with all longitudinal, lateral and lateral cracks.

I will try to build a barge (Spitzschute) from the year 1926 as exactly as possible. For that I have already scaled the three line chracks to 1: 22.5 and assigned the three levels to each other.

Spitzschute_1926_01 (fspg2)
(http://www.buntbahn.de/fotos/data/9461/2903Spitzschute_1926_01.jpg)


Since this about 55cm long unpowered barge should never swim in real water, I'm still undecided in the choice of materials.


If you are looking for plans of such barges, you can find old blueprints and drawings at digipeer (http://www.digipeer.de/index.php?sf=0&al=schute).


There are pictures of old barges, for example here (https://historische-bilder.com/photo/frachter-geier-versmannkai-baakenhafen-fest-gemacht-seine-heckleinen-sind-TAkzGvNrWo), here (https://historische-bilder.com/photo/gleisanlagen-hafenbahn-kirchenpauerkai-hamburger-hafen-waggons-kohle-werden-XZWtPmYMip) and also here (https://historische-bilder.com/photo/britische-frachter-liegt-dalmannkai-hamburger-grasbrookhafens-hafenkrane-RcbrYTWhbN).


To construct ship hulls, you can use Freeship (https://www.google.de/search?source=hp&ei=GWobXK2jIpLqrgT3trigBA&q=freeship&oq=freeship&gs_l=psy-ab.1.0.0l10.1485.3718..5597...0.0..1.120.918.7j3....2..0....1..gws-wiz.....0..0i131j0i10.tRxV2U1TI8Q) or maybe also Delftship (http://www.delftship.net/DELFTship/index.php/delftship/delftship-free).
I have not tried it yet, but only read it in a ship's model building forum so far.

Finally, for today a beautiful film from the 1950s on a coal transport with barges (https://www.youtube.com/watch?v=nNnG7eBi4HM) in Hamburg.


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on January 14, 2019, 02:10:39 PM
I will miss the red Lego boat when you return it. Still, I look forward to seeing how you build the dinghy. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on January 19, 2019, 02:47:06 AM
I wrote:
Quote
However, I miss the dimensions and more detailed photos currently.

If you know the right name, then something comes to light!
I didn´t have the desired success with "dinghy" or "rescue boat" before.
Helmut gave me the hint with which word I had to search.
So I checked for "Schottel-Nachen" and found several pictures of the boat I´m looking for.

For example:  here (https://sarahontheriver.wordpress.com/2009/12/07/mein-freund-der-nachen-oder-wie-ich-mir-einen-ganzen-ort-zum-feind-machte/), here (http://www.rheinanlagen-rheinbrohl.de/front_content.php?idcat=106), here (https://www.sbs-andernach.de/index.php/de/bootsbau/arbeitsboote/arbeitsboote-serien/67-boerse/boote/263-gebrauchtes-arbeits-und-beiboot-typ-schaluppe) or here (https://hatzenport.de/wp-content/uploads/2018/09/Kahnclub-2-1440x460.jpg).



For the two bridgeheads, the "sandstone curbs (http://www.finescalerr.com/smf/index.php?topic=1424.240)" at the bottom were provided with a 5.0mm wide groove,

Modul-Montage_38 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Modul-Montage_38.jpg)

mounted on MDF boards and glued with superglue.

Modul-Montage_39 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Modul-Montage_39.jpg)


Modul-Montage_40 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Modul-Montage_40.jpg)

Now these pre-assembled parts have to be painted before they are glued to the bridgeheads finally.

Modul-Montage_41 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Modul-Montage_41.jpg)


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on January 19, 2019, 02:57:01 PM
I think the generic name for the boat you want to model is simply "rowboat".

The English word for "rescue boat" is "lifeboat" and most tend to be larger and even shaped differently than the boats in your links.

That is your vocabulary lesson for today. Now let's get back to modeling.

Russ


Title: Re: Feldbahnmodule with ship
Post by: Design-HSB on January 19, 2019, 05:57:08 PM
Russ,

these boats were work boats and always in the water. On inland waterways it is usually not far on land and there are also rescue equipment only according to A4, which includes this ship. Much more important, however, was that maintenance work could be carried out from outside on the ship with this ship, or cables could be brought ashore to moor. The German name for such ships is "Nachen or Schaluppe."


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on January 20, 2019, 02:10:47 PM
A Nachen seems to be what Americans would call a "rowboat" but a sailor might use a more specific word. A Schaluppe seems to be what we call a "dinghy" because it can have a sail. Language is far more complicated than modeling! -- Russ


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on January 22, 2019, 02:04:00 PM
@Russ, @ Helmut,
thanks for your explanations!


Last weekend, the plexiglass cylinder for the well of the lifting bridge was rebuilt, as there was a mistake in the arrangement of the guide rollers.
In the following picture, two guide wheels were drawn on the right and left at the top of the lift cylinder.


Schwimmer_07 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_07.jpg)


At that time I had seen a total of four rolls on another schematic sketch. After that, I built my first shaft.


Schwimmer_43 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_43.jpg)


Schwimmer_44 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_44.jpg)


Schwimmer_46 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_46.jpg)

As far as the old condition!


When I had the first well ready for installation, I got exact drawings of the lifting bridge  (http://www.finescalerr.com/smf/index.php?topic=1424.180).
We can see, the four guide rollers were each offset by 45° from the version I built.


Hubbruecke_Portal_Detail-1 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Hubbruecke_Portal_Detail-1.jpg)
Copyright: WSA-Lauenburg

So changes were made in the 3D drawing and a new Plexiglas tube with 120mm outer diameter purchased ....



Now the new condition:

.... after looking at this tube again and again for several years, I have made it anew.


Schwimmer_52 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_52.jpg)


Schwimmer_54 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_54.jpg)


The four guide rollers are not drawn yet.


Schwimmer_56 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_56.jpg)


Schwimmer_58 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_58.jpg)

To make the four slots for the roller guides, I have made a small simplification.
At that time, I had laboriously turned the tube 90° each time, taking a close look at the cutter on  positioned auxiliary lines  (http://www.buntbahn.de/fotos/showphoto.php?photo=87063&size=big&password=&sort=7&thecat=7452),
so I have positioned the tube in two 10mm thick MDF boards now. These had got a tight-fitting 120mm neckline.


Schwimmer_59 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_59.jpg)


After each milling pass, the entire unit was rotated 90° and placed in the two grooves of the base plate. A wooden staff and two small clamps held everything in position.


Schwimmer_60 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_60.jpg)


The plexiglass tube was installed in the system only as a trial. Now missing are the bricks, the guide profiles, as well as the surrounded MDF boards.


Schwimmer_61 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_61.jpg)


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on January 22, 2019, 04:08:51 PM
Excellent design and fabrication. Most satisfactory. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on February 10, 2019, 03:17:49 AM

In the meantime, the MDF panels for the shaft have been re-milled and assembled.

Schwimmer_70 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_70.jpg)


Now the new Plexiglas® cylinder also needs a new brickwork in the visible area!

Schwimmer_62 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_62.jpg)


The old CAD drawings have been adjusted accordingly. There are a few more stones in the round and a few rows have also been added below.

It was glued again 1.0mm waterproof glued plywood on a MDF board with Gudy 870 (https://www.neschen.de/en/product/gudy-870/) and the router could work while I had time for other things.

Two small video clips you can see here (https://vimeo.com/313644360) and here (https://vimeo.com/313644505).


Schwimmer_67 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_67.jpg)


Schwimmer_68 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_68.jpg)


Schwimmer_69 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_69.jpg)


For my first shaft I had exposed the plywood in the dishwasher the hot steam.
Posting from November 03.2012 (http://www.finescalerr.com/smf/index.php?topic=1424.135)
Afterthen the plywood was dried quite laboriously,


...now it was much faster.

Schwimmer_71 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_71.jpg)


In a large metal sieve, the plywood panel had to bend out of the saucepan for a few minutes in the steam.

Schwimmer_72 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_72.jpg)

Still damp, the plate was fixed with Tesakrepp inside the Plexiglas® cylinder for drying,
to be finally fixed with a Plexiglas®  adhesive (https://www.acrifix.com/product/acrifix/en/products/reaction-adhesives/acrifix-1r-0192/) later.


I glued the thin plywood wall plate into the Plexiglas® cylinder and let it dry overnight.
From the outside, the slots for the roller guides were cut with a cutter.

Schwimmer_76 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_76.jpg)

So that the plywood did not break from the inside, I had inserted a rolled thin metal sheet on the inner surface. It snuggled close to the wood and gave the knife a good counter pressure.
Then the upper edges were cut with an 0.5 mm thin saw blade.
Schwimmer_75 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_75.jpg)



Also the lifter went on. The manhole was fastened with 12 M0.8mm screws. Two rivet straps were milled and riveted out of 0.4mm nickel silver. In the following photo the second band has to be soldered on.


Schwimmer_74 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_74.jpg)

The lifter has now 1.0mm side height too much, this will disappear in the ground later!

Here is the first lifter burnished appeared to the photo date.


Heber_16 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Heber_16.jpg)



When the old Lauenburg lifting bridge was demolished in the early 1950s and replaced by a new building (http://www.buntbahn.de/fotos/data/7473/2903Hubruecke_1901-1965.jpg), the old iron parts landed on the scrap probably.


As luck would have it, I got from a French model railroader an indication that at least a side of the winch on a local junkyard may have appeared.
Pretty desolate and partially broken, I was able to inspect some of the remains yesterday.

Winde_25 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Winde_25.jpg)


Title: Re: Feldbahnmodule with ship
Post by: Bill Gill on February 10, 2019, 07:20:13 AM
More excellent work. I like your method for steaming the plywood to curve it (you could steam your lunch at the same time and enjoy a meal while the plywood cools to its new shape :) ).

Your craftsmanship and attention to detail is great to see.


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on February 10, 2019, 02:25:24 PM
To a "normal" person like me such design, engineering, craftsmanship, and ingenuity is just amazing. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on February 10, 2019, 11:47:25 PM
Beautiful, especially that burnished piece.


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on February 13, 2019, 02:50:58 AM
Thank you for your approval!

On the east side of the lifting bridge were three smaller bridges, which lay in an arch.

Hubbruecke_Anschlussbruecken_ (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Hubbruecke_Anschlussbruecken_.jpg)
Copyright: WSA-Lauenburg/Elbe


So far there was no direct connection from my ramp modules to the lifting bridge module.
For adjustment I had to shorten a module by 29,0cm - built in 2007.


Modul-Montage_46 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Modul-Montage_46.jpg)


The exact alignment was helped by a long aluminum profile and a few angle irons.

Modul-Montage_42 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Modul-Montage_42.jpg)


Modul-Montage_43 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Modul-Montage_43.jpg)


Modul-Montage_44 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Modul-Montage_44.jpg)


Modul-Montage_45 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Modul-Montage_45.jpg)


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on February 13, 2019, 01:37:46 PM
I love what you are doing. Very creative and unique. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Hauk on February 14, 2019, 05:42:37 AM
Thank you for your approval!

It is hard to express how much I enjoy this thread!

This is industrial archeology at its best. 


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on February 19, 2019, 02:46:14 PM
Thanks Russ, thanks Hauk!


The work on the wall parts come to an end slowly, only a few finishing metal edges still need to be adjusted.

Modul-Montage_47 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Modul-Montage_47.jpg)


The diving bell served as a counterweight to move the floodgate.


Tauchglocke_2 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Tauchglocke_2.jpg)


To allow for smooth movement on the model, I will install small linear guides with a slide (https://www.google.de/search?q=MGN7H+7mm&source=lnms&tbm=isch&sa=X&ved=0ahUKEwiF386W0cfgAhUCb1AKHeGtA_8Q_AUIDygC&biw=1486&bih=1089#imgrc=DNJaidjJmDgXqM:).

Tauchglocke_32 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Tauchglocke_32.jpg)


Let me see if the Faulhaber 2020 will be enough as a propulsion engine:?:

Tauchglocke_33 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Tauchglocke_33.gif)


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on February 19, 2019, 11:41:28 PM
Nice. Those linear guides are interesting -- I might find have some uses for those.


Title: Re: Feldbahnmodule with ship
Post by: 1-32 on February 20, 2019, 12:30:54 AM
Frithjof.
very cool love seeing it come together.
cheers


Title: Re: Feldbahnmodule with ship
Post by: nalmeida on February 20, 2019, 10:06:06 AM
Nice progress, I use that kind of rails in my projects, they are a precise but a bit heavy when pulling. You'll need a bit of lubrication, I'm not sure if the motor will have enough torque but I'm curious to see the outcome.


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on February 20, 2019, 12:16:06 PM
@ Ray
Those linear guides are a little help to get a precise movement. I ordered very small one – the rails are 7.0mm wide only.

@ nalmeida
With these carriages you can get very different qualities. There are seemingly the same parts for very different prices (from 12.00 € to about 30.00 € each one). Lets see what I will get.
I certainly have some fat left from my milling machine.
Even with the engine, I let myself be surprised.

@Kim
Yes - everything grows together, but slowly.
So yesterday evening a few parts were put and glued together.

Already I had built and burnished the counterweights on 2010.02.05 - on top of this page (http://www.buntbahn.de/modellbau/viewtopic.php?p=275135&highlight=gegengewicht#275135). Sorry - this Link is only German!


Gegengewicht_Schleusentor_2 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Gegengewicht_Schleusentor_2.jpg)


Since then, they were waiting for installation in the guide rails.


Gegengewicht_Schleusentor_1 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Gegengewicht_Schleusentor_1.jpg)

Gegengewicht_Schleusentor_5 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Gegengewicht_Schleusentor_5.jpg)


Gegengewicht_Schleusentor_7 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Gegengewicht_Schleusentor_7.jpg)


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on February 25, 2019, 07:28:03 AM
If the lifting bridge will be a major challenge in terms of stamina, I have not really looked at the two gates of the lock so far.

About 9000 - 10000 rivets will be pressed into each miter gate. Let's see when I'll be finished with it.


Stemmtor_3a (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Stemmtor_3a.jpg)
Copyright: WSA-Lauenburg/Elbe

Stemmtor_4 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Stemmtor_4.jpg)
Copyright: WSA-Lauenburg/Elbe


Stemmtor_5 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Stemmtor_5.jpg)
Copyright: WSA-Lauenburg/Elbe



Here I am in the process of putting together the various levels in a 3D sketch in order to generate the individual files for the milling work. I will use 0.3mm and 0.4mm nickel silver sheets because they can emboss the rivet heads very well.


Stemmtor_6 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Stemmtor_6.jpg)
Copyright: WSA-Lauenburg/Elbe


On the lid of the lifting cylinder, I had originally milled out four pockets for the pedestals, in which (the falsely assumed) pedestal + guide rollers should be positioned.


Schwimmer_28 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_28.jpg)


When I got the exact drawings, it looked a bit different! The positions shifted by 45°.


Hubbruecke_Portal_Detail-1 (fspg2)
(http://www.buntbahn.de/fotos/data/7473/2903Hubbruecke_Portal_Detail-1.jpg)
Copyright: WSA-Lauenburg




A first resort would have been a new replacement lid for the lift cylinder ...

... but then came a second way to my mind: not a new lid, but instead of the four pedestals a few new parts to fill up the wholes and connect the the four holders of the guide rollers. It had to be used in this solution, only the lifting cylinder rotated by 45°.


Schwimmer_79 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_79.jpg)


Schwimmer_Laufrolle_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_Laufrolle_01.jpg)


Schwimmer_Laufrolle_02 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_Laufrolle_02.jpg)


The rollers - with 8,0mm diameter - were milled from 2,0mm brass, whereby first the back got four 2,0mm holes drilled. Afterwards an 0,5mm deep material recess and finally the outer contour of the small sheet metal was milled.


Schwimmer_Laufrolle_03 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_Laufrolle_03.jpg)


Then the sheet was turned over and glued with Gudy 870 film in the same position on the MDF board. Four 2.0mm rivets helped to got the exact positioning.


Schwimmer_Laufrolle_04 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_Laufrolle_04.jpg)


Milling was done with a short 1.0mm cutter. Even if I only need four wheels in the end, I have milled two more .... you never know where they sometimes go missing. Then it's now faster than doing the same again!


Schwimmer_Laufrolle_05 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_Laufrolle_05.jpg)


The 4.0mm ball bearings make the rollers rotate easily. For the roll holders, parts made of 2.0mm sheet brass were milled out also.


Schwimmer_Laufrolle_06 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_Laufrolle_06.jpg)


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on February 25, 2019, 03:08:47 PM
Another inspirational post. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on February 25, 2019, 10:52:08 PM
Awesome!


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on February 26, 2019, 09:34:12 AM
Today we continue with small pieces. The roll holders should receive on each side three M0.6mm screws (wrench size = 1.0mm) on the inclined surfaces.

For this I have drawn small drilling jigs and milled from 3.0mm and 4.0mm brass material.
During drilling, the small roll holders are aligned at right angles to the drill and get the correct distances through the pre-drilled template.


Bohrschablone-Rollenhalter_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Bohrschablone-Rollenhalter_01.gif)


Bohrschablone-Rollenhalter_03 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Bohrschablone-Rollenhalter_03.jpg)


On the miniature vise, the jigs were always brought into the same position by a stop.


Bohrschablone-Rollenhalter_05 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Bohrschablone-Rollenhalter_05.jpg)


Bohrschablone-Rollenhalter_06 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Bohrschablone-Rollenhalter_06.jpg)


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on February 27, 2019, 11:51:10 AM
The first float roller has swum free, so that the remaining three rollers can also be soldered together.

Although it was already predictable in CAD, I am always happy again when the milled and assembled parts mesh together just as well.

Schwimmer_Laufrolle_07 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_Laufrolle_07.jpg)


Schwimmer_Laufrolle_08 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_Laufrolle_08.jpg)


Schwimmer_Laufrolle_09 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_Laufrolle_09.jpg)


Schwimmer_Laufrolle_10 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_Laufrolle_10.jpg)


As a precaution, the roller has some play on the side in its axis to compensate for any assembly errors.


Schwimmer_Laufrolle_11 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Schwimmer_Laufrolle_11.jpg)


Title: Re: Feldbahnmodule with ship
Post by: Bill Gill on February 27, 2019, 12:26:03 PM
This just keeps getting better and better. Sort of like fractals in that the closer you get the details just keep going on and on.


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on February 27, 2019, 01:16:01 PM
I doubt any other hobbyist on the planet is working on a comparable project. Satisfactory. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Ray Dunakin on March 01, 2019, 12:08:25 AM
This is so far, far, beyond amazing!


Title: Re: Feldbahnmodule with ship
Post by: Design-HSB on March 03, 2019, 03:06:30 PM
I know this excellent project, even from my own point of view and I am glad to be able to support Frithjof a little bit.


Title: Re: Feldbahnmodule with ship
Post by: SandiaPaul on March 04, 2019, 07:49:39 AM
I have to agree with Russ, this is truly outstanding.


Title: Re: Feldbahnmodule with ship
Post by: Barney on March 06, 2019, 03:55:29 PM
Speechless  big time !
Barney


Title: Re: Feldbahnmodule with ship
Post by: 1-32 on March 07, 2019, 03:58:54 AM
very cool again.


Title: Re: Feldbahnmodule with ship
Post by: fspg2 on March 09, 2019, 01:32:45 PM
Thanks a lot, guys!

After just under three weeks, the two small linear guides (MGN7H 7mm) have arrived from China today.


Tauchglocke_34 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Tauchglocke_34.jpg)


Tauchglocke_35 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Tauchglocke_35.jpg)


In reviews there were very different opinions to read - from positive to bad rollable.
I do not regret the 13,00 €/piece. A little oil and a few movements back and forth made the sled easy to slip.

They have a length of 200mm. In order to get the required travel distance for the stem rod of approx. 180mm, the carriage must be able to drive to both ends of the guide rail.

However, I have only 185mm available between the wall and the cylinder.
Therefore, I will relocate the tubes for the submerged cylinder in the same distance as the required space. I hope none of you betray me.  :)

Tauchglocke_36 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Tauchglocke_36.gif)


Alternatively, I could also take such rods as I used for the lifting cylinders - half way, twice the lifting height. Let's see, where I can get such parts in "small":

Hubmechanismus_01 (fspg2)
(http://www.buntbahn.de/fotos/data/7452/2903Hubmechanismus_01.jpg)


Title: Re: Feldbahnmodule with ship
Post by: finescalerr on March 09, 2019, 03:15:59 PM
I have run out of hyperbolic expressions of praise. Forgive me. -- Russ


Title: Re: Feldbahnmodule with ship
Post by: Kevin Sikorsky on March 16, 2019, 12:23:25 PM
Every so often I have to shake my head and reconsider what’s going on, here. It’s a scale model, I tell myself. It’s not real world, full scale engineering. And it takes me a while to believe that. So I read some of the notated sizes again, like 2mm holes, or 60mm bracket, etc. That helps me re-establish the sense of scale.  And even that doesn’t work every time. I still think, 60”mm” ?? That can’t be right. It must be 60cm, or maybe 6m?? Things like the red LEGO boat are very helpful because it brings me back to my sense of 1:1. ;D It’s really exciting to watch your steps.  They begin to give me some understanding of your methods and abilities. Wow. Really cool.