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General Category => Modellers At Work => Topic started by: fspg2 on May 09, 2018, 12:32:44 PM



Title: DEMAG ML15 (engine locomotive with 15hp)
Post by: fspg2 on May 09, 2018, 12:32:44 PM
In the last few weeks, I have had some more time to draw thanks to the rehab.
Besides the Kemna Gigant 8, I also have created a small field railway locomotive - first virtually.

A DEMAG ML15 (engine locomotive with 15hp) will be made in brass - 1: 22.5 scale.

Demag_ML15_Montage_016 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_016.jpg)


Demag_ML15_Montage_001 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_001.jpg)


Demag_ML15_Montage_003 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_003.jpg)


Demag_ML15_Montage_004 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_004.jpg)


Demag_ML15_Montage_009 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_009.jpg)


Demag_ML15_Montage_010 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_010.jpg)



Today it was burning under my fingers .... the frame was milled out of 1.0mm brass (MS58).

Demag_ML15_Montage_011 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_011.jpg)



To facilitate assembly, I got 10.0 mm hard paper gauges from the milling machine.

Demag_ML15_Montage_012 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_012.jpg)
 

Loosely put together then a quick photo was taken on the windowsill.

Demag_ML15_Montage_015 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_015.jpg)


Demag_ML15_Montage_013 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_013.jpg)


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: Gordon Ferguson on May 09, 2018, 12:45:40 PM
Your jigs are of a higher quality than my models , sigh!

Lovely work , would you mind if I “borrowed” your side elevation profile with dimensions , might like to try this in 1/35 scale ........ hacked glued together in plastic with lots of filler  ;D

I am presuming it’s 600mm gauge


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: Greg Hile on May 09, 2018, 12:48:41 PM
More wonderful stuff!


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: finescalerr on May 10, 2018, 01:36:17 AM
Gorgeous drawing and metal fabrication. Besides, I love Feldbahnen. -- Russ


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: fspg2 on May 10, 2018, 03:06:06 AM
Thanks a lot for your friendly statements :)
@Gordon
I sent an email to you with some downscaled drawings. If you need further information, please let me know!

Some more pictures you´ll find here (https://www.google.com/search?q=demag+ml15&client=safari&rls=en&source=lnms&tbm=isch&sa=X&ved=0ahUKEwiD7eaw4fraAhVREVAKHWQuBmEQ_AUICygC&biw=1196&bih=1093).
The sound: click (https://www.youtube.com/watch?v=Ar1s422r8Cc)


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: fspg2 on May 12, 2018, 10:41:04 AM
The 5.0 x 5.0 mm brass corner sections have the same hole pattern received as the outer walls. For this I have milled a groove in a hard paper gauge and placed opposite two equal length brass profiles with the thighs.


Demag_ML15_Montage_017 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_017.jpg)

As a stop serve two small brass plates. Everything was fixed with Tesakrepp (not visible in the photos). In addition to the 1.0 mm holes, the respective top was milled in length with a 0.8 mm deep 1.2 mm cutter. The profiles have a wall thickness of 0.6 mm.
Thereafter, both profiles were rotated and the same procedure was carried out with the required parts separated to the final dimension now.

Demag_ML15_Montage_018 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_018.jpg)


Demag_ML15_Montage_019 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_019.jpg)

The additional overhead frame should be bolted to the engine part later. At the moment it is free to move because I have designed the drive part not yet.

Demag_ML15_Montage_020 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_020.jpg)



The bonnet is made of 0.2mm nickel silver.
For bending, I have built a small auxiliary gauge to be able to bend the two sides equally in radius. The chimney hole serves for exactly centered alignment.


Motorhaube_Biegeschablone_01 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Motorhaube_Biegeschablone_01.gif)


Motorhaube_Biegeschablone_02 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Motorhaube_Biegeschablone_02.jpg)



Motorhaube_Biegeschablone_04 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Motorhaube_Biegeschablone_04.jpg)


Motorhaube_Biegeschablone_05 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Motorhaube_Biegeschablone_05.jpg)

Let's see if bending works that way.


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: finescalerr on May 12, 2018, 12:39:33 PM
I can't imagine having the ability to build anything so neatly. -- Russ


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: fspg2 on May 13, 2018, 09:46:05 AM
@Russ
I enjoy not only a finished model, but also the implementation and modification of an idea in order to arrive at this model.

I modified the bending template a bit.
In order to press the nickel silver plate better with the bending block to the curves of the 6.0 mm brass rods, I have further milled out the base plate.
I also made two sheets of hard paper. They hold the brass rods securely on the base plate with the 6.0mm Allen screws.
Even if the milled 0.2 mm nickel silver sheet is bent transversely to the rolling direction, it has an enormous spring force.
Therefore, the distance between the two brass rods was already brought closer by 1.0mm.

Motorhaube_Biegeschablone_06 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Motorhaube_Biegeschablone_06.jpg)


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: 5thwheel on May 13, 2018, 03:46:37 PM
fspg2, I don't know your real name. What is the purple material you are using for jigs? I see you refer to hard paper, is that what it is?   I have not seen any thing like it here in the States. Very interesting looking material.

I enjoy following your projects.

Bill Hudson


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: fspg2 on May 14, 2018, 05:23:42 AM
@Bill

My name ist Frithjof.

The hard paper can be found with different names, such as:
laminated paper, synthetic resin bonded paper, Pertinax®, Bakelite®, ...

But, please uses a filtering facepiece when working with these materials.


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: fspg2 on May 18, 2018, 07:28:05 AM
Another sheet was annealed before bending. It could be more precisely adapted to the desired radius.

Motorhaube_Biegeschablone_07 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Motorhaube_Biegeschablone_07.jpg)


Meanwhile, I milled the upper sheet walls, the window frames and the curved roof angle profiles.

Demag_ML15_Montage_021 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_021.jpg)


M0.6mm hexagon bolts and nuts (wrench size = 1.0mm) were assembled..

Demag_ML15_Montage_023 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_023.jpg)

A headband magnifier helps assemble these small parts.
Since the screws are too long for the Model Socket (https://ghw-modellbau.de/product_info.php?products_id=4944&language=en&MODsid=e9e6d6fd6601ac022fca13778ed0bfdf), I have drilled a few 0.5mm holes in an 1.5mm thick brass plate and cutted 0.6mm thread with a tap drill (https://ghw-modellbau.de/product_info.php?products_id=3933&language=en).


Demag_ML15_Montage_24 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_24.jpg)

70 screws were screwed in ...

Demag_ML15_Montage_25 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_25.jpg)

... I cut the bottom protruding threads roughly with a small side cutter. Then the remaining supernatants were smoothed on a sandpaper board.
Since the height of these screw heads seemed to me a bit too high and bothered production-related sharp parting stubs, I also pulled the top of the head over the sandpaper.

Demag_ML15_Montage_27 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_27.jpg)


Now all screws have a length of only 1.5mm.

Demag_ML15_Montage_28 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_28.jpg)

Step by step I get closer to the drawing. :wink:


For testing I had let print two buffers at Shapeways from Black Hi-Def acrylate (The material is no longer in the delivery program since a few days), I did not want to spend 120.00 € for the brass version, without knowing if all fits...... Grrrrrrrr.... The size was true to the point ....... only the stuff is just too soft, it stinks and is very light. The support structures are very easy to sand, but brass is just brass.  ;)

Demag_ML15_Montage_022 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_022.jpg)


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: finescalerr on May 18, 2018, 12:35:30 PM
It will look beautiful in brass. -- Russ


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: Gordon Ferguson on May 18, 2018, 03:31:05 PM
Frithjof,

With your range of skills why not use the the Shapeways pieces to make a sand mould and cast them up in brass 😀


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: Ray Dunakin on May 18, 2018, 09:12:09 PM
I continue to be amazed at the effort you put into your models! Customizing all those tiny bolts -- wow!


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: fspg2 on March 17, 2019, 08:49:56 AM
It's been a couple of months since I built the little loco.

At the moment I am trying to draw the wheels for the Demag ML 15.

Unfortunately, I have no photo of the inside of the wheels, only a  drawing from an old brochure page (https://servimg.com/image_preview.php?i=306&u=11913305) I could take as a basis.


However, it seems to have a different geometry than in the pictures, you can see in this post (http://www.buntbahn.de/modellbau/viewtopic.php?p=281775&highlight=demag+ml15#281775).

.
Demag-ML15_Rad_01 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag-ML15_Rad_01.gif)


Demag-ML15_Rad_02 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag-ML15_Rad_02.jpg)


Demag-ML15_Rad_08 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag-ML15_Rad_08.jpg)


Demag-ML15_Rad_10 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag-ML15_Rad_10.jpg)


Demag-ML15_Rad_11 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag-ML15_Rad_11.jpg)

Let's see what else I can find about the wheel.


The hood I had bent in a bending template and thereby let the two side walls protrude longer to have enough material when bending.

Before the hoods can be mounted on the frame now, I shortened them on my sheet metal cutting machine.

Demag_ML15_Montage_29 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_29.jpg)

In order to get the same dimensions everywhere, a Pertinax gauge was milled as a stop.

Demag_ML15_Montage_30 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_30.jpg)


Demag_ML15_Montage_31 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_31.jpg)

The M 0.6mm screws with a wrench width of 1.0mm I had previously shortened to 1.5mm length and brought the head height to about 0.4mm.
They were screwed into the frame wall with a suitable socket wrench and the predrilled lower reinforcement strip.

Demag_ML15_Montage_32 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_32.jpg)


Demag_ML15_Montage_33 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_33.jpg)


Demag_ML15_Montage_34 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_34.jpg)

Slowly you can guess the locomotive.

Demag_ML15_Montage_35 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_35.jpg)


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: Buster95 on March 17, 2019, 10:48:47 AM
Which milling machine do you use?


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: fspg2 on March 17, 2019, 11:12:30 AM
Hi Buster 95,

at German Buntbahn forum I reported about the assembly kit of my milling machine, it started at 2017/07/06.
Sorry its in German language, but google can help: klick (http://www.buntbahn.de/modellbau/viewtopic.php?t=6691&postdays=0&postorder=asc&start=800)


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: finescalerr on March 17, 2019, 03:11:04 PM
From now on I want you to build all of my locomotives. -- Russ


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: Bill Gill on March 18, 2019, 02:33:59 PM
This is more wonderful work. I look and read with awe.


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: Lawton Maner on March 19, 2019, 10:55:59 AM
You put more effort into the jigs and fixtures used to make the parts for your models then most of us put into the models themselves.


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: Ray Dunakin on March 21, 2019, 11:29:24 PM
Sweet!


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: fspg2 on April 10, 2019, 09:15:34 AM
Thank you for all the nice comments!

The bonnet is connected to the front plate with several hexagon bolts. In my five locomotives that should be implemented as well.

In order to drill the 0.5mm holes in the 1.0mm thick sides of the front plates and the 2.0mm wide brackets of the engine cover, small Pertinax gauges were milled again.

Demag_ML15_Montage_42 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_42.gif)


Demag_ML15_Montage_43 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_43.jpg)


Demag_ML15_Montage_44 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_44.jpg)


Demag_ML15_Montage_45 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_45.jpg)


Demag_ML15_Montage_46 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_46.jpg)


In the mini vice, the sheets and brackets were clamped. The respective Pertinax teachings were used to accurately position the drill holes.

Demag_ML15_Montage_47 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_47.jpg)

After half of the holes I had to take a break, as the clamped 0.5mm drill was broken (by my own carelessness). As I  changed the drill, the box fell with the last remaining drill to the ground .... now, of course, the drill is much shorter than before!

New drills are ordered!


For the two windows, I got a width of 500mm and a height of 350mm. So I had calculated the outer edges of the window frame with these dimensions.

When compared to photos from the prototype (https://www.google.de/search?q=Demag+ML+15&source=lnms&tbm=isch&sa=X&ved=0ahUKEwjVm-jAj8HhAhXGsaQKHZmrAagQ_AUIDygC&biw=1442&bih=1059), my window size seemed quite small.


So the old things were handed back to the scrap dealer and 12 wall parts milled again from 0.3mm nickel silver, now with an adjusted inside dimension! Likewise, new window frames were created.

Demag_ML15_Montage_48 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_48.jpg)


For comparison, the old frame ....

Demag_ML15_Montage_003 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_003.jpg)


... and the new one:

Demag_ML15_Montage_49 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_49.jpg)


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: finescalerr on April 10, 2019, 01:02:21 PM
You probably could build a full size locomotive in the same way; you just need bigger tools. -- Russ


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: Franck Tavernier on April 14, 2019, 05:09:49 AM
Hello Frithjof,

I'm still so impressed by the techniques and the work done, well done!

Franck


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: Chuck Doan on April 14, 2019, 07:24:07 PM
Wonderful fixtures! This is the highest form of fabricating.


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: fspg2 on April 16, 2019, 09:46:53 AM
In order for the techniques to work as desired, the CAD program is a great help.

The two center bonnet mounts were also pre-drilled with 0.5mm and then the 0.6mm threads cut.


Demag_ML15_Montage_50 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_50.jpg)


Demag_ML15_Montage_51 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_51.jpg)


Demag_ML15_Montage_52 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_52.jpg)


Demag_ML15_Montage_53 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_53.jpg)


Demag_ML15_Montage_54 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_54.jpg)


In this moment the front model has so far 38 rivets (1.5mm x 1.0mm x 1.5) and 34 M0.6mm screws (SW 1.0mm) installed.
But a few more rivets and screws will be added soon.
They could only be tamed with pointed tweezers and a strong headband loupe.


Demag_ML15_Montage_55 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_55.jpg)

In the background you see the exercise model, where I can test if I did everything right in the CAD.


Although the hood panel is only 0.2mm thick, it is very stable!


Demag_ML15_Montage_56 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_56.jpg)

Now diligence is needed to build the next four models.


Frithjof


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: finescalerr on April 16, 2019, 11:24:24 AM
Extremely adequate. -- Russ


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: Hauk on April 16, 2019, 03:53:52 PM

Although the hood panel is only 0.2mm thick, it is very stable!


Demag_ML15_Montage_56 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_56.jpg)




Frithjof

Stable? It looks totally bulletproof!
Very inspiring, and just a tad intimidating...


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: Ray Dunakin on April 17, 2019, 05:33:41 PM
Inspiring work, as usual!


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: fspg2 on April 18, 2019, 01:00:58 AM

Thanks to the Pertinax teachings, the assembly of the other Demag ML15 frames went quickly.


Demag_ML15_Montage_59 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_59.jpg)


Demag_ML15_Montage_60 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_60.jpg)

Now a lot of small screws and rivets have to be installed.


The window frames will get 10 small rivets with a head diameter of 0.8mm.

Demag_ML15_Montage_61 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_61.jpg)


To ensure that the rivets are soldered aligned vertically, a Pertinax gauge helps again.

Demag_ML15_Montage_57 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_57.jpg)


Demag_ML15_Montage_58 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_58.jpg)


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: finescalerr on April 18, 2019, 12:58:24 PM
Incroyable! - Russ


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: fspg2 on April 21, 2019, 01:51:56 PM
Here comes the next Pertinax gauge.

Demag_ML15_Montage_62 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_62.jpg)


Demag_ML15_Montage_63 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_63.jpg)


It makes the assembly of the small items much easier, especially as it should be several identical elements.


[Demag_ML15_Montage_64 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_64.jpg)


Demag_ML15_Montage_65 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_65.jpg)


Demag_ML15_Montage_66 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_66.jpg)


It is quite difficult to mount these small M0.6mm nuts on the screws. The Allen wrench does not always help, because the nuts are turning part way sometimes.
But with patience, a headband loupe and a pointed tweezers, after soldering, all the pieces were sitting.


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: Hauk on April 21, 2019, 02:53:13 PM
A pleasure to follow your progress with these fantastic models.

One question: Where do you buy your miniature screws and rivets?


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: fspg2 on April 28, 2019, 01:49:06 AM
@Hauk

There are different suppliers:

A)
https://ghw-modellbau.de/index.php?language=en

semicircular-rivet brass, finely twisted:
https://ghw-modellbau.de/index.php?language=en
These rivets have a small pimple on the head from turning on the machine unfortunately.

model flat-heat screws GHW 4000:
https://ghw-modellbau.de/index.php?cPath=4_5_7_103

B)
https://knupfer.info/shop/
Somewhat expensive but very precisely made screws and rivets! The heads of the rivets are really semicircular.

C)
https://en.fechtner-modellbau.de/material/mechanik/modellbau-schrauben/?p=1
In Norwegian: https://no.fechtner-modellbau.de/material/mechanik/modellbau-schrauben/


D)
The company Nolte in Germany manufactures wonderful screws and rivets.
Adress: http://www.geocities.ws/sven1n32/gr/modelling32/modelling32.html

Unfortunately no web page - only by letter, telephone or fax.
After payment in advance, the delivery of the first-class goods takes place.
Prices can be seen on the following three links. They are not completely up-to-date, but they can serve as orientation.

http://www.buntbahn.de/fotos/showphoto.php?photo=102334&size=big&password=&sort=7&thecat=9189
http://www.buntbahn.de/fotos/showphoto.php?photo=102335&size=big&password=&sort=7&thecat=9189
http://www.buntbahn.de/fotos/showphoto.php?photo=102336&size=big&password=&sort=7&thecat=9189




It continues with the roof for the Demag ML15.

Demag_ML15_Montage_76 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_76.jpg)


Just as with the bonnet, I milled a Pertinax gauge to bend the 0.2mm thick roof.

Demag_ML15_Montage_67 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_67.gif)


Demag_ML15_Montage_68 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_68.jpg)


Demag_ML15_Montage_75 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_75.jpg)


Before the roof was milled out, I drilled 0.5mm holes on both long sides. Later they will pick up the rivets for the roof attachment.
The two sides are 12mm longer (cyan colored) to better bend the roof.


Demag_ML15_Montage_69 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_69.jpg)


The bending gauge has corresponding 0.5mm holes. In order to position the sheet in the middle, the small rivets (in the red circle) helps.


Demag_ML15_Montage_70 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_70.jpg)


Previously, I had annealed the sheet metal at the bending points with the flame.

In another lesson, the nickel silver sheet was pressed to the final shape.


Demag_ML15_Montage_71 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_71.jpg)


Demag_ML15_Montage_72 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_72.jpg)



The protruding ends were then separated with the sheet metal cutting machine (similar to here (http://www.buntbahn.de/fotos/showphoto.php?photo=117817&size=big&password=&sort=7&thecat=9409))...

Demag_ML15_Montage_73 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_73.jpg)


... and already easily putted on the locomotive - it seems to fit.

Demag_ML15_Montage_74 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_74.jpg)


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: Barney on April 28, 2019, 11:26:57 AM
The quality and the precision leaves me speechless
Barney


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: finescalerr on April 28, 2019, 01:01:31 PM
Adequate. -- Russ


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: Ray Dunakin on April 28, 2019, 10:21:00 PM
The quality and the precision leaves me speechless


Ditto!



Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: fspg2 on April 29, 2019, 12:01:22 PM
You should not be speechless, but only stimulated a little bit! ;)

When assembling the small M0.6-mm screws (wrench size 1.0 mm), it proved difficult to fix the screw heads on the opposite side when mounting the nuts. First attempts with a small piece of wood to fix the screw heads were not very helpful.

So I need an open-end wrench!

It was not long sought, but briefly drawn:


Maulschluessel_1_0mm_1_3mm_01 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Maulschluessel_1_0mm_1_3mm_01.jpg)


... and the wrench was milled out of 0.8 mm nickel-silver sheet metal.

Maulschluessel_1_0mm_1_3mm_03 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Maulschluessel_1_0mm_1_3mm_03.jpg)


Now one side fits on the 1.0mm nuts, the other side has a key width of 1.3mm.


Maulschluessel_1_0mm_1_3mm_02 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Maulschluessel_1_0mm_1_3mm_02.jpg)


Especially in places where there is no place enough for the socket wrench, it will help!


Demag_ML15_Montage_80 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_80.jpg)


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: finescalerr on April 29, 2019, 09:32:59 PM
That is just NOT FAIR! You are cheating by manufacturing special tools to create your incredible models. Go stand in the corner! -- Russ


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: Ray Dunakin on May 01, 2019, 11:40:44 PM
Simply amazing!


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: fspg2 on August 30, 2019, 11:21:12 AM
The DEMAG ML15 should learn to walk soon. So far, only the "shoes" are drawn.

Demag_ML15_Montage_81 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_81.jpg)


From the cab side gives a clear insight into the engine area.

Fortuna_2018_004 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Fortuna_2018_004.jpg)
Copyright:: Achim Kuhlmann


Fortuna_2018_006 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Fortuna_2018_006.jpg)
Copyright:: Achim Kuhlmann


At least the front and back of the engine block should be simulated as a dummy and conceal the Faulhaber engine.

As a side view I will use this sketch (https://servimg.com/image_preview.php?i=306&u=11913305) !
A few views of the original motorblock you can see  at Buntbahnforum  (http://www.buntbahn.de/modellbau/viewtopic.php?p=281775&highlight=demag+ml15#281775).

Now will try to derive from it all the necessary details - let's see if it succeeds.


Demag_ML15_Montage_88 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_88.gif)


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: finescalerr on August 30, 2019, 12:27:20 PM
Yes, let's see if it succeeds. My guess: It will. -- Russ


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: fspg2 on September 22, 2019, 11:12:57 AM
Russ, may be you are right!

For the Demag ML15 I need two motors - one for driving the locomotive and a second for the constantly rotating flywheel.

The drive is constructed similar to my Gmeinder 10-12 (http://www.finescalerr.com/smf/index.php?topic=1358.30). However, here is no toothed belt, but gears will be used.

Demag_ML15_Montage_099 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_099.jpg)


Demag_ML15_Montage_100 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_100.jpg)


First of all, I interviewed the data sheet for the little Faulhaber motor 1512 and calculated the three model speed levels of 5.5km/h, 9.5km/h and 13.5km/h in an Excel spreadsheet.


Demag_ML15_Montage_101 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_101.jpg)


The already small space in the locomotive allows only very narrow gears and small engines.

Demag_ML15_Montage_102 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_102.jpg)

The gear unit has the following dimensions: height = 27.0mm, width = 20.0mm and depth = 4.0mm.

Demag_ML15_Montage_103 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_103.gif)


Demag_ML15_Montage_104 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_104.gif)

The second gear for the flywheel now has a depth of 4.7mm available .... enough space!

Demag_ML15_Montage_105 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_105.jpg)


Demag_ML15_Montage_106 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_106.jpg)


Demag_ML15_Montage_107 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_107.jpg)

Now a few comments on the gears:

The gear ratio is about 2: 1.
The gears will have module 0.5.
The gear on the lower drive shaft has about twice as many teeth as the drive gear on the motor shaft.
In order to fit into the given space, I decided to use the following gear arrangement: 9 theeth – 9 teeth – 19 teeth.

Demag_ML15_Montage_108 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_108.jpg)


A few formulas for calculating the center distances:


Demag_ML15_Montage_109 (fspg2)
(http://www.buntbahn.de/fotos/data/9409/2903Demag_ML15_Montage_109.jpg)

No matter how many teeth the middle gear has, for the gear ratio of gears only the two outer gears have to be considered: 19/9 = 2,11. The middle gear only bridges the distance between the two motor and drive axles.

The gears are ordered - let's see if they fit as well as I think.  ;)


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: finescalerr on September 22, 2019, 08:24:32 PM
I have developed a terrible inferiority complex after reading today's posts. The engineering and fabrication are most satisfactory. -- Russ


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: Hauk on September 22, 2019, 11:33:52 PM

First of all, I interviewed the data sheet for the little Faulhaber motor 1512 and calculated the three model speed levels of 5.5km/h, 9.5km/h and 13.5km/h in an Excel spreadsheet.


Interesting choice of motor!

I am planning to use a couple of those motors for some of my own projects, but I am a bit concerened about their power.

So it would be interesting to know if you have done any calculations on the pulling power of your engine.  And have you estimated the weight of your model?


Title: Re: DEMAG ML15 (engine locomotive with 15hp)
Post by: Ray Dunakin on September 26, 2019, 09:43:58 PM
Nice bit of miniature engineering!