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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hafenmodul_001.jpg&hash=48f61093bc908f7f5c6bd5f96e47faaec5a3c278)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Brueckenmodul_9.jpg&hash=7e3329da958e51e7acfbc78c711427d142accbb5)
Hubbruecke_Aufsicht(fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubbruecke_Aufsicht.gif&hash=5ea6d6e1b351b4c9fac1b4ad911579c7a5c54f1c)
Copyright: Lauenburger Elbschiffahrtsarchiv(fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Hubbr_cke_LEA-261b.jpg&hash=30f6dd9d243261e6ff72b52e10bd31f0ae9d02c2)
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:
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.tueren-albrecht.de%2Ftuerenkalkulation%2Fhilfe%2Fimages%2Fwabe.jpg&hash=eab50ecf5fc9cef5dc72a5407f650299ef2734d4)
found at: http://www.tueren-albrecht.de/tuerenkalkulation/hilfe/images/wabe.jpg
So, such a door has been misused!
Module-Montage_001(fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Modul-Montage_001.jpg&hash=e25136f95d4f5449f873e3d1d2862fee2d3e95a7)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Modul-Montage_002.jpg&hash=50ff75f9209f4720f6e0a8fbe9077ba333469548)
Recesses were sawed at the corners for the aluminum legs.
Module-Montage_003(fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Modul-Montage_003.jpg&hash=99b2460f6312bb6f2d0c4f69488c77030ba1afff)
Module-Montage_004(fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Modul-Montage_004.jpg&hash=1947c399c55a425a43bccfaccd427603f56ab4da)
Frithjof
:o WOW! :o ;D
-Marty
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?
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
Wonderful work, I love all the planing involved. Lot's of head scratching I'm sure. Looking forward to watch your progress on this.
Quote from: fspg2 on April 21, 2011, 12:42:16 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) ...
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
I like the interlocking bricks at the edges of each wall. Why can't commercial manufacturers do that more often? -- Russ
Quote from: finescalerr on April 21, 2011, 12:22:06 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
great project! especially the track going through center of the lock during construction...
phil 8)
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.
Thank you for starting this thread, I have followed your work and spent a LOT of time admiring it!
Paul
Same as Paul, I have read through the pages of your posts on another Forum. Very enjoyable to see, welcome here!
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
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.
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubbruecke_Sockel_links_01.gif&hash=c43ba79f88fc010ecb0d1dbacf3c6e25142e1591)
Excerpt from drawing revision of 1899 - Copyright Plan: WSA-Lbg[
... drawn and converted to milling files within an hour.
Seitentreppe_01 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Seitentreppe_01.jpg&hash=3d07a412a50dae7aafe6d0549931f52f1533c31a)
Seitentreppe_02 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Seitentreppe_02.jpg&hash=09cfd52c0f4d62440654fcfb2a87943e00a38f8c)
The milling of MDF took about an hour, the stairs were ready to install in 35 minutes.
Seitentreppe_03 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Seitentreppe_03.jpg&hash=a8f36471aafbfe8562cb8a34416a9785c63e646b)
Seitentreppe_05 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Seitentreppe_05.jpg&hash=f5584e1d81bc088843b987d438b19a5686024711)
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
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!
In 1992 I found two pictures of the former fire station of my hometown in an old photo album,
Feuerwehrhaus_Lbg-1953_01(fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8702%2F2903Feuerwehrhaus_Lbg-1950_01.jpg&hash=7bc366f6fd859f57cb481e342538acdac5a85109)
Feuerwehrhaus_Lbg-1953_02 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8702%2F2903Feuerwehrhaus_Lbg-1950_02.jpg&hash=9c4aca4be080367bf1cde1149069ba4d228148cc)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8702%2F2903Feuerwehrhaus_Lbg-1992_01.jpg&hash=752d3cd1d27572e8874ae42a0480c802e178dc2d)
Feuerwehrhaus_Lbg-1992_02(fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8702%2F2903Feuerwehrhaus_Lbg-1992_02.jpg&hash=207be92b55484ad24484b17ba819bc7b650f29da)
Feuerwehrhaus_Lbg-1992_03(fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8702%2F2903Feuerwehrhaus_Lbg-1992_03.jpg&hash=e856c30c573bcd1abdf969a9cd50c43c9dcb0d2f)
Feuerwehrhaus_Lbg-1992_04(fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8702%2F2903Feuerwehrhaus_Lbg-1992_04.jpg&hash=180c0f24865c3f358430054c68991e9b0c791da5)
Feuerwehrhaus_Lbg-1992_06(fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8702%2F2903Feuerwehrhaus_Lbg-1992_06.jpg&hash=1767dd3c6dcb56feaf5d32b2e7a4cf529108f653)
Feuerwehrhaus_Lbg-1992_07(fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8702%2F2903Feuerwehrhaus_Lbg-1992_07.jpg&hash=5ba8c871b47a2a29ad4e1cfdb6e3839fe8061429)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8702%2F2903Feuerwache_Lbg_Front_1.jpg&hash=cda94ada771f4f91c6fc666bc61dbfc79b3fb440)
Feuerwache_Lbg_Front_2 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8702%2F2903Feuerwache_Lbg_Front_2.jpg&hash=d11120d1521ca2204b564c933a03645fc5cebae9)
Feuerwache_Lbg_Front_5 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8702%2F2903Feuerwache_Lbg_Front_5.jpg&hash=45990d35cd93dbd12cfa1cb862caca9e2c6302d7)
Feuerwache_Lbg_Front_6 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8702%2F2903Feuerwache_Lbg_Front_6.jpg&hash=b4daa90bedbe8db7e9e94fa5ff9a34e04fc476c2)
Straight masonry at the front and crooked timber round about, that is the attraction for me.
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8702%2F2903Feuerwache_Lbg_Front_007.jpg&hash=a4918bdb86f3bd022a53c96ca0dfb8cd772532bd)
By gearing, the two halves align well.
Feuerwache_Lbg_Front_008 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8702%2F2903Feuerwache_Lbg_Front_008.jpg&hash=2c3c1ff7bb3dc232c2ea91212a1b14572e09dd01)
Here you see the parts joined together loosely.
Feuerwache_Lbg_Front_009 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8702%2F2903Feuerwache_Lbg_Front_009.jpg&hash=c2ee3d6038dedb6a2790ba1e3686b373598739ba)
The total length is now 74cm.
Feuerwache_Lbg_Front_010 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8702%2F2903Feuerwache_Lbg_Front_010.jpg&hash=e7d1dac63dfaeba7d8775f2ae5248345aa351832)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8702%2F2903Feuerwache_Lbg_Front_0110.jpg&hash=2050b176c3b696730d55582d94e6d329163e936d)
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
Would a laser be able to cut straight enough to accomplish interlocking bricks as square as those? Outstanding work! -- Russ
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.
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
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.
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.
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.ndetail.de%2Fspur-0%2Fmodell%2Feisenbahner-wohnhaus-5-650.jpg&hash=f080feb200623adf6919020d9452db753f7320b7)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Muenzel_Kran_Lauenburg_-1956_b.jpg&hash=0c5a63ed14b959e19a5c7289e26d020d6d9aa0b2)
So we give it a compromise now. The structure will be similar to the Hamburg crane,
Possible Vorbild_Hafenkran (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hafenkran_1.jpg&hash=974f1bbc4f0055d90c3bb31507ff200b4dc2ed2b)
... 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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_001.jpg&hash=fb88f9facaadd7a967d49673f7a249c17df876b0)
Münzel-Kran_002 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_002.jpg&hash=47c8c12163bcbc0743c2e6350a44c8b2cd675e19)
Münzel-Kran_005 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_005.jpg&hash=13543fdd73f3929f9529820eedb10960d16f0e6f)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hafenkran_Lbg_1-klein.jpg&hash=b97de491198afe679c425828db1cf6cc9581deba)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_006.jpg&hash=5de7b57c93324cb24a248050b34b9d9a4d71c063)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7443%2F2903Rollenbiegemaschine_02.gif&hash=a7b874af594de2fdde4991b172e4fe2726f3ad6c)
...like here:
rolls bending machine_03 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7443%2F2903Rollenbiegemaschine_03.jpg&hash=d2edafa88048cc1faae46a2e81c6bb5cd9641bc8)
Frithjof
This is more than modeling: It is small scale manufacturing. Impressive. -- Russ
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!
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_008.jpg&hash=6302c45212f20af3b8e968ec440965fa35265ce9)
Münzel-Kran_009(fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_009.jpg&hash=8c38c679f5a61e0b9fb7b489d42b4645066ffce0)
The template for milling with sheetcam:
Münzel-Kran_0011(fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_0011.png&hash=8b614635dedd5507a6a52c2637d589c4da897da4)
Round about two hours later, the frame was milled. I am amazed about the stability of the framework mostly.
Münzel-Kran_012(fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_012.jpg&hash=7e68250f72f29f47813abfae3377b4887f7877bd)
Münzel-Kran_014(fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_014.jpg&hash=097bf0880f4b98d17ee5f6d30dc4b37ceca35264)
The next parts will be the movable windows and the hinges (hole diameter: 0,5mm)
Frithjof
Wow. -- Russ
Double wow! That is really impressive work. Is the window frame milled out of brass?
Superb, not only in the use of modern technology but in the interpretation and skill shown
Boah!...mensch ist das eine spinnerei! Just beautiful!
M
Excellent work!
Michael
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_018.jpg&hash=7c68e61a24b25508c4cb4c72860cd5303c0844dd)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_017.jpg&hash=863fefbeacd21c476aaa7ed77de7f9af78c5bcf8)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_019.jpg&hash=fbb9cf1f7fdd039b9caa3addde9ec894d988d9c6)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_020.jpg&hash=11f299d32d83cc4e79e2a279c00b95432b63c0e5)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_021.jpg&hash=fda4b4e3330a16e727d1ac0a2b0c169ebe6a0806)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_022.jpg&hash=ccc42b38786cb91249e2eb83d712ccba21159c3b)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_023.jpg&hash=80fd4443949d73c61556d06eb349137f94c60817)
Frithjof
Frithjof,
found some spare time to get back at the work bench again ... ?! ;)
Impressive. -- Russ
Frithjof,
Impressive ? ...................... absolutely superb !!!!
May just pack away my modelling tools after seeing this quality of work
HUCH! WOW!! :o :o
It's like jewlery.
M
Now, this is rivetting at its best!
While the parts are most impressive, the SBS is superb!!!!!!
Thanks for posting.
Mj
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
Very, very impressive I would say!
Stunning, especially the rivets! They look like real rivets, not at all like embossed rivets.
Another mind blowing project!!!!
:o :o :o
Stunning. I feel like I'm working with Crayons... (talent wise... not the finely cast colored wax implements).
Excellent, they are worth counting!
Michael
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_026.jpg&hash=eb371e352a26ff83245357333297183640435a28)
The result: a subframe for the front and side walls of the crane.
Münzel-Kran_027 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_027.jpg&hash=c2dabb647d8be4447b36a5eaf56fdbc65f45a12e)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_028.gif&hash=735359ff04fcf98d59bb2c601862a0a25f80cf08)
A happy new year to all of you!
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!
I am definitely modelling with crayons... and ten thumbs!
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
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.
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7443%2F2903HF_und_HK_130_C_Gestaenge_5.jpg&hash=ae907dfa6a3df93c980d938167a4d856877940fa)
My CNC-machine is this one:
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fcnc-step.de%2Fimages%2Fstories%2FProdukte%2FHigh-Z_S%2FS_720_Fraesmaschine_vorne_CNC_STEP.jpg&hash=55066b1672642d9c45e3663b694e00767f9bc023)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_029.jpg&hash=02009e7a3600f3131e452e89913d9fd59ff8e1cf)
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?
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.
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7835%2F2903Gmeinder_10-12_Getriebedeckel_01.jpg&hash=099bf05fc31aedf431f98bf6b49a4d0233a11ac2)
Here a little movie (http://vimeo.com/21721057) from milling with the Kress.
Best regards
Frithjof
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_033.gif&hash=2042ecaaed42f5cd45e41bae2b622e9512e19ed0)
First I drawn the roof bow frame. It can be lifted from the housing together with the yellow U-profiles.
Münzel-Kran_034(fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_034.jpg&hash=b21976179a56c0356636de803bcca33ffa71ac4f)
The curved roof beams were milled from 2mm brass.
Münzel-Kran_038(fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_038.jpg&hash=b46974881481eadb089d54671448362531bb4f29)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_040.jpg&hash=c1334ff14395b650110365b8ac90cd40ad6b5169)
Münzel-Kran_035(fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_035.jpg&hash=6bb0a05666e334a7b3910e4353863086fd93e8e2)
As previously I have used a pertinax gage to align everything exactly.
Münzel-Kran_036(fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_036.jpg&hash=f0c5fb36ee11d4b8313209f0f7b8061cf66482d9)
Münzel-Kran_037(fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_037.jpg&hash=8c660d01497ce1287f8aa97d6c8b7875992607c0)
Münzel-Kran_039(fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_039.jpg&hash=4260a1ede3c1b7373776e37361d34c3a6376b1ad)
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
I am impressed by every step. Wow. -- Russ
Holy Smokes. This is......is........(I can't think of any words to describe it).
Holy frijoles! Simply masterful work!
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
@ 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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_045.gif&hash=eea3570efe9610040d31cf7ff09674f067b2dc70)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_046.jpg&hash=69b55bbaa7cffc6081d73920047507d1d8ac5cc3)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_047.png&hash=f20fb4809cdb6ef3fa1e7d48fd45ec7cbf2b9bf5)
The visible black lines mark the lower contour of the once vaulted roof. They should not be milled.
Münzel-Kran_048 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_048.png&hash=a7333521d7fa0d132e8d0d2a037c306bd9902125)
Sheetcam (http://www.sheetcam.com/index.shtml) is a very helpful software to generate the neccessary tap-file format .
Münzel-Kran_049 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_049.jpg&hash=ebd0dac5df066090c1d7376e250d96ab5cb688fc)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_050.png&hash=8a403531e8acd9046287aca390702cf0b8215aa1)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_041.jpg&hash=34d99dc6b2bbe0c706770b2a044a47d9f5e373c2)
Münzel-Kran_042 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_042.jpg&hash=3873ba632ee7c83b55c658e947c974ed740255d8)
Münzel-Kran_043 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_043.jpg&hash=4c7a612899e73930673f853f6409e50fd852fa24)
Münzel-Kran_044 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_044.jpg&hash=3ececadc59eaf9bcc6c8aec8d20a0aa1fcb281d0)
hello munzel
from a person who does not have a clue as to how you do it-
just lovelly work
kind regards kim
Thanks for the step-by-step, very interesting!
The latest addition to the model is, as usual, superb.
Beyond comprehension. -- Russ
It continues with the substructure of the harbor crane.
Münzel-Kran_051 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_051.jpg&hash=bbbbb6ca256899407ae9e7c0ff1effb51970d9b1)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_055.jpg&hash=2d32e1cede58a2f6c5e49036a54d43bd7c9c676c)
... and the side wall was modeled rivet for rivets.
Münzel-Kran_052 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_052.jpg&hash=2c3d9b74574865cbd86cd7545ef184c41d70f2e5)
Münzel-Kran_053 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_053.png&hash=90ccee3848068a1f56fa944105536910db733267)
The cutter got this DXF file ...
Münzel-Kran_054 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_054.png&hash=7d7c1e25907bb796d704c8c7a0143d9164962bf2)
... and I received a few nickel silver plates in which I have to press a few hundred rivets now. ;)
I already can visualize the result. Wonderful. -- Russ
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_056.jpg&hash=a9cc67627c2c091cd7105bf58c706a064efcf372)
Münzel-Kran_057 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_057.jpg&hash=b45f673f6feef4ae0fe5e644fe590912ad673b27)
Münzel-Kran_058 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_058.jpg&hash=9748454f96b1fd2bd88e6a2b1a3bfc88f010e9ef)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_059.jpg&hash=54320155019929f950ec15ab953893388c83466f)
That is some really sharp modelling. I look forward to every new posting on your project. A great inspiration.
Regards, Hauk
@ 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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_060.jpg&hash=45925ef0cad2975a50526b9462ec67dc453c585b)
This resulted in the settlement:
Münzel-Kran_061 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_061.jpg&hash=adeb35aeb625c7ed5f5fa91d58dd26fd5372bbdf)
... the dxf file with different colors for the 0.5 mm drill and the two different cutters:
Münzel-Kran_062 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_062.gif&hash=d97e59fdc717b8ff25fa27b3e500bb205517813b)
... and the milling file:
Münzel-Kran_063 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_063.gif&hash=41f0d7b840263514170536c37679d1ba2a81125e)
Münzel-Kran_064 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_064.jpg&hash=695c33a760b3905fae631bf2dd542b8d5769f440)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_065.jpg&hash=729aa06cb0fac8b41bd5857460bfa636df6c7a13)
The result for today - folded and soldered:
Münzel-Kran_066 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_066.jpg&hash=c67b242faabdf3cf8016980bc443518a7b70e484)
Nice! A very simple structure, elegantly engineered.
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_067.jpg&hash=80c936fa34364c9cef13b37d2888b11f153fc86b)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_068.jpg&hash=bf662f58e399550bdc87eab70b952bf7f8a282d3)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_069.jpg&hash=6f68d9d6614a97af3e7542d311d7668ac1c13c6e)
There are kits available for clamshell buckets, at least in HO and I think in O scale, too.
dave
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...
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.dredgingengineering.com%2Fdredging%2Fmedia%2FLectureNotes%2FMiedema%2F1992_Wodcon_13_Clamshell%2FFigure02.jpg&hash=4f26bea256bf40f69d198e4be3bb9f1523580b1d)
@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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_076.jpg&hash=ca6ac2073e10a10e834bbf62f401ecb942048642)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_074.png&hash=4f6346701ac95c61fa151f409f2a6b1766779e40)
The center bars are for the fixed clamping during cutting the opposite side.
Münzel-Kran_073 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_073.png&hash=aa5d08d59a6152d4c2d96003f445c6c3f21151d1)
The centrally exciting vice helps for fixing the parts correctly.
Münzel-Kran_077 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_077.jpg&hash=97c2d6af69e229278ff34f1e9ebc69d5974e544b)
Then I milled a 9.0 mm deep pocket into a piece of hard paper.
Münzel-Kran_071 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_071.jpg&hash=8aec242b91fcac70fcfe729e00cf44e4a4010744)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_070.jpg&hash=6d246db7316b34f3bf84f1d5063219861e707f4a)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_072.jpg&hash=d42365cc8f68c2d4358e8f7b33f8dcb8348c7f57)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_079.png&hash=539cc0a07a2b55622f02ea40d270c45bd806019e)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_080.jpg&hash=dccbd58c0c45fc6bf45f6f35f3a239589176641e)
Münzel-Kran_081 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_081.jpg&hash=a26e3a257608b9f843e76c520626d0a13fa5673f)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_082.jpg&hash=85c6b39a0cccce0ead7cb9d67ba6941411a37d9e)
It is beautiful progress. -- Russ
Quote from: fspg2 on April 06, 2012, 11:28:22 AM
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
Wauw! Beautiful. That interior shot could be of the real space.
Superb work from all points of view :o!
Anders
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_084.jpg&hash=7ef29490ae744befecb31a7cfce2c26ef762b7f7)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_083.gif&hash=6d518328996071ad83a2afcbb96d76c2ec0e8511)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8180%2F2903Hamburger_Hafenkran_050.jpg&hash=3a4e719981008ef4e5f20d74b9bd95e351497299)
Hamburger_Hafenkran_052 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8180%2F2903Hamburger_Hafenkran_052.jpg&hash=0aa7be7d6762ea3c13f9714a19260b8ce15aaeaf)
Hamburger_Hafenkran_053 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8180%2F2903Hamburger_Hafenkran_053.jpg&hash=ae05dfffe37b7a7be032df964f25a487ace4db60)
Hamburger_Hafenkran_051 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8180%2F2903Hamburger_Hafenkran_051.jpg&hash=299a0cd64f588f748cd921d87c920a6c36f8ee6d)
Hamburger_Hafenkran_054 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8180%2F2903Hamburger_Hafenkran_054.jpg&hash=3ad92b3042d250d381098a0b1742eb54d6ef3d28)
Today I drawn on the claw.
excavator-Museum-of-work-HH11-4 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Bagger-Museum-der-Arbeit-HH11-4.jpg&hash=6a92fe66926243673731dc659c2491e6bf6da348)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_087.jpg&hash=1e41ba26434ed1cc1e379160e884e4b436fb0516)
Münzel-Kran_085 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_085.jpg&hash=4ca5e82fa436434e25436e76a6592fe5c9552da1)
Münzel-Kran_086 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_086.jpg&hash=c648cd9432511f06da86328ffc461cb38dc5dc5a)
Münzel-Kran_088 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_088.jpg&hash=c8104ce8ceb7af0cea00ee14e1e88da7c6257944)
It is a pleasure to watch this project develop. -- Russ
Unbelievable detail.
WOW! I really look forward to seeing all this interior detail anf the clam-shell come to life!
Marc
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_089.jpg&hash=27ee6fbd72379a9a0dfdb0f9c12b405faf79f765)
Münzel-Kran_090/B] (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_090.jpg&hash=981dc8422f63a2418fe3baf4792226a58c7ecbcc)
Münzel-Kran_091 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_091.jpg&hash=3adae4994e0e81c6df166158fbfbc41d130d36dd)
Münzel-Kran_092 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_092.jpg&hash=b5c3154b2f602f2f614b66540655291aded22283)
Münzel-Kran_093 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_093.jpg&hash=5dc4d66911d147bceb77d486360bd577aebf3bb3)
:o :o :o :o :o :o :o
Where can I order my kit!!!!!!!
Just awesome!!!!
-Marty
Marty,
Only one kit? ;)
Other clamps parts have been cut out and the first blade half was soldered together.
Münzel-Kran_094 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_094.jpg&hash=0e4641d941c92c107d682f565db720e271bed799)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_095.jpg&hash=0bd28bb754175bcb1dfe4d2cf51346fcbf716e95)
Otherwise the length of the gripper is also incorrect!
Münzel-Kran_096 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_096.jpg&hash=b50559cbea6b27371bba65261f73ccdbf3c4fbd1)
So I'll scale everything once again. And the milling machine has to do a new job!
Fabulous work! So neat and clean.
Bill Martinsen
Stunning! As Bill said, very neat, clean work!
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
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.
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
@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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_097.jpg&hash=8838dbe0348ebef4d222a18d24465c2b94eb56cb)
Münzel-Kran_098 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_098.jpg&hash=47a28710cda67ab1f8c748d003af6999336735c0)
The next parts are the U-profiles, the cover for the pulleys and the two blocks for the joints.
Münzel-Kran_100 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_100.jpg&hash=d47bad4be58e02a89370ecdee5a6ed5a828a4a86)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_099.jpg&hash=fe686b90aeae1f606ceaed6914dbf38e5f9e3daf)
Münzel-Kran_102 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_102.jpg&hash=019f6ed5659f94753c5ebd2652d2f2a7a3e17a31)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_103.jpg&hash=610ac58eb3af03ae743a774e5e23bda9fed38757)
For comparison, the picture below shows the sizes of the old and the new shell.
Münzel-Kran_101 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_101.jpg&hash=096cc562f666d01211a6c765dfa59cfe205b0862)
Now I am looking for pulleys, which are similar to the drawing: 15mm - 16mm outside diameter with recesses.
Münzel-Kran_104 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_104.jpg&hash=8aa4ae20dae69704b747e1b0ca470354d4ab990e)
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.
Quote from: fspg2 on May 18, 2012, 12:01:58 AM
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_097.jpg&hash=8838dbe0348ebef4d222a18d24465c2b94eb56cb)
I´m suffering from a serious case of CNC-mill envy.
But the cure is too expencive!
Regards,
Hauk
Moin Frithjof,
Quote from: fspg2 on May 18, 2012, 12:01:58 AM
...
For comparison, the picture below shows the sizes of the old and the new shell.
...
Münzel-Kran_101 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_101.jpg&hash=096cc562f666d01211a6c765dfa59cfe205b0862)
... 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
Stunning work. I'm so envious.
@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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_105.jpg&hash=49148669dcd5e2b7652f78393e9c82ccf8bb5f4f)
Münzel-Kran_106 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_106.jpg&hash=96e83d85db765e0c5a279fad3c491dfeea654bff)
Münzel-Kran_107 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_107.jpg&hash=465a1f3c9246dc9fc9dd4b207b9a554a6425ee06)
Not bad. -- Russ
Beautiful work.
but is it art?
regards kim
I think it is!
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
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_110.jpg&hash=967d44be19105e3f7f62327191eb408170995227)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_111.jpg&hash=0121c2df9ea304b5b2ae4d0d16fef1a5dfc1659b)
On the hook only a few hex screws were placed.
Münzel-Kran_109 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_109.jpg&hash=7705bca2ca935a55b1e629f5c03d85f12de18ba4)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_108.jpg&hash=4bacfb2804f8c90b9e588401a11ab7d81d8a09ed)
I love your metalwork and fixtures.
Always a lesson in your posts.
Marty
This project never ceases to astound me. I hope I can publish something about it when you finish. -- Russ
@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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_112.jpg&hash=c5c3b58c6528416369b6d7501436e8fe280fa6a7)
It consists of two parts that were cut from 2mm brass.
Muenzel-Kran_113 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_113.jpg&hash=de1dc7df77ba3c573f323a0185558d1677800684)
Münzel-Kran_114 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_114.jpg&hash=84f91886fedb78ad3a05563a62cfd178bb7e7529)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_115.jpg&hash=b73174c8e1140f9c6396eb4ff3e26cd773f6bf7a)
Tomorrow the sprocket will be milled on the milling machine.
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
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_116.jpg&hash=9115bd47b36e6a46246059fc47692a82fa439da8)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_117.jpg&hash=f541a2e2794fe5771c322b9493b0babbed0332f1)
Now a 3mm cutter came to use and the upper sprocket was milled off.
Muenzel-Kran_118 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_118.jpg&hash=b7a7b85cc40ca539f5104fec0d61e3f4febe3ebb)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_119.jpg&hash=01c0d498107e94216915aeb4d2a38168d3097c3f)
As always, this continues to be a very fascinating project!
A work of art. Ingenious as well.
@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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_120.jpg&hash=01eb0258436f02a4c928ab1648821275772ca826)
Münzel-Kran_121 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_121.jpg&hash=09bb513e6846d69debe8e2f8f1e9b15e23a1f408)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_122.jpg&hash=463f852503b0a18c6591ee8942476aac3ab4df49)
Satisfactory. -- Russ
Today only a tiny little interim report:
Münzel-Kran_123 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_123.jpg&hash=ec4fea533e1e83786a8a7419a89c88a3717a9307)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_127.jpg&hash=453b22a366159356fac49967713b9d193cd2fcb2)
Hamburger_Hafenkran_033 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8180%2F2903Hamburger_Hafenkran_033.jpg&hash=03a29eed31ee7d8c82b82182233d1000cf2c4e61)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_124.jpg&hash=edea7511010ce242cf206ead1ea9d35939dcc6b0)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_128.jpg&hash=d550bbf8af098c6144b520e877755f3ac87e50c7)
... scale of the picture about: 1:1 ...
Münzel-Kran_129 /b] (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_129.jpg&hash=26c72f47606a9262b6cd832cb9cc702ec43019cb)
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.
Nice! I like how the triangular supports are keyed into the base plate for added strength.
@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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_130.jpg&hash=9f58e9f77ea78009bd801ce96b8b200ec4b08da5)
Münzel-Kran_131 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_131.jpg&hash=bef12a24faf9b39f36ab6c3d6bacfc853b087a71)
The 8mm center column was grooved with a 0.8 mm cutter every 90 degrees 0.2 mm deep.
Münzel-Kran_132 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_132.jpg&hash=0f19b3b03b3d1a6b011693987a408de48afebb1c)
As soldering jig a Pertinax board served again.
Münzel-Kran_133 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_133.jpg&hash=e885da3afcfbb82b54f28ce1052f900ae74bab49)
Münzel-Kran_134 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_134.jpg&hash=6d0425885096fb3066e5f86f8f0628ed38f614c6)
Loosely put together all parts you can already recognize the similarity with the drawing.
Münzel-Kran_135 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_135.jpg&hash=63be896bdb0f706e1045cff951867d26b1ac04d9)
I am reeling in stunned disbelief. That is amazingly sophisticated! -- Russ
Those last few images are just simply amazing art!
Really beautiful mechanical masterpieces!
Will be a shame to cover them up!
-Marty
Russ and Marty have said it all for me! Spectacular fabrications.
:o :o :o :o :o
Wonderful!
Marvelous!
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Weiche_Abzweig_1.jpg&hash=45b9bbb4fa18fadc840abeac36cc589278a6ec56)
For the turnout switch two parts were been casted.
Feldbahn_Stellbock_DIN9939_01 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8231%2F2903Feldbahn_Stellbock_DIN9939_01.jpg&hash=cb94bdac0bae36ac7df7dbf634d668042a10d682)
Gussbaum_Stellbock_001 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8231%2F2903Gussbaum_Stellbock_001.jpg&hash=0ebcfb15d1a5ce6d930aacb29ac1aeed947c5312)
Gussbaum_Stellbock_002 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Gussbaum_Stellbock_002.jpg&hash=7cdc400d0c8f8281a6610654813fb73295db2dc0)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903U-Buegel-2.jpg&hash=97d6205cdf643cf6e7b1f7a576692414bd728dfa)
For milling the second beam I have designed a template in which the profiles are processed.
U-frame (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903U-Buegel.gif&hash=0f9770359da4df97659666c1e7242efe38bae069)
The animated gif is very helpful in showing how you did it.
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Bohrhilfe_Buegel.jpg&hash=f3214fc97205d4f164f7dbb2a787c72715d645fa)
...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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Feldbahn_Stellbock_DIN9939_02.gif&hash=b50e8f8d9a841bb2fb49a6ab1ee504d7ca368a5a)
Instead of drawings a few pictures now!
U-bolt-3 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903U-Buegel-3.jpg&hash=9724d40de2556bb66d4ecd0d8fa101d78865708e)
U-bolt-4 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903U-Buegel-4.jpg&hash=630019884adaf11d5a6124932426fac6de11f32f)
U-bolt-6 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903U-Buegel-6.jpg&hash=b9c6e2e2b79f7bd0ae5b2d9f57296cada839a5e0)
The first turnout switch is mounted to sample now - present it remains only 8 more ☺
U-bolt-8 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903U-Buegel-8.jpg&hash=d7f32535e7c53745ae76a9b370724c5aa4787367)
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
Most impressive. -- Russ
Fantastic work and great weathering too :o! I especially like the weathering of the ties.
Anders
Beautiful work as usual!
@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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Lagerschuppen_307.jpg&hash=469d8aafc3335144a29f2eeb784178fa6fe15ba9)
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)
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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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Lagerschuppen_306.jpg&hash=ad2fc54f943238eb6eca5f03fde1651a2b905e82)
After half an hour and 28 solder points I could sandblast the stairs.
Alter_Lagerschuppen_308 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Lagerschuppen_308.jpg&hash=f0b6cc6b57b5063a5368666bb42ceb8dac0f8bf5)
Alter_Lagerschuppen_309 (fspg2)
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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
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
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
Nice! Did you mill the tread texture into the steps? Or is it photoetched?
Fantastic stairs.
@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!
Frithjof, Great work on the steps, reminds me of some that I made a while back.
Michael
@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)
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Modul-Montage_007 (fspg2)
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Although not operated with real water, some belowground functions shall be on view through a hole in the module box.
Modul-Montage_008 (fspg2)
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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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Heber_01.jpg&hash=d1e9537f947ff5b8b4f97457c587d7dfd1c6855e)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Heber_02.jpg&hash=9f0d2016a42ff3e47229c57db67d76c7424eacd3)
... and the left side kept cool ... :)
Heber_04 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Heber_04.jpg&hash=c072aabb192a1e40bcb86faa782962517c018e2b)
Heber_05 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Heber_05.jpg&hash=b399da33c83cae9d0f8119af38f867b9db09173e)
The water lifter could be viewed during the demolition of the old Lauenburg sluice in 2006 precisely.
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.rondeshagen.com%2FGrafik%2FKanal%2FBau_Schleuse_LB%2FLB_Schleuse_Abriss%2FAbriss-15-01-06%2FIM000499-2006.jpg&hash=adcf0602c9d38d67d94f52d3222acbe983eb973e)
source: http://www.rondeshagen.com/Schleuse_in_%20Lauenburg.html
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.rondeshagen.com%2FGrafik%2FKanal%2FBau_Schleuse_LB%2FLB_Schleuse_Abriss%2FAbriss-25-01-06%2FIM000541-2006.jpg&hash=f869ee9aa19103cc06350e306dd0210d949445e6)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Heber_08.jpg&hash=79bfe7e7cd4eba32f7264471dc1bd51dc7fbdadc)
Copyright: Lauenburger Elbschiffahrtsarchiv
Heber_09 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Heber_09.jpg&hash=212a8cd4264c0470f031313eba52209794eacf12)
Copyright: Lauenburger Elbschiffahrtsarchiv
By drawings (converted to scale 1:22.5) I could determine the sizes:
Heber_06 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Heber_06.jpg&hash=bb0379c68cd7ed4bcf841b906773a5ea825be57c)
source:Hellmich
Heber_07 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Heber_07.jpg&hash=2b93dbf57786241f31712a84472e467b6157e01e)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Heber_10.jpg&hash=64caaf958fb326a52d54321bdae5a192fea1a012)
Copyright: Lauenburger Elbschiffahrtsarchiv
Very interesting!
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Heber_02.jpg&hash=9f0d2016a42ff3e47229c57db67d76c7424eacd3)
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
I use Lego to achieve the same result. This looks slightly more high-tech to me!
@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)
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These two half-shells will be fixed with four pins in the correct position, so that I get a mold.
Heber_13 (fspg2)
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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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Kruemmer_Flansch.jpg&hash=81d555510826264ef64127c2410175716ac7c0de)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Heber_11.jpg&hash=27a929e8ca3f5e50504801cf544c1320bbd64492)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_01.png&hash=c4c0deaab787a086d677e2ddff4385067b5a7c10)
Through a hole in the module wall we´ll watch it later.
Schwimmer_02 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_02.gif&hash=ca13c414f345804be6f056e2a80c8d864b8fa8f5)
The cover for the float are made of brass.
Schwimmer_03 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_03.jpg&hash=d8346184e2050baaf7df1355f2af4249aaf79550)
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)
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Sigh,.....and you continue to be just as crazy as ever. ;D ;D ;D
As always, beautiful,fascinating, and educational.
Marc
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_04.jpg&hash=c8a8c597c1b1ab90f2cdd45ef2b440928057fcde)
Schwimmer_05 (fspg2)
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Schwimmer_06 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_06.jpg&hash=5c28515c064d1a58e779edb12bf768134276bb8c)
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)
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Currently I let everything cool down slowly. Tomorrow I´ll know the result.
Schacht_Mauerabwicklung_03 (fspg2)
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Schacht_Mauerabwicklung_04 (fspg2)
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Quote from: fspg2 on October 25, 2012, 05:39:16 PM
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?
It looks like a strange science experiment! ;D -- Dallas
I think this man is amazing. Let's see what the Mad Scientist has created. -- Russ
QuoteIf 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
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903lift-bridge-operation-principle_01.jpg&hash=94eb4df0f9aff00619675ff994ea61c31797a93e)
2: lifted position - at high flood (in winter at snow melt) - the bridge can not be driven
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903lift-bridge-operation-principle_02.jpg&hash=c381fa1d8cc48f8e5c6d00740b5578836a927c4f)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903lift-bridge-operation-principle_03.jpg&hash=8d50283c2610185944d6575e0da8c27e0ba08d8d)
Ah, I see. Thanks.
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.
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fbuchhorsterwaldbahn.de%2Fstuff%2FInteraktiver_Streckenplan%2FBuchhorster_Ziegeleibahn%2FEntdecke_die_alte_Trasse%2FUmschaufeln.jpg&hash=d06bf44eea4e6c6f21579435eb77bdeaa1f21541)
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)
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The cross sections were made on the Böhler saw. Like here:
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7443%2F2903Boehlerkreissaege_mit_Hilfsanschlag.jpg&hash=b3cbec9baad88a05147521e7c1fa8ba5b04f21d5)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schacht_Mauerabwicklung_08.jpg&hash=ddad9bcd585c826c1107ad2b092d76194881ee3f)
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)
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It serves as a guide rail for the rollers of the float.
Schacht_Fuehrungsschiene_01 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schacht_Fuehrungsschiene_01.jpg&hash=5540b7631707bcaf98e026d0e00acd88a13a18da)
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.
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)
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Schacht_Mauerabwicklung_10 (fspg2)
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... and milled ...
Schacht_Mauerabwicklung_12 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schacht_Mauerabwicklung_12.jpg&hash=5969d5ab37933c487a30d92d03643cb314c832d2)
... and installed only as a trial.
Schacht_Mauerabwicklung_11 (fspg2)
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At the two following sketches of the float you can see two different versions:
Schwimmer_07(fspg2)
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Schwimmer_08 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_08.jpg&hash=36777d182bedac39c140b1538e270de1f709c332)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Hubbruecke_Winde_01.jpg&hash=b05ba7e2c9c5bafc463bc8587a6d596f798172a2)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Plexiglass_schlitzen_01.jpg&hash=4698637a8be353706949032618b5fd4b0b27bf7d)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Plexiglass_schlitzen_02.jpg&hash=a3700f1323abcb464eebab85e6304aebb399f216)
Along these lines the four new slots were milled.
Plexiglass_schlitzen_03(fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Plexiglass_schlitzen_03.jpg&hash=992f97f15c9afec2c0c74e64c43e6c7cfa2d5ffb)
Plexiglass_schlitzen_05(fspg2)
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Schwimmer_09(fspg2)
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A colleague turned the domed lids of the float from brass.
Schwimmer_10(fspg2)
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Schwimmer_11(fspg2)
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The float inside has four supports and two rings of brass.
Schwimmer_14(fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_14.png&hash=8337e4b2a12f2f4b67f219c8001e2d14cd3415f9)
I milled four small holes into the underside for a safe connection. A MDF-plate works as a milling gauge.
Schwimmer_12(fspg2)
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Schwimmer_13(fspg2)
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Schwimmer_15(fspg2)
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... Resistance soldering is really great, I would not miss it anymore :-)
Schwimmer_16(fspg2)
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Schwimmer_17(fspg2)
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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)
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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)
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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)
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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)
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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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_22.jpg&hash=21a96897b049443ab520c2d267aa3b9ae874d9f9)
Schwimmer_23(fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_23.jpg&hash=280565cb899a4e2b3bdee58ba48334b6945d05ad)
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)
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Schwimmer_25 (fspg2)
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Satisfactory. -- Russ
I really love watching this all come together!
Don't encourage him. His work is so good it is disconcerting! -- Russ
@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)
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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)
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Schwimmer_28(fspg2)
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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. :)
This is modelling with a difference with standards and techniques of the highest I and Im sure others have lernt a lot
Barney
@ 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)
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Schwimmer_29(fspg2)
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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)
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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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_30.jpg&hash=0800e03ce33f135e2e580f27b81fcde71ce835bf)
Slowly it comes out of the ground in the open pit, the supports will be cut on next weekend.
Schwimmer_31 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_31.jpg&hash=945ddd2bfde132a7b8eab508028034d37b338221)
To solder a few items together only, I draw up the two lower L-profiles in one sketch:
Schwimmer_37(fspg2)
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Schwimmer_36(fspg2)
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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)
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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)
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On the following picture you can see the profiles assembled loosely. They fit neatly into each other thanks to CAD.
Schwimmer_35(fspg2)
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The next step will be the ,,cross".
Schwimmer_38(fspg2)
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Holy cow, that is incredible milling! Such close tolerances on such small pieces!
@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)
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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)
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Schwimmer_41(fspg2)
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Next will follow a jig for the screws.
Can you believe this guy? He must be a genius with an electron microscope to create that stuff. -- Russ
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
Thanks for showing the "set-up" I am sure learning a lot from your posts!
-Marty
I am having modeling apoplexy. :-X
@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)
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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)
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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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_45.jpg&hash=0d2e416ae96136455ee2d899911522ea11053f97)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_46.jpg&hash=af263211c5906eed97d819bfa82e249918983aff)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_43.jpg&hash=48d32c3b31d2380245b9cb94dc01c84c213a4c33)
Schwimmer_42 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_42.jpg&hash=0472e2c5b6ed9e69d76bb55bd565bc620f267c87)
Spectacular! Fun to watch.
A real piece of jewelery! :P
Franck
@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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_50.jpg&hash=ac332f38eae0e94c486d78c8fcc38848d26ceeb8)
Some boards will cover the inspection chamber later.
Schwimmer_48 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_48.gif&hash=bd4f074d71e9b3d0c050b535d4ccbbbedd334849)
Schwimmer_49 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_49.jpg&hash=285fae485b6848895c3c4cf49b5b5046b2285c57)
Schwimmer_51 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_51.jpg&hash=9c8a1fba56d6a4314d3737095776f8bd66db8f5f)
Now only a few drawings. They are intended to show how it goes on next.
Schacht-Abdeckung_001 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schacht-Abdeckung_001.jpg&hash=c848e02a66b784d2a49ee01f126495f545284fec)
Schacht-Abdeckung_002 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schacht-Abdeckung_002.jpg&hash=9467e2e0bb55ae7322e5b46b6063a4b6be0e2de2)
Schacht-Abdeckung_003_jpg (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schacht-Abdeckung_003_jpg.gif&hash=9e05a3612698b5a0996eae43ff6c2f63d6fc0d53)
Cool. Now I am waiting to see you build those towers on each side! ;D ;D
Yes! This does look interesting ... looking forward to more! -- Dallas
Awesome ! 3D drawings are a good help for scratbuilding...
Franck
@ 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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Plexiglass_schlitzen_05.jpg&hash=c76f51b6608c8216c6477e69d1e3263cf7cc3907)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903alte_Kamerafuehrungen.jpg&hash=6065d2c7b13ab6be698a0298f458376f38c88290)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubmechanismus_01.jpg&hash=424f95dc3f4c800be279d4a9c57ee5455ec48a8e)
Hubmechanismus_02 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubmechanismus_02.jpg&hash=1c5167da01ba7b57cc1a22e25057a36bf51e3dbf)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_01.gif&hash=21deeff5c3312abd80a8050089452901bf123aef)
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.
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_02.jpg&hash=1b525e7d7c4f685a97aad6237d1021e4e9182442)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_03.jpg&hash=db28a56399b0c0defb0a7bc2f6ae7078cf76bb3e)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_04.jpg&hash=e39208cce8c928ed421eacb9041497e34ddca0f4)
Hubeinheit_Traeger_Montage_05 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_05.jpg&hash=4b345f7d964ad4fdc2de8271d2d5479747ddcc28)
Hubeinheit_Traeger_Montage_06 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_06.jpg&hash=a918725c54ebdfe47b98e4e6801d6904446b3ee7)
Now all we need is the shortened spindle rod for final assembly.
Hubeinheit_Traeger_Montage_07 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_07.jpg&hash=166bf7a8b0762369b74fb29069a844ba7ff359c3)
Ho-hum, another example of a genius at work .... -- Russ
Quote from: finescalerr on June 16, 2013, 12:35:17 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
Normally I am on the opposite side of Russ's opinion , but What the F!@# who the hell are you some mad scientist?
MPH
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
Said it before - say it again - A...R...T !!!!!!!
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??
QuoteVery 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
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_05b.gif&hash=21acb5fb37539b1d142b559cc397e9fc3687db69)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_08.jpg&hash=37282996b179b491f8a8cd3b7e9f8e424fee8a40)
It lacks the two lateral L-profiles at the image.
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Motor_01.jpg&hash=c5041d855809b48a4c052e6b4ffcb2dabbbd5fd0)
Hubeinheit_Traeger_Montage_09 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_09.gif&hash=23f11372b4070c067963eaef04b078e63743de1d)
... 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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_10.jpg&hash=4e3c9b98579c75c94f89c1c1ff59cb57149e695d)
Hubeinheit_Traeger_Montage_11 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_11.jpg&hash=e775398081b5d4b2c8fde7ce4cbed91fcf2814c2)
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. :)
There is also the "servo-link" style of chain.
Not sure of the strength limit or your need though.
Marty
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.
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_12.jpg&hash=f7e244061867837e17d80e8891751cd599260e30)
2mm deep pockets were cutted into MDF and the L-sections were placed...
Hubeinheit_Traeger_Montage_13 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_13.jpg&hash=cc7e44d7dfbfce440e43d6a1211e06fe2abd8b3e)
...and 2mm holes were drilled next.
Hubeinheit_Traeger_Montage_14 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_14.jpg&hash=070482659aa3f68565ecd6839d95cfab7729929f)
Two 6mm aluminum plates (shown in blue) are used as carriers for the two ball bearings.
Hubeinheit_Traeger_Montage_15 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_15.jpg&hash=24a1ecd8e856c174ada845f8ec262433996e7ae4)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_16.jpg&hash=3a4068248158db64d1b64c38e2d5583355bb9500)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_17.jpg&hash=abe4374612caab2d5ee45342754c4ad43f0be8ce)
Hubeinheit_Traeger_Montage_18 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_18.jpg&hash=e0008cea9713226e25bd6ff659e486255ed2c8de)
Hubeinheit_Traeger_Montage_20 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_20.jpg&hash=49413305743034ca40585ceaa60dada76a9e65eb)
A final look at the bottom of the module. The pulley and the belt will be freely accessible.
Hubeinheit_Traeger_Montage_19 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_19.jpg&hash=563e72fc74bb9b8816cab6e36f6bb0e439d77268)
It looks just like the rendering! -- Russ
We want video!!!
As always, truly amazing work!
Absolutely amazing work.....
Ken
Like Marc said, it looks like jewelry. Fascinating/fantastic.
@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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_021.jpg&hash=a2432ce437358f77f8c594f50da674b82318a804)
Hubeinheit_Traeger_Montage_022 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_022.jpg&hash=b7ed1173c0e8dc79c0fefbe1252c21289d70c6ef)
Hubeinheit_Traeger_Montage_023 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_023.jpg&hash=72cce51047295dcc0d6c48c54d56f85357d44d66)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_024.jpg&hash=b42132a91cac227299ae77ee8788d9461b35753e)
A few new drawings were made with CAD.
Hubeinheit_Traeger_Montage_025 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_025.jpg&hash=c6fadd365345fb7e02b76d233934190c297c7a0f)
Hubeinheit_Traeger_Montage_029 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_029.jpg&hash=c428f330d9c6fde20ec3ebdcdc96bb68f4834bcc)
Hubeinheit_Traeger_Montage_30 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_30.jpg&hash=f1e320f6a7de0cad612bdbe72be114f7903ccbc9)
Meanwhile the water jack has been printed: SLS-Verfahren (http://de.wikipedia.org/wiki/Lasersintern) Print .
Heber_11 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Heber_11.jpg&hash=27a929e8ca3f5e50504801cf544c1320bbd64492)
Heber_14 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Heber_14.jpg&hash=4703b9aa3ebb2cf72f8faae6dc759f90743cdbd2)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Heber_15.jpg&hash=7ec6ae3d97ffc53f3fad080631134bde10bca025)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_32.jpg&hash=d46ac7289d64b9c777042e5aed111331bfcaa813)
At the bottom of the module (door leaf) I have mouted the drivebelts and the new motor unit.
Hubeinheit_Traeger_Montage_31 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_31.jpg&hash=48e88e065dba03a9b51ce9e6d2dc50e2dadd10e4)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_33.jpg&hash=d2777f3f287604c6c722cb7d15f80eda89e578ad)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_34.jpg&hash=7a364bbdb82ba19378b4ad0a0f8cff279d0e1bb9)
Meanwhile, I've wired the limit switches.
Hubeinheit_Traeger_Montage_37 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_37.jpg&hash=50444c0730a9581eb793fbadee3c53848aff3afc)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_36.jpg&hash=05ebf8ee62db9d246e68bc7b218c556e0e42241f)
Two brass square pieces serve as a tappet .
Hubeinheit_Traeger_Montage_35 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_35.jpg&hash=340519c517c7fda61a0cc2db3507b82ce0a7cd80)
At the end a brass cover plate and a snap ring will secure everything.
Hubeinheit_Traeger_Montage_39 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubeinheit_Traeger_Montage_39.jpg&hash=8e1da71c460f35244b461a7b5075a90b35ec2273)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903lifting_at_7_Volt.jpg&hash=f8f504780a6c6a7b0f2c78b918ce01790a2df114)
Frithjof
Sorry about your problems, but great to see your progress!
What a relief to know you're not perfect. I was about to jump off a cliff. -- Russ
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
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+++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Doppelfalzziegel_02.jpg&hash=f80aa56474443ed20dabfd3c0c6871ad5f1c8166)
Doppelfalzziegel_06 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Doppelfalzziegel_06.jpg&hash=377e214f12c32124e96808cad3e1b69a291dab19)
The roofing tile was drawn by Volker.
Doppelfalzziegel_07 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Doppelfalzziegel_07.jpg&hash=6e10aef039b2a8cf27fba76ff4397ab28e3ac41c)
Afterwards I have covered the roof, but only in CAD.
Dachgerippe_01 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Dachgerippe_01.jpg&hash=6f117889cfaf511c472e60436b85c8d7d0c77f06)
Dachgerippe_02 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Dachgerippe_02.jpg&hash=c0fb7cea9f113db1164c9b20f795253ad2e5da46)
Dachgerippe_03 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Dachgerippe_03.jpg&hash=3f81a65c29964197a26878896fc90676b77b7c04)
Dachgerippe_04 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Dachgerippe_04.jpg&hash=f068a19511ae031bf640869a929e1b02d6b37e6c)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Hubbruecke_Anschlussbruecken_.jpg&hash=4f3b0b4fec90ce16fabd0d3962cec121df4e4c7e)
Copyright: WSA-Lauenburg/Elbe
Hubbruecke_beweglicher_Brueckenteil_1 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Hubbruecke_beweglicher_Brueckenteil_1.jpg&hash=ec9378a5e9d346c743ec9cc08efe93297f931173)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Hubbruecke_Mappe_1.jpg&hash=c33433784f90f8f1a3ab6e201fca4f2cfaedb412)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Hubbruecke_Portal_1.jpg&hash=83b55c93e41736a995c5b34ac108acb5c38f2cd6)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Hubbruecke_Portal_2.jpg&hash=f58dfa8fa7ce2c2d316b8c70e88fecfb4eb68961)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Hubbruecke_Winde_1.jpg&hash=d9aa78b5e8e1c68e4879326bb500937c72d10322)
Copyright: WSA-Lauenburg/Elbe
Hubbruecke_Winde_2 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Hubbruecke_Winde_2.jpg&hash=73643a4dee4755d30c1eccc1b7c9c940f45699db)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Stemmtor_1.jpg&hash=d4b63fd510bfb8b74204791d21fdaebaf0236153)
Copyright: WSA-Lauenburg/Elbe
Stemmtor_2 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Stemmtor_2.jpg&hash=efe25bd8adf26ca12d2918f7b6f349b6faec6a02)
Copyright: WSA-Lauenburg/Elbe
Stemmtor_3 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Stemmtor_3.jpg&hash=7de5a2d01a0c2e947c7fc00ce5d57d4dc0912c29)
Copyright: WSA-Lauenburg/Elbe
Stemmtor_Details (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Stemmtor_Details.jpg&hash=dfeaf71f35c5c68f9477a2fcc1f9da5d70d444a8)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Hubbrueckentraeger.jpg&hash=6b0a61a48552fdebcaeb5267d2c1f244b06924a4)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Nebenbrueckentraeger_002.gif&hash=e2039fe569210f3a3800022f5d0200a65c7411c0)
image (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903image.jpg&hash=fadfd1d3afa2b96c3d8f8a18557affa1775dbc14)
Nebenbrueckentraeger_004 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Nebenbrueckentraeger_004.jpg&hash=a61b7ad84eba24413f5cbe32e2cac0338d33ddfb)
... and the conversion in two milling data for the front and back follows.
Nebenbrueckentraeger_005 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Nebenbrueckentraeger_005.jpg&hash=b925f1d98640eff3c9907befdb607656138303fa)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Nebenbrueckentraeger_006.jpg&hash=672b686e39ab8ac107a95254ce24576cd8b4b05b)
On Friday evening I was able to mill out the parts and press the first 288 rivets.
Nebenbrueckentraeger_007
(fspg2)(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Nebenbrueckentraeger_007.jpg&hash=8b599b6d68b7d719f5d550097690262f36cc1d93)
The plates have been slightly distorted by the pressing – so they have to be addressed a little.
Nebenbrueckentraeger_008 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Nebenbrueckentraeger_008.jpg&hash=10d5cbcc248d45da3974ffe50e76405c5b92a6a8)
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.
Excellent!
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.
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
Meanwhile, the western part of the bridge is created on the computer.
westl_-Nebenbruecke_Montage_001 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903westl_-Nebenbruecke_Montage_001.gif&hash=208d4ce56618c93aaa0b50264442b330dea4a056)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903westl_-Nebenbruecke_Montage_004.gif&hash=f16312e95b8c81b613e3ab41373d3678f01209e6)
The cross beams and braces followed.
westl_Nebenbruecke_Montage_007 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903westl_Nebenbruecke_Montage_007.jpg&hash=79d8d0bdc9d2255d81f205be1293bdfd123ec35a)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903westl_Nebenbruecke_Montage_009.jpg&hash=1ff6a3775d705652c02d6022c4829a8a70343376)
Always four lumbers were processed at the same time. The result at the end: 26 small beams.
westl_Nebenbruecke_Montage_010 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903westl_Nebenbruecke_Montage_010.jpg&hash=97e01ff9232e79c04ef0ea1ab081dd933d10a961)
westl_Nebenbruecke_Montage_011 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903westl_Nebenbruecke_Montage_011.jpg&hash=acc1e6bf1440f61070108fc4479c69f9567167aa)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903westl_Nebenbruecke_Montage_012.jpg&hash=4b2a6a0649bce44dcbc17c50a5cf87591ddd86fb)
westl_Nebenbruecke_Montage_013 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903westl_Nebenbruecke_Montage_013.jpg&hash=653b19c688f531f9406f36fb4c4be07cc9a6a18a)
westl_Nebenbruecke_Montage_014 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903westl_Nebenbruecke_Montage_014.jpg&hash=7a0b5504d4bcf8ad354994f3199195e50b1443ad)
westl_Nebenbruecke_Montage_015 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903westl_Nebenbruecke_Montage_015.jpg&hash=8c77fcd10c8e5632a46b952ac9e7af4a4e348f12)
westl_Nebenbruecke_Montage_016 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903westl_Nebenbruecke_Montage_016.jpg&hash=fd13e9186dd5fc4df49031342653a090d8443fb2)
westl_-Nebenbruecke_Montage_018 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903westl_-Nebenbruecke_Montage_018.gif&hash=b8119172a5ab3fd2d2da6acfc04e984347251085)
Your work is intimidating. Most satisfactory. -- Russ
I truly envy you, in a positive sense of course! All this represents a huge pool of accumulated knowledge in engineering - hats off!
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fi240.photobucket.com%2Falbums%2Fff181%2FPeter_T1958%2Fklose_zps9aac5366.jpg%7Eoriginal&hash=ca59111150981c6b8acc692f39c4bf260ecc7784) (http://s240.photobucket.com/user/Peter_T1958/media/klose_zps9aac5366.jpg.html)
Peter
So glad that you are posting again!
Your work is a great inspiration.
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
@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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903westl_Nebenbruecke_Montage_008.jpg&hash=d0af076ec36c53311b666e788789931f45d66270)
Nobody can supply in this dimension. Therefore I`l put it together from 3 parts.
Langtraeger_I-Profil-16x6-Haasler (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Langtraeger_I-Profil-16x6-Haasler.jpg&hash=4caebf635b3c9f975162ce11040350eefdd41907)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Doppelfalzziegel_008.jpg&hash=aace698f3eb7c122e1311800d5a58b20d7374f5a)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Doppelfalzziegel_011.jpg&hash=37ebb0344a72041d252c648e32a1892f9d493c0b)
Doppelfalzziegel_012 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Doppelfalzziegel_012.jpg&hash=1ab718e707d8106394cb9934a445d2207dc274d3)
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!
Amazing detail in those tiles!
Perfect as usual.
It may be a heavy roof.
Russ
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?
Impressive precision and beauty, as always!
Congratulations,
Franck
Thanks for the update! Just amazing work at all levels.
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903westl_Nebenbruecke_Montage_022.jpg&hash=d93984ecfa95dc6f57950a657c27353f6d71a5db)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903westl_Nebenbruecke_Montage_023.jpg&hash=b3e428cf3b6005565c7ae2c7098a8c8ece0fdfd4)
Holes were drilled into the legs accordingly for fixing the 5,0mm x 3,5mm fastening angles.
westl_Nebenbruecke_Montage_024 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903westl_Nebenbruecke_Montage_024.jpg&hash=4ee2e29c8e7f2a1db6a03aab7cea167e99ff6a7c)
westl_Nebenbruecke_Montage_025 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903westl_Nebenbruecke_Montage_025.jpg&hash=f7b3abf0d042d5860ed9f1563b6c884e255a685e)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903westl_Nebenbruecke_Montage_026.jpg&hash=275246e58ab83fa32a90af0edbc9f6fe42720279)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903westl_Nebenbruecke_Montage_030.jpg&hash=0b264cddd62deeaf38c6093e08db3065f506f4fe)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903westl_Nebenbruecke_Montage_027.jpg&hash=21f62abffbff423624e12a0dfdf399cc19300075)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903westl_Nebenbruecke_Montage_028.jpg&hash=136f34b2e3c973248c4724f9a7fc34aebbf8abbc)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903westl_Nebenbruecke_Montage_029.jpg&hash=95231bf5c5594c131126515afa12fed1085252b1)
There are only small steps, but the job comes first.
Your latest progress lives up to your usual horrible and depressing standards, Frithjof. Seriously, every time you post something it inspires me. -- Russ
Astounding. I mean really.
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
As always, very impressive and fascinating work!
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:
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9000%2F5715IMG_7947b.jpg&hash=6181be82ce6b1fbc74dc55c60fc2007712a68a4d)
And that's the copperized one:
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9000%2F5715IMG_7948b.jpg&hash=d86586d3dcd767dc3ad505721d8f8045a17887c3)
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!
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9000%2F5715IMG_7951b.jpg&hash=14908059c3476a075b178627cb6f58b05fda072f)
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.
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9000%2F5715IMG_7956b.jpg&hash=40089dd171b6bb068f914d1294b040968839efe7)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9000%2F5715IMG_7959b.jpg&hash=dbd617582152756414861ab615fc5e69f71fd092)
And the tile beside the tile.
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9000%2F5715IMG_7953b.jpg&hash=7dd563cef64659a2955d49a9ab5063984c364a46)
Cheers,
Volker
Very nice!
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.
Quote from: Ray Dunakin on September 05, 2014, 01:36:29 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.
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
Beautifully made and finished.
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Pendel-Pfeiler_01.jpg&hash=3ed053e03bfdcaedc161f941e14bec005241171b)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Pendel-Pfeiler_ankoernen.jpg&hash=3314625c4e8c107e7ea4df91574f81d9037d9c56)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Pendel-Pfeiler_ankoernen_02.jpg&hash=6f2135613436a90d5b813c9187aa0be75e942205)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Pendel-Pfeiler_ankoernen_03.jpg&hash=00afdb519e2d0c45b9bdfe6baedd8f3f988c560f)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Pendel-Pfeiler_ausgluehen.jpg&hash=97b25b6a0f6c5a51bad75c49f0fb7e3f360a8e10)
For my embossing machine I habe corresponding punches.
Punzen_Nietenpraegen_01 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7434%2F2903Punzen_Nietenpraegen_01.jpg&hash=3dab2ad8456bd82a61be4b208bb9ff9114217492)
Pendel-Pfeiler_Nieten-druecken_01 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Pendel-Pfeiler_Nieten-druecken_01.jpg&hash=d60f49db9ad6a11c0aa9cade5109bda4c4b71cd7)
Pendel-Pfeiler_Nieten-druecken_02 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Pendel-Pfeiler_Nieten-druecken_02.jpg&hash=a4ffe75f70b27203df6354d44ac6c084a6b27f99)
From Pertinax an assembly aid was milled .
Pendel-Pfeiler_Montagehife_01_ (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Pendel-Pfeiler_Montagehife_01_.jpg&hash=5eb1375e62fbac4e881593e68004ec605bc1c023)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Pendel-Pfeiler_Montagehife_04_.jpg&hash=583b28a51309d4a81db9e2b6a450ae1eb1e7cd60)
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
Your work is great!!! Allan
So glad you are back!
You never fail to inspire.
Most satisfactory! -- Russ
It's always a pleasure to see your modeling posts!
very cool frithjof
great colour match with the roof tiles volker texture is a good match also
kind regards kim
Beautiful work!
Outstanding Brass work
Barney
@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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Pendel-Pfeiler_Montagehife_05_.jpg&hash=0a8c4b50047c03c1d1f4ce217bedbb7d41bde22e)
Pendel-Pfeiler_Montagehife_06_ (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Pendel-Pfeiler_Montagehife_06_.jpg&hash=4e1c85fbae6a2428206484178117f5fe74a6bca8)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Pendel-Pfeiler_02.jpg&hash=1227b02061a8b8d36976163271bfe33f732a36c6)
The two equal halves I putted together. The 0.4mm thick nickel silver plate served as a conduit.
Pendel-Pfeiler_03 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Pendel-Pfeiler_03.jpg&hash=c59711602db2084c6b3a063e1bd2bff4722b2fd1)
Both parts were pressed together easily. The overhanging L-profiles were cutted with the Böhler-saw.
Pendel-Pfeiler_04 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Pendel-Pfeiler_04.jpg&hash=fbc705d06956496df837e0f904cea51cdd6191b7)
The similarity with the drawing is wanted.
Pendel-Pfeiler_05 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Pendel-Pfeiler_05.jpg&hash=f4c938c8224a3f01a53c871a0336411b36752f70)
Such marvelous miniature engineering!
Gosh. -- Russ
Quote from: fspg2 on August 23, 2015, 02:01:21 PM
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Pendel-Pfeiler_02.jpg&hash=1227b02061a8b8d36976163271bfe33f732a36c6)
The two equal halves I putted together. The 0.4mm thick nickel silver plate served as a conduit.
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Pendel-Pfeiler_03.jpg&hash=c59711602db2084c6b3a063e1bd2bff4722b2fd1)
Bulletproof modelling!
@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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Grundriss_FMmS_2.gif&hash=b95d0457eea01d961ab68c6c96a9496d60a8bcdb)
Grundriss_Module_bislang-fertig (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Grundriss_Module_bislang-fertig.jpg&hash=4ff4d5683b622e0dfc2d3f4a6f43e0f59a686dbd)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Firstziegel_00.jpg&hash=097f48332c0bfd0216f24a12a1f0157b35024820)
(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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Firstziegel_01.jpg&hash=7f49e2ef55233df38b1262f7dd3d047eb68b6542)
Firstziegel_02 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Firstziegel_02.jpg&hash=90e5eac31731bca32250c7d656cecb3ab3c417e0)
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)
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.
Not only do the new parts look terrific but I love the concept of the entire layout. -- Russ
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
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Brueckenkoepfe.jpg&hash=8e2b08214357733ff21b732dae544e1bdf05a5c9)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Brueckenkopf_02.jpg&hash=813753cd0ac2fa0c5d6b31325a13931eb8ecb2d0)
Currently the bridgehead looks more prototypical.
Brueckenkopf_05 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Brueckenkopf_05.jpg&hash=c606573408fb9e5cab562c111dbf086f5771b901)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Brueckenkopf_06.jpg&hash=f862b17574ed07362ef48f50b3d916a32b37acd4)
Brueckenkopf_07 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Brueckenkopf_07.jpg&hash=2f5b9d4028d1fef544743aa06ee62cb99d3b5291)
This is the DXF file passed to Sheetcam.
Brueckenkopf_08 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Brueckenkopf_08.jpg&hash=8164da9b8c5eea9fc79928b19f435ca9199d0d49)
Three and a half hours later, plates for one bridgehead were finished.
Brueckenkopf_09 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Brueckenkopf_09.jpg&hash=239fc566d94038f5978ed2ff49b9c1cafc102a53)
At German buntbahn forum I was asked for the dimensions overall the modules:
Module_Abmessungen (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Module_Abmessungen.jpg&hash=a0413bfefb5961403dfc88a82996cb824b0ccc5e)
That should be a wonderful module. -- Russ
@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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Brueckenkopf_16.jpg&hash=7f4af05909f8e7b389b3f382119d2248da14623a)
sandpaper (600 grain) smoothed the complete surfaces and a brass brush cleaned the joints from dust.
Brueckenkopf_14 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Brueckenkopf_14.JPG&hash=b767683f56f92e0c5d121b65c4d206d3d21888b3)
Frithjof
That looks solid to me!
I wish I had one of those cnc routers!... :-[
Thanks for posting - always an inspiration!
-Marty
That turned out great! Can't even see the joint.
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Brueckenkopf_18.jpg&hash=190211dd00cfe60ff09e4fb086b9072fbbf10d65)
top left = roughly smoothed with sandpaper 1000grain, top right = sandblasted addition, bottom right = unmachined casting
Brueckenkopf_17 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Brueckenkopf_17.jpg&hash=13645b51bd59083160bb161a42a9bbbbc862a334)
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
Looks great!
hi friithjof.
are those stone cappings 3d printing.just very clean and convincing.
regards kim
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
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9033%2F4389Frithjof-BK-3D-01.jpg&hash=04ec01d3173b5104b09fcb17a1c3bbf1d82bddff)
two half shells for left and right capping
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9033%2F4389DSCN9547.JPG&hash=ec07e86cef887be67325cd29bc4d52999ff72c15)
ready for casting
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9033%2F4389DSCN9548.JPG&hash=14491b412609d4486686e64a0f1b82469c2f360a)
half shells with cast
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9033%2F4389DSCN9586.JPG&hash=6359e4e5a77600bbdd4c72da09731c4fcbd92fc0)
castings before clean up
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9033%2F4389Br_ckenKopf01.jpg&hash=aa551964ba6463f679f870d5561078c9e028b245)
How do you fill the molds?
I can not see plaster flowing into the molds.
Marty
I love this blend of traditional and hi-tech and the results speak for themselves. -- Russ
3d printing to make the molds and you can use any material for the finish-nice
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Hubbruecke_Anschlussbruecken_.jpg&hash=4f3b0b4fec90ce16fabd0d3962cec121df4e4c7e)
Copyright: WSA-Lauenburg/Elbe
oestliche_Bruecken (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903oestliche_Bruecken.jpg&hash=3702d57bffb1f6358b19f7a7c84a2cd465deb2d0)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Knoten_A-Gussbaum-neu_001.jpg&hash=e56ca7341ae80e779a94016369d36081523129e9)
The blue selection indicates the finished part. The lateral parts will be cut off.
Knoten_A-Gussbaum-neu_002 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Knoten_A-Gussbaum-neu_002.jpg&hash=dc1c38bc4dd19f54bbd10e0aaa77fe26e5263503)
U-Profil_6x3x0_5_56_5mm_Gussbaum_002 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903U-Profil_6x3x0_5_56_5mm_Gussbaum_002.jpg&hash=406f9dc8831ab4970b5910f4453570c979a8f606)
U-Profil_6x3x0_5_56_5mm_Gussbaum_003 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903U-Profil_6x3x0_5_56_5mm_Gussbaum_003.jpg&hash=8fa71ec12951249021e66f0a96be9595fc303859)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Loetlehre_Winkel_oben_01.jpg&hash=e8c1ec564d35349b16bd426a458bc464fb659bf9)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Loetlehre_Winkel_oben_05.jpg&hash=79587171f8217d587d34078db3f1111d0f193154)
Loetlehre_Winkel_oben_06 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Loetlehre_Winkel_oben_06.jpg&hash=49b3721c7ec92945af25bcd5bd6b99a8c4e77915)
Loetlehre_Winkel_oben_07 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Loetlehre_Winkel_oben_07.jpg&hash=f314a1fce09a33fc019e8bc1d22d49bbfbb4c1b8)
Loetlehre_Winkel_oben_08 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Loetlehre_Winkel_oben_08.jpg&hash=8ab27de0d622511d5eb39e95d12646888c573716)
Loetlehre_Winkel_oben_09 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Loetlehre_Winkel_oben_09.jpg&hash=f15fc79896c7ca6e51320cc3954f5c1c805f6df6)
Well done!
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Langtraeger_01.jpg&hash=1d8fe7e6ab1f2d1faf84c0b6158185a3077d63f8)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Langtraeger_02.jpg&hash=507e04dd57d7eaafe730e11be2c1463028bfe61d)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Langtraeger_03.jpg&hash=2f2e23e6b6158acecdb507128b47eb379ea1cdd0)
Langtraeger_04 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Langtraeger_04.jpg&hash=fdb60ffa22bd0cb5fb8f9494db7786177eb98f9d)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Langtraeger_05.jpg&hash=c93d6083e38901fd21c3cc8be7a75cd780c74db7)
The silky shiny surface is achieved by glass beads.
Langtraeger_06 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Langtraeger_06.jpg&hash=ebf78c430ae286b0c1ad79c111b5e4baeccfd49d)
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 ;-)
Beautiful workmanship.
Most satisfactory! -- Russ
Hard to believe it could get better...but it did!
Quote from: fspg2 on December 13, 2015, 07:48:18 AM
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?
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Langtraeger_07.jpg&hash=7d9f8fa4c88ceeb8d85cb7dbef3ee6a069156810)
Langtraeger_08 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Langtraeger_08.jpg&hash=66ec2a00735783b981a18edd9d9118cb9cc240ce)
Langtraeger_09 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Langtraeger_09.jpg&hash=dc25a3c3816c964390b1ba5fe585c2ef7c22b412)
Langtraeger_10 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Langtraeger_10.jpg&hash=b0f2cabb379bae8363e96d16400b970d093043c9)
The model matches the drawing so precisely it's frightening. -- Russ
I agree with Russ!!!!!!!!!!! Allan
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Knoten_A-Gussbaum-neu_003.jpg&hash=a928f23f922ad9339d491da2ab896950d218fb2b)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Langtraeger_Montagelehre_01.jpg&hash=efc930eefb2b9257f0c0f42980cd46977b37e56c)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Langtraeger_Montagelehre_02.jpg&hash=e088bd5caa1d37cfc7d4ce27ffd2049c50875c06)
Langtraeger_Montagelehre_03 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Langtraeger_Montagelehre_03.jpg&hash=5d3c5ff964b8b533ceffccc77f9d5a1d8e633178)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Nieten-kuerzen_01.jpg&hash=237744ea9431135531718c7e8c53ef9f3620b3c9)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Quertraeger_01.jpg&hash=db7b926c3f6b9e001f2c87402b87a82a0ddacad6)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7443%2F2903Schrauben_kuerzen.jpg&hash=7540740d31a2f91c949bfe2ed0e2e07f1665605a)
The recesses for the nuts have been milled tightly so that I need no further wrench during assembly.
Langtraeger_11 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Langtraeger_11.jpg&hash=f418027eeb48e0fdad00bc91124d767574d12386)
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
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Werkstatttisch_01.jpg&hash=22d8f7839c29e6e34341ca70fce097c0565ec6d9)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Werkstatttisch_02.jpg&hash=7a94d0ae678f4b3c7c6750e58f666469fe723a5a)
... the parts were milled in brass....
Alter_Werkstatttisch_03 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Werkstatttisch_03.jpg&hash=fb7e88443aeddba28566efb4cdbb422f3883e9dc)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Werkstatttisch_04.jpg&hash=48eabd64b23681be43227ebab3c57b5f2b826da7)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Werkstatttisch_05.jpg&hash=2f28e27c1b1b17e2e76e389c0565a0130ec1dfce)
Overall, I needed about 1h for drawing and 2.5h for milling and about 35min for solderimg.
Alter_Werkstatttisch_06 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Werkstatttisch_06.jpg&hash=55bed811d656c9e3d057ea161f581323159b12fb)
The upper edges of the worktop have to become more blunt before the next steps can follow.
Acceptable. Please proceed. -- Russ
Masterful craftsmanship, as usual!
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Knoten_A-Gussbaum-neu_003.jpg&hash=a928f23f922ad9339d491da2ab896950d218fb2b)
Masterform - red mark is required
Knoten_A-Gussbaum-neu_004 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Knoten_A-Gussbaum-neu_004.jpg&hash=68771a02e45e474ee0e29e47fbfa0194f7fe1236)
First the sprue webs were detached using a cutting disk.
Knoten_A-Gussbaum-neu_005 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Knoten_A-Gussbaum-neu_005.jpg&hash=9e68d1d14ebb8a755070c879f6aaa42eb656cd7c)
Then I cleaned the edges with a sandpaper file.
Knoten_A-Gussbaum-neu_006 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Knoten_A-Gussbaum-neu_006.gif&hash=130a360f3df9a6f9920c497e3bf74b9a7a8932ec)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Knoten_A-Gussbaum-neu_007.jpg&hash=469bae303656b5aa591f98b923401abc76f5aa19)
Each redundant rivets were milled either on the front or on the back.
Superb. -- Russ
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Knoten_A-Gussbaum-neu_008.gif&hash=a46b7e1d9025beb602729eb952e0efa6237ffcda)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Knoten_A-Gussbaum-neu_009.jpg&hash=ba5523f5c266611b583b4b58656ae7673787f83b)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Halter_Fiinierfraeser_01.jpg&hash=ea11e056800408c5a90bf5d2f77801d98e3e219b)
Halter_Finierfraeser_02 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Halter_Fiinierfraeser_02.jpg&hash=ddef2573242ab76fcff910a36e137c92eece5aca)
The slots in the base board located the five carriers.
Halter_Finierfraeser_03 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Halter_Fiinierfraeser_03.jpg&hash=d2daa980d2ac9be7b8c0ab69bc5287353df53c76)
Halter_Fiinierfraeser_04 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Halter_Fiinierfraeser_04.jpg&hash=7a6bbf08023bf9dd186827f04dcce6ce534524e3)
I love that cutter! -- Russ
This is just incredible engineering!
Wow!!! Wow!!!.....Allan
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
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.
@ Russ, Ray, Allan, Bill Thanks for your recognition
@Volker
QuoteWhich 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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Halter_Finierfraeser_05.jpg&hash=3c95a6b64449a07161b97a84dae5a6099cdba6ea)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Halter_Finierfraeser_06.jpg&hash=20849a3a865ef9d13536205c72a01d81f7d3eccc)
Halter_Finierfraeser_07 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Halter_Finierfraeser_07.jpg&hash=3b8acc784d53053390a24bef8c68a3604e540bdd)
Halter_Finierfraeser_08 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Halter_Finierfraeser_08.jpg&hash=fc547c1383040c9e1cc76a70b2c92638d4c6e657)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Beng_Loetpaste_01.jpg&hash=336695bb521761c35ce5978a9a568dd5bb49a921)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Beng_Loetpaste_02.jpg&hash=7345dbf58d559e85647c52d4965df441f6408a04)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Knoten_A-Gussbaum-neu_010.jpg&hash=f5d40d7117b876c6519224ef621b514dc9ccffc8)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Knoten_A-Gussbaum-neu_011.jpg&hash=9cf89ba9d7605079591e91c2e0a9f14e1a1304ec)
Knoten_A-Gussbaum-neu_012 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Knoten_A-Gussbaum-neu_012.jpg&hash=04b81d417dfb168cd12e88c344b489abd17a201d)
Knoten_A-Gussbaum-neu_013 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Knoten_A-Gussbaum-neu_013.jpg&hash=10a61cf9e1598052a24a7730e1bff2f56ad9a774)
Knoten_A-Gussbaum-neu_014_ (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Knoten_A-Gussbaum-neu_014_.jpg&hash=818857910328ea92f1ea24ee7c654d3c77651868)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Knoten_A-Gussbaum-neu_015.jpg&hash=558c938e8bea14df475e19031daff49f7df6b797)
Knoten_A-Gussbaum-neu_016 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Knoten_A-Gussbaum-neu_016.jpg&hash=0ca7e05d9b3aefdf0de9a96257a013fda5f13eec)
diagonal braces view from bottom side
Inspirational and educational as usual!
Incredible work.
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
I agree with Marty. -- Russ
Marvelous precision and a joy to follow along!
@ 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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Traeger_Montage_20.png&hash=7c0ba69178ffbee8c8f83778283dbbce3fbded0e)
Since the original drawings were photographed very wavy, you can see mistakes especially at the top end.
Hubbruecke_Portal_1 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Hubbruecke_Portal_1.jpg&hash=83b55c93e41736a995c5b34ac108acb5c38f2cd6)
Copyright: WSA-Lauenburg/Elbe
Traeger_Montage_Grundskizze_frontal_1 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Traeger_Montage_Grundskizze_frontal_1.jpg&hash=f45e89084bb5e049db179c776e3f838c77646ffb)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Traeger_Montage_Grundskizze_3D_01.jpg&hash=a39f7769bab44519fe2fad0ca04a09c7a90ea902)
Traeger_Montage_Grundskizze_3D_06 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Traeger_Montage_Grundskizze_3D_06.jpg&hash=fbbe6a02838744aff2580f3fecd57ba26124210a)
Traeger_Montage_Grundskizze_3D_05 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Traeger_Montage_Grundskizze_3D_05.jpg&hash=105acc2e70ecec21ad80896aea83b9095ea9c242)
The blue intermediate layer characterize the position of each angle section.
Traeger_Montage_05 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Traeger_Montage_05.jpg&hash=5790258011e397f9be2b087aef363941b493f4fa)
The blue lines mark the location of the corner profiles.
Traeger_Montage_06 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Traeger_Montage_06.jpg&hash=c7a0d258930cfef303557330b46745d23b12e65c)
In the following animation the procedure can be seen:
Traeger_Montage_00 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Traeger_Montage_00.gif&hash=7e88d8b929033edd8693072787ab756fd63456ba)
Traeger_Montage_15 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Traeger_Montage_15.jpg&hash=d1e1d49d7465c4eca0e98e9c2ec95a5879380f58)
Traeger_Montage_17 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Traeger_Montage_17.jpg&hash=6c10abe3be78660b24db974856dbc5d5433f5535)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Traeger_Montage_21.jpg&hash=06115109c342719a5b096b35b2f992aa42b5b774)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Traeger_Montage_22.jpg&hash=d0f75e4df41d3e588bbe95f7c9c79d8f570957ee)
Impressive. It would take me six months to figure out how to interpret those drawings and I'd probably still do it wrong! -- Russ
I agree, very impressive, and quite interesting! Also, I really enjoy your animated drawings! Very helpful for seeing how you plan to assemble things.
This project will go down in history as one of the most fantastic modeling projects ever!
You just have to love it.
@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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Bodenrahmen_01.gif&hash=f0a5c96544aec4698d5f19a467ec13a3457d424c)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Bodenrahmen_02.jpg&hash=61db9eeb2425a9c5bcb0dfaa110cc050cdeeae47)
I annealed the sheets before bending. This ensures that the edges didn´t break (depending on the rolling direction).
Bodenrahmen_03 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Bodenrahmen_03.jpg&hash=798f7b02890e170ae414b1fe1b234fc17ea84627)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Bodenrahmen_04.jpg&hash=2318c93ae31786e4a9dfa622a45500b2e233d32e)
Triangles made from 1.5mm brass MS58 serves as base feet.
Bodenrahmen_05 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Bodenrahmen_05.jpg&hash=6e142dd3063c39076adb90048465b002bb054e56)
Bodenrahmen_06 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Bodenrahmen_06.jpg&hash=87aaaad207fe58f3283867aa98f759d8a259e8f6)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Oberhaupt_01.jpg&hash=5fb9f55272eb4832b6d28c84e20265bbee762f62)
Oberhaupt_02 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Oberhaupt_02.jpg&hash=efa96707cfa57f916663b5db046dc747fe74ac08)
Oberhaupt_03 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Oberhaupt_03.jpg&hash=9849d4b257f93a5b1454389ab93656576bacbda6)
Traeger_Montage_32 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Traeger_Montage_32.jpg&hash=5ceab209f93030e865ddccd4532ffddf22811712)
I have the feeling Frithjof knows what he is doing .... -- Russ
More excellent work!
Quote from: fspg2 on September 07, 2016, 10:39:58 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.
@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-Fr%C3%A4ser/VHM-Mini-Fr%C3%A4ser-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.
Quote from: fspg2 on September 17, 2016, 10:24:09 AM
@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!
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Quertraeger_trennen_01.jpg&hash=39557a269842caedad787c294cf4c8ab1ebdec4b)
The result are a 4x2 curved L-profiles (the braching was out).
Quertraeger_trennen_02 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Quertraeger_trennen_02.jpg&hash=84a8884a266596ce9367cff1c82ebc40a768a5ad)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Quertraeger_trennen_03.jpg&hash=36b88f4c5a0037d6c5cab5f78dd48317e055d0e2)
Quertraeger_trennen_04 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Quertraeger_trennen_04.jpg&hash=6b461b01f336e12c4b344f1428b0aa0f8a69ab69)
Quertraeger_trennen_05 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Quertraeger_trennen_05.jpg&hash=d5b0a5c5befe071f81ee6847fa933a870c8bceb4)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Traeger_Montage_36.jpg&hash=ef90895ccc751ff0e7e7c49058ab6975cb52a9ae)
Traeger_Montage_39 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Traeger_Montage_39.jpg&hash=a524eec86446130ea8b69c1155c094ceb4a46186)
I've never seen anyone do that with brass. Incredible. -- Russ
I never cease to be amazed at how much effort you put into making this, and making sure it's exactly right!
I look forward to seeing the soldering - before you clean it up!
Torch or iron?
-Mj
Quote from: fspg2 on October 03, 2016, 12:49:28 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.
Crazy stuff. In a good way, of course.
A great inspiration to get some milling done myself.
Thanks a lot :)
Present I am drawing the head of bridge support:
Oberhaupt_05 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Oberhaupt_05.gif&hash=3bca649e96272806fd8047e48c2b4b29a3c69a93)
Oberhaupt_06 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Oberhaupt_06.jpg&hash=f5fbeb22e81e64f2c021cf3c7f13e0d7f8cb2d83)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Winde_01.jpg&hash=d29f4d36498b1e4e5cc3b19a14fcd197f0d0c3ae)
Copyright: WSA-Lauenburg/Elbe
Winde_02 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Winde_02.jpg&hash=b7e5faf381146d1caf7f2397efb818bec4f07879)
Copyright: WSA-Lauenburg/Elbe
Winde_03 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Winde_03.jpg&hash=9f86df7a133c3c3fd6113336e10632e7b1f0384c)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Oberhaupt_04.jpg&hash=f44e8bc05c35095a4ee524b9799e2d3282d7fb06)
Copyright: WSA-Lauenburg/Elbe
The horizontal pulley (right side) I haven´t drawn yet!
Copyright: Lauenburger Elbschiffahrtsarchiv (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Hubbr_cke_LEA-261_mitte.jpg&hash=eb0904d7f43cc6bfae6938423c8a5c03ff628140)
Feldbahn-Hubbrücke - Mittelteil
love the color renderings.
cheers
Cool!
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Antrieb-Seilwinde_01.jpg&hash=c850c91c76a69099e9621f78b0d375824fcdea5d)
schematic diagram
Antrieb-Seilwinde_02 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Antrieb-Seilwinde_02.jpg&hash=2d6bcb68ed98f128f4cc2c8d604afb542eb727ce)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Winde-18.jpg&hash=6eb70e3fcf891f00a8408b1ef3678ef0268e6d56)
Winde-19 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Winde-19.jpg&hash=7c9de9e66a52f0acf228160935632018645ace29)
Winde-20 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Winde-20.jpg&hash=5c01288998470195d8326a681a7e34bafce1ec40)
Zahnrad_43mm_136Z (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Zahnrad_43mm_136Z.jpg&hash=878a3d20522031986b2d8bbe6402205b418e0137)
Zahnrad_43mm_136Z-02 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Zahnrad_43mm_136Z-02.jpg&hash=da74cfea2a0444025cd94a0b63aa6ac5647c6155)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Zahnrad_Tabelle.jpg&hash=73f9863ccbcc88be70b3de50a48743b5fcac9c64)
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?
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
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Quertraeger_trennen_06.jpg&hash=fb78211244298aadddc1679f408474307c5fe49c)
The surfaces were trimed with sandpaper first and afterwards with the sandblaster.
Quertraeger_trennen_06-Ausschnitt (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Quertraeger_trennen_06-Ausschnitt.jpg&hash=2fdd9176552314b25cb7fba2996c84db9849966c)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Quertraeger_trennen_07.jpg&hash=c8b2e4a7aa88532516791f134d4c081c5fc8792a)
Also the remaining gears for the winch were drawn.
An animation shows the function already.
Winde_Animation_01 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Winde_Animation_01.gif&hash=8f753e15287fcad2bfd1b5e950094dbf8f7bc67f)
I'm still not quite sure how the four weights were built in the original.
Gewichte_05 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Gewichte_05.jpg&hash=d6f1851928fbce9de5934865c2cc8c35e3bf07a8)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Gewichte_06.png&hash=beaf0be3ca770abd8104177c442c1d6d3db74f44)
Gewichte_01 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Gewichte_01.jpg&hash=81c17f6ab538c8c878bd3659afe7bd621acb01cd)
Gewichte_04 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Gewichte_04.jpg&hash=7ceca1a971dcc772449cde19183d7f05c456361b)
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?
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Gewichte_15.jpg&hash=13c559ad0410e9337334d00821002bd8a575ff55)
They were arranged pairwise ...
Gewichte_16 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Gewichte_16.jpg&hash=fc1898303f7951808e813802373f8321c05a21c4)
... and milled from a 2.0mm MS58-sheet.
Gewichte_12 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Gewichte_12.jpg&hash=5ac36e0da0648344d78fb9e1c29974260b4f95a6)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Gewichte_13.jpg&hash=e4feb11681d9e1c449c2ac63e66dd9113cf85dad)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Gewichte_14.jpg&hash=7a2c8214586148e8b6cae8af667f4287b0ef4cd4)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Gewichte_07.jpg&hash=267af296e89d7e36fd66b3e2b0e62a77020e18ad)
Gewichte_08 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Gewichte_08.jpg&hash=dca6ad706df54b57394b78893fd7a78dc33bfd80)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Gewichte_09.jpg&hash=34c1dddf1b6779e57aa76829bafb84bc41a8e315)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Gewichte_11.jpg&hash=a7e52d627d57477c5e6ffc2da78128bd2cd281e0)
Gewichte_10 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Gewichte_10.jpg&hash=a506e23c0a9641b3665cd42f4c013b007536f9c9)
I am constantly in awe of the precision you achieve in milling such small details.
Im blown away. Thanks so much for sharing and please, please keep it up.
-Michael
@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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Seilrolle_02.jpg&hash=d81a594bf0b4c4c83044df9bea26833951628507)
the individual steel ropes run through various small pulleys (diameter 10.0mm).
Rollenmontage_02 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Rollenmontage_02.jpg&hash=cffbb7ef1d71db682d208d0cbd88d0275b61c710)
Seilfuehrung_01 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Seilfuehrung_01.jpg&hash=e0cf34a3090bb3859fcb0fa017e01688d6f943b9)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Rollenhalter_03.jpg&hash=d1fe31df62a0ef80b832c4928fb9fc888a8fd52e)
Seilfuehrung_02 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Seilfuehrung_02.jpg&hash=7211e4a37c8af729488d7984a45236392afe4841)
Afterthen a small pocket was milled into Pertinax and the brass block was putted inside.
Rollenhalter_02 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Rollenhalter_02.jpg&hash=0593af43639e1b31f5cd5cb287341ffccf701048)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Rollenmontage_06.jpg&hash=32156eb56c78317ef1dbcdb322b2dada23a37e06)
Rollenmontage_07 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Rollenmontage_07.jpg&hash=89000013aec552d2dc59c57129a63b571adb5332)
Rollenmontage_08 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Rollenmontage_08.jpg&hash=fc3ab212f4bc06688b6886d0f789c440e8b2ae2f)
Rollenmontage_09 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Rollenmontage_09.jpg&hash=511a0e4b40c0b03651225207574ae8109c764201)
Rollenmontage_10 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Rollenmontage_10.jpg&hash=23eeac2a85282ad2018e08270dd49a94fe581dcf)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Rollenhalter_01.jpg&hash=51a40a2aa58344f96943f257d1f3fc2b1d7a42b8)
That should suffice. -- Russ
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
@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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Rollenmontage_11.jpg&hash=25745c54a64deb143dda342f450dbb320beb14d4)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Rollenmontage_12.jpg&hash=6f106f0617911066a25b26b4b3130aaf7358b937)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Rollenmontage_14.jpg&hash=6881988cd806c46f5a7f86b3e631187e6842fbaa)
Rollenmontage_13 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Rollenmontage_13.jpg&hash=b3724246d6bedab6cf9899ea9262029311ba2724)
I'm not sure there are words to describe this incredible "art". Allan
I agree with Allan. I also must compliment your professional quality photography. Most satisfactory. -- Russ
Ditto to the previous comments!
Its very satisfying just watching the process unfold. Thanks for sharing with us!
This is an amazingly professional build. Well beyond being a hobby. I am deeply impressed at your micro engineering.
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Metallkante_1_25mm_01.jpg&hash=99a5d6944b6debf65f8724800e7d053f92d5f0ac)
For test purposes I profiled Ureol rods and the brass profiles afterwards.
Metallkante_1_25mm_03 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Metallkante_1_25mm_03.jpg&hash=97bfef1c6b596e72b21fab6b8926cb8ba59b49dc)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Metallkante_1_25mm_02.jpg&hash=a4c1812c58842898d4d8eee3d4759f35afa41e7f)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Winde_21.jpg&hash=3b95d24a3dd848ef4e95c341aff228d19b43c5fc)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Winde_22.jpg&hash=2c5725507c2dcbdde856230bc16475e1bc41e53c)
Winde_23 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Winde_23.jpg&hash=6f3138f4431e657a1782c0af4ee6840be20e5a79)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Winde_24.jpg&hash=6fd7b13b0312f21796bdf2906b62dcbdfc0ad2cb)
Where is the spoked gear coming from?
Or are you going to modify a solid one?
Great gear site - thanks!
-Marty
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Zahnrad_136-Zaehne.gif&hash=7488bec41d5377f5b9544087c5fed4d756ed81cd)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Seilrolle_03.jpg&hash=9982e7d19bbb321a5bf6aa150df3206a2bc2494b)
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.
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
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Modul-Montage_009.jpg&hash=0277712d4077f46ca41da8ecae39d19ddc523de8)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Mauer_rund_01.jpg&hash=7040adac2012a111e34b5c76431db7ae748fb7d8)
Copyright: Lauenburger Elbschiffahrtsarchiv
Mauer_rund_02 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Mauer_rund_02.jpg&hash=3c154454b7f007b97c9c2dbcec3d751b17407dd7)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Mauer_rund_03.jpg&hash=5c1098bbd806e7189b93a320f05bf9c28b42e355)
Mauer_rund_04 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Mauer_rund_04.jpg&hash=f04c0426e151c17e699d882e8a548fef7298f4cb)
Slowly the left wall of the sluice gateway grows in appearance.
Spanten_Wand_schraeg-01 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Spanten_Wand_schraeg-01.jpg&hash=a53b83e096283a429e22242bfd760254e6528982)
So I cut the frames for the "round" wall and mounted it.
Modul-Montage_011 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Modul-Montage_011.jpg&hash=efebb2463e6387b79e5ad730bfd2a284354dd215)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Modul-Montage_010.jpg&hash=e3fe82a0deb1c0243834de8b1533e3abac01fe38)
Many materials, many techniques, one remarkable result!
The techniques are creative and professional and their implementation outstanding. All in all, rather adequate. -- Russ
It's great to see it all coming together.
With Photoshop I created a floot marker.
Pegel_5_2mm_breit (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Pegel_5_2mm_breit.jpg&hash=53e73a342fe864e9aa6fca6943d7b049e2b17818)
For trial I printed it out on plain paper and attached it to the wall tentatively.
Modul-Montage_014 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Modul-Montage_014.jpg&hash=2747403836db6cbe7ef6c85560b42c93a56ffaf6)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Modul-Montage_016.jpg&hash=14a995175a3569b062fda8b8fbe354f6c3c224ee)
The large corner UREOL-"calcareous sandstones" I have mutually mounted on two 8.0mm brass tubes and glued with superglue.
Modul-Montage_012 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Modul-Montage_012.jpg&hash=ece58897a7dc08d759ca21c0c8ab4c848778102b)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Modul-Montage_013.jpg&hash=ce23f4fbd5cb9c5d77195f14649c4e25ce1f1dab)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Modul-Montage_017.jpg&hash=e907c9bccea441db8b0b72d4a7583ee91261c6e0)
Modul-Montage_018 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Modul-Montage_018.jpg&hash=cd6a8f42f06391dd6b510d52d59eb5494d6ec2cb)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Hubruecke_1901-1965.jpg&hash=284685184ea6519fc7f50285af4dfb0e95d424a4)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Hubbruecke_Archiv_0-3.jpg&hash=4939710bd90348f608b94297c4814a49c83c64ae)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Angebot_Neubau_01_04_1950.jpg&hash=4b86f89f51f60870a7cbdb4ee84f9ea39afd8b67)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Die_Bruecke_30_08_79.jpg&hash=46c47d568829e047bce773d9603bf40ace7699b8)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F290308_Hubbruecke_1964.jpg&hash=7226daf5d27745b67954b5283df282fdffef6347)
Slg:Hellmich
This build is so interesting, I'll be sorry to see it end when you finally get it finished!
This is a wonderful project to follow.
I love all the research that has goneon to make the build a reality. And the quality of the build itself is seriously impressive
@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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Sandstein_Ecke_006.jpg&hash=fe5bb7f87fcdb0f6530f7efeb45372834270f106)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Sandstein_Ecke_007.jpg&hash=a681d7f02a67e73acea19b19c19248adde5d382c)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Sandstein_Ecke_008.jpg&hash=cd0f781600f56f18326e7dfaafab748c8588d417)
Sandstein_Ecke_009 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Sandstein_Ecke_009.jpg&hash=59263da98f00fa64bb539cf60da6102972f5dc12)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Sandstein_Ecke_010.jpg&hash=52321b8955e30766a1d17cd7c4f9b137d0d368b0)
On the following picture you can compare the new bricks and the old one. They are only loosely laid.
Sandstein_Ecke_011 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Sandstein_Ecke_011.jpg&hash=8235a48a6b7557a2c7a35ef913a5b7870764c221)
Now the stones must be cut to the correct length and width before I can glue it.
Sandstein_Ecke_013 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Sandstein_Ecke_013.jpg&hash=2b464d1c88d8a6d46c22f21d40a544d6901f9ce5)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Sandstein_Ecke_014.jpg&hash=ffb1f5567aa6923b2405ac626c0bf095e1be218a)
they were glued.
Sandstein_Ecke_16 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Sandstein_Ecke_16.jpg&hash=ee50120d7cbcd35d9c7a6ef78c1fb0e525a61a7c)
The border edge on the left side I adjusted to the same level of the right plate.
Mauer_rund_05 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Mauer_rund_05.jpg&hash=0d3355954115b073f8a7c0571112a8fd27457c5e)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Mauer_rund_08.jpg&hash=96af58b2a51beb0fbec2625ed32ab72c4f7c4333)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Kante_fraesen_01.jpg&hash=40925f8a51668ac9f9363c09ec90e6ae31bec25b)
Mauer_rund_06 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Mauer_rund_06.jpg&hash=e3a480ba76db855663dcc0344668576f31d98765)
Mauer_rund_07 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Mauer_rund_07.jpg&hash=31d1c91f52f45a3ff51588700009b77d47b61f87)
Perfect. -- Russ
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Stehpult_04.jpg&hash=a71df0f3da08ee0842c184089b316cf4b0ce7f3e)
As a little finger exercise in between I drew this high desk...
Stehpult_01 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Stehpult_01.jpg&hash=0747f5d67259088d414982192bd538bc9e26aea0)
... and milled the first parts of nickel silver and brass.
Stehpult_02 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Stehpult_02.jpg&hash=e3515812f7d524ff330a758a27b5d5c0d2fea618)
Stehpult_03 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Stehpult_03.jpg&hash=c5b987ea895d3385ca15ad92174e2be2eeb7bf05)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Stehpult_05.jpg&hash=38beda5d91f2eb03750eb9ca98a194df5e91b8d3)
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-Fr%C3%A4se-quot-Frieda-quot).
But the result is ok:
Stehpult_06 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Stehpult_06.jpg&hash=8179755fd548571169bf2197e062bb301db23753)
Stehpult_07 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Stehpult_07.jpg&hash=7a75e0e0f4598b58a13cad9c7001037ed76d2630)
Next step will follow soon – I ordered a new Kress 1050 FMT 1.
Nice! I hope your new milling machine understands what great work will be expected of him :)
Ho-hum, perfection as usual. -- Russ
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.
Perfect work !
After a new milling motor was commissioned, I could mill out two jigs from Pertinax.
Stehpult_08 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Stehpult_08.jpg&hash=ddd3dd2677ec18382768e8719c6325ad7ad07a71)
Stehpult_09 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Stehpult_09.jpg&hash=94d983f4505fe083a805a35fd6fcd8cda73e2241)
Stehpult_10 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Stehpult_10.jpg&hash=d07f2c0a8f9155677392f91fea917ab8bdf5fb98)
Next, the cover plate for the high desk came into line.
Stehpult_15 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Stehpult_15.jpg&hash=fa5ce640bccfc0c334c8d941f028ee1d8ea61223)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Stehpult_13.jpg&hash=df53a144c305de1a46a1b99d41cfa98e9a3127fd)
So a new milling file was created.
Stehpult_14 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Stehpult_14.jpg&hash=915e58bdfcdda53673b12803f40d3aa5bf6bc4e7)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Stehpult_11.gif&hash=a1a3e3b58748db087f5caf579e1984e13d812885)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Stehpult_12.jpg&hash=91636fc2cc23d2faf68dc485ac9411357f2d88ed)
After that I bent the sheets with the help of two brass profiles, into which I saw 0.3mm wide slots.
That is so sophisticated I think I'm getting a headache! -- ssuR
These methods are so far beyond me, yet still fascinating to see!
Russ, Ray - Thanks :)
Today, the first high desk was soldered - the Pertinax gauge helped. Then I cutted off the overhanging legs.
Stehpult_17 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Stehpult_17.jpg&hash=c4c3fb7bb9751300cbdba7f2fa06385d13622323)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Stehpult_18.jpg&hash=a3f84a2a5b9a413d80a0411f64563681f691601d)
Stehpult_19 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Stehpult_19.jpg&hash=158fd6ee24a07f0ed52c500c6851959b04f6d583)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Stehpult_20.jpg&hash=b5bf0cd43699774e2f3f1f1e3867a395336ed256)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transtportwagen_01.jpg&hash=bad893d5b8b59778b7f8bee2898c552b6aa13924)
Alter_Transtportwagen_02 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transtportwagen_02.jpg&hash=81c1e5ac7e51cf1366158585f0ef9567539142b3)
Existing limewood cutting boards were cut to 9.4 mm width and 1.0 mm thickness.
Alter_Transtportwagen_03 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transtportwagen_03.jpg&hash=d4000acb4d7f662ad539af80bddbd4f32bf877e0)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transtportwagen_09.jpg&hash=ba865d568098f28ebef9c7b467689a9478b54084)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transtportwagen_04.jpg&hash=1e66c85697b5b903ad052be252b3339d238335b8)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transtportwagen_05.jpg&hash=928a84b02ef67b7abb70ffca42b77505a0c7f27f)
Alter_Transtportwagen_06 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transtportwagen_06.jpg&hash=e93c6d209a61c961ecaf78ac4dec8663c1cc6eb2)
The milled brass frame received the same holes.
Alter_Transtportwagen_08 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transtportwagen_08.jpg&hash=cfa19d10155924f5592c6131498c510108d4e911)
Nice. I like the idea of sandwiching some metal between the planks to give it strength, without detracting from the appearance.
Beautiful fabrication. -- Russ
Nicely planned and constructed. The model will look really good and not be too fragile.
Great!
I assume you will make the wheels?
Looking forward to seeing that process!!!!
-Marty
Yes, I'm particularly interested in how you do the wheels. I have a project on the go which uses similar wheels.
Les
Thanks for your interest ☺
Now I´ll go on with the wheels. They have a diameter of 26.5mm.
Alter_Transtportwagen_10 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transtportwagen_10.jpg&hash=878537546b092429d29990e2e3836a61b48efaca)
With Sheetcam the milling file (.tap) was created.
Alter_Transtportwagen_11 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transtportwagen_11.gif&hash=9c1cdca8e582aa2bd5486d9243ac3350f6988a48)
Each two wheel halves were cut from 2.0mm brass sheet.
Alter_Transtportwagen_12 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transtportwagen_12.jpg&hash=3d1831225cbe33dab85675991662cc2040351bb4)
Alter_Transtportwagen_13 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transtportwagen_13.jpg&hash=62183839587cbd6fea4fb40d6b268ece9792787d)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transtportwagen_14.jpg&hash=b819201715fb99a0f37408f8d6034b4d5dccfcac)
Wow! Just...wow!
Ditto. -- Russ
love the trolley cheers
Nice!
CNC makes it (look) easy!
Marty
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transtportwagen_15.jpg&hash=dd5ed56bcfdaa2fa011b113993e583ba5c662edf)
Alter_Transportwagen_17 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transtportwagen_17.jpg&hash=b5611d0b6591bfc3764d7cf6c0904035cb0f141b)
Alter_Transportwagen_18 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transtportwagen_18.jpg&hash=b9d85bdeb27cb0adee327e762a990a4c334d623e)
That is just beautiful. -- Russ
I agree with Russ: Beautiful!
Yep, definitely beautiful!
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_19.jpg&hash=04f584578c5213ac2c7747ff9c0c0337dd754a07)
The rivet heads I grinded on a sandpaper file.
Alter_Transportwagen_20 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_20.jpg&hash=b9fe504622bca9bdbcf4b5898f30dca9ee35ffcb)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_21.jpg&hash=2a96299442763f270ae371e54e24194b9d223cc6)
... and the lathe did the rest.
Alter_Transportwagen_22 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_22.jpg&hash=ddaf0c716c5cb548d68a1ed2a2dd3365a149e978)
Now a first rehearsal on four wheels.
Alter_Transportwagen_23 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_23.jpg&hash=80639244169754337fe23e36d7c4cd2911fb2152)
Wow!
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
@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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_klein_01.jpg&hash=7cef4db0c62dcdc4bc6c8c5fab819c6babf10225)
Alter_Transportwagen_klein_03 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_klein_03.jpg&hash=227a3ce7d6d91feb8ab43cf683f583f646133bce)
Alter_Transportwagen_klein_04 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_klein_04.jpg&hash=e5f50f5c11b86b417da02bca736730243c5ba7c7)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_klein_05.jpg&hash=4f673d4a257094dec1315afadd1e072d4546de4e)
Alter_Transportwagen_klein_07 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_klein_07.jpg&hash=872970f1adda494e092578c40ea8e2819e4df225)
Synthetic resin bonded paper gauges facilitate the installation of the crossbars.
Alter_Transportwagen_klein_08 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_klein_08.jpg&hash=198076569eb0509fd26ae1ed33ce2259f2eecbad)
Alter_Transportwagen_klein_10 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_klein_10.jpg&hash=05d126d1d023bac595b25dfa5ec2f2b339e6889d)
The foreman must always complain about - of course he immediately noticed that the wheel is slightly oversized.
Alter_Transportwagen_klein_09 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_klein_09.jpg&hash=0050781b89b315846de277a799efcf5848e77f7c)
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
Another terrific start! Maybe a little filing can resize the wheel :)
You're a wizard of miniature fabrication!
Russ, Bill, Ray - Thanks! :)
See how the Pertinax gauges looks after four trolleys were soldered.
Alter_Transportwagen_klein_11 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_klein_11.jpg&hash=587a5e41b106b247a559bcb0944fafa13a783338)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_klein_12.jpg&hash=3f8db1c8261e4a9d47599d940e0fea49b3dae246)
At the old trolley the shaft is still missing.
Deichsel_01 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Deichsel_01.jpg&hash=33e4cc9756780c7f3f66f86598cecd2b532ce79e)
For the cross-connection I have milled a little gauge with an 1.5mm ball cutter.
Deichsel_quer_bohren_01 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Deichsel_quer_bohren_01.gif&hash=9a4f9b879874f9734eee9a3033edc935989d7616)
Deichsel_quer_bohren_02 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Deichsel_quer_bohren_02.jpg&hash=7d32dac334494911b5a061a3e7cb019053bf052b)
In the vice both oblique holes were placed vertically by the help of a second gauge.
Deichsel_quer_bohren_03 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Deichsel_quer_bohren_03.jpg&hash=33155256a1486a0b5c516b4e70c221a295dbb382)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Deichsel_quer_bohren_04.jpg&hash=076970dc9f7ca28e9e35efb0ee54739c5fd231df)
The two long shaft halves were "sharpened" in a hard paper gauge.
Deichsel_quer_bohren_05 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Deichsel_quer_bohren_05.jpg&hash=057f3f9268211281dbc966bdebb5a8003f03e69a)
Deichsel_quer_bohren_06 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Deichsel_quer_bohren_06.jpg&hash=ef280ba7d54900c01ef6809703daefa85c061154)
It's pleasing and inspiring to see the consistently high quality of your work.
as always a great series of photos of lovely work.
cheers kim
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
Marvelous work!
@ 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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_klein_13.jpg&hash=ad4f7e3251f4cebcf3db34c1d5b80779f147748a)
Alter_Transportwagen_klein_14 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_klein_14.jpg&hash=17ad1ae9b5ed79240e2bfe37da11732de8ed6014)
Alter_Transportwagen_klein_15 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_klein_15.jpg&hash=5487b02929f311021bc6a4cd4cc06a7a76284dbe)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_klein_16.gif&hash=149b922a905e2be656245d619b92be528d0e1103)
To get equal shafts for the large trolley, I also milled a small gauge from 1.0mm brass sheet.
Deichsel_quer_bohren_07 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Deichsel_quer_bohren_07.jpg&hash=ed76ddd4259b8a481a8671215975591b54273bd2)
Deichsel_quer_bohren_08 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Deichsel_quer_bohren_08.jpg&hash=59244eafb0d6209419c18c076fb0bf0739db3222)
Deichsel_quer_bohren_09 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Deichsel_quer_bohren_09.jpg&hash=1d632649e8bd544762dc061326cf31b022dbec5d)
Deichsel_quer_bohren_10 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Deichsel_quer_bohren_10.jpg&hash=0a0930d79a19a2d7b3e45445840a02a8262992f4)
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
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fi232.photobucket.com%2Falbums%2Fee275%2Fgfadvance%2FAndrew%2520Barclay%2520Narrow%2520Gauge%2520Loco%2Fimage_zpsufawphls.jpeg&hash=4bc3f48ba9eb121d155db37ea78ef0931b7b9fce)
Satisfactory nonetheless. -- Russ
Gordon, your skills and models are excellent. The choice of materials and tools take nothing from that.
Excellent work, Gordon!
"INCREDIBLE".....Allan
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_26.jpg&hash=3653d18af76ca197e1b27525b4303245a58fab9d)
Also the same soldering jig served as a fence for the saw - here the tip was separated ....
Alter_Transportwagen_24 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_24.jpg&hash=59d1533c81e874d50378b38132c34bedf4661636)
... and the edge was rounded with an 1.5mm ball cutter.
Alter_Transportwagen_25 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_25.jpg&hash=87a557ed0cf2b5dba288c3a05da325aa07d39f10)
The first old trolley is almost ready .... he must be grown old a little.
Alter_Transportwagen_27 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_27.jpg&hash=1839afbad155de77953336a77df295409778882c)
For the small trolley I had milled the steering roller holder - made of 0.5 mm nickel silver.
Alter_Transportwagen_klein_17 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_klein_17.jpg&hash=9ddbaeedf380a813be024e40a997182481a61dff)
The other small bearings were milled – they are waiting for the assembly.
Alter_Transportwagen_klein_18 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_klein_18.jpg&hash=8fd304d87cbb9db671bb3dc303102d70fc7644f6)
Geeze. Watching the world class work in the thread is both wonderful and depressing ... ha.
Frithjof, following along your construction by looking through your lens rather than over your shoulder is a very enjoyable and educational experience.
I'm loving it!
"World class" is no exaggeration. (The same applies to a few others here.) -- Russ
This is incredible stuff. WOW
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_klein_19.jpg&hash=3f30e1f5010a8141f7643842e2f578efe718b811)
Alter_Transportwagen_klein_20 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_klein_20.jpg&hash=c25560454cd16fd9a533a0282eaeb4cc65a6b1d6)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_klein_21.jpg&hash=bbdd0277e3433e759fd63546c8878b1cc1f9e51d)
Alter_Transportwagen_klein_22 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8054%2F2903Alter_Transportwagen_klein_22.jpg&hash=f1fc77ce789f14eb09d427c416e80ca40b4ab9d5)
Another adequate development. -- Russ
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 ☺
Good to hear you will be resuming model work soon!
I was wondering where you were .... -- Russ
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_051.jpg&hash=bbbbb6ca256899407ae9e7c0ff1effb51970d9b1)
Münzel-Kran_Lauenburg (Copyright W.Hinsch-LEA)
Muenzelkran_Lbg_2k (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzelkran_Lbg_2k.jpg&hash=5f562f3ce13f85436b20bfc0281898d6b17ef0b1)
Münzel-Kran_Lauenburg (Copyright W.Hinsch-LEA)
Muenzel_Kran_LEA_03 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel_Kran_LEA_03.jpg&hash=c437e802dfdec4e09724efea905b763f8f488477)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_136.jpg&hash=51468794258c4b024362ed4bc8ea4703ed4122ae)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F8181%2F2903Muenzel-Kran_137.jpg&hash=0a4e509ec735367b904361096bc5dfe232160ae3)
hi Frithjof.
how are you I went through the photo reference on Hamburg I really enjoyed it cheers Kim.
Nice. I like the look of that crane. It will make an interesting model.
Hi Frithjof,
Crazy stuff!
What is the brand of lathe that you use? Proxxon?
Franck
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?
@ 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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Winde-21.jpg&hash=6895407a9cc07480163c762e476bcc3fd0c3f79e)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Winde_21.jpg&hash=3b95d24a3dd848ef4e95c341aff228d19b43c5fc)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Zahnrad_136-Zaehne_02.jpg&hash=fc3f4762c0bb41b3f616615e3cadacdddcb714a5)
Thanks for the link to the mill.
Another question. Which CAD software do you use?
Hi Lawton,
it´s Inventor®: please look here (https://www.autodesk.com/education/free-software/inventor-professional)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Steigung_14_06_08_1.jpg&hash=1441a3725ec89c770d4c19e6198cc4feb6ff5c54)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9406%2F2903Feldbahn_Schotterwagen.gif&hash=db294c9aa1c3ed2abaf06b3424e122117b1b74d7)
Feldbahn-Schotterwagen_01 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9406%2F2903Feldbahn-Schotterwagen_01.jpg&hash=7f7e24fee6a91edcfa55a5e5f208050008457608)
Feldbahn-Schotterwagen_07 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9406%2F2903Feldbahn-Schotterwagen_07.jpg&hash=0fc2c4c934e735ea24195a56e4bd179f6295d1e4)
Feldbahn-Schotterwagen_08 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9406%2F2903Feldbahn-Schotterwagen_08.jpg&hash=1ae89a78244edb5a0d048d4bd7ab70300c7d45c0)
The funnel was drawn as an unrolling ...
Feldbahn-Schotterwagen_09 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9406%2F2903Feldbahn-Schotterwagen_09.jpg&hash=2e1ad596143449012fd363cfe565b2bdacdfadb9)
Feldbahn-Schotterwagen_10 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9406%2F2903Feldbahn-Schotterwagen_10.jpg&hash=96cc44d3bf3518cb91b29da8d3ac09d9edb6cedd)
... 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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9406%2F2903Feldbahn-Schotterwagen_11.jpg&hash=3e6a1b0028c112348367fdf589755f78bf862363)
Milling took 15 minutes - with two changes of milling cutter.
Feldbahn-Schotterwagen_12 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9406%2F2903Feldbahn-Schotterwagen_12.jpg&hash=3dcf587b401e4906e385b39fd734052364e9fd6c)
In addition, small assembly jigs were milled out of 5.0mm Pertinax.
Feldbahn-Schotterwagen_13 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9406%2F2903Feldbahn-Schotterwagen_13.jpg&hash=403b0f43c2d1a737029f9ad3ff82cc2db88363ba)
Feldbahn-Schotterwagen_14 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9406%2F2903Feldbahn-Schotterwagen_14.jpg&hash=88e8c90202b0068879ffebbdee9ec89126f2a038)
Feldbahn-Schotterwagen_15 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9406%2F2903Feldbahn-Schotterwagen_15.jpg&hash=ae8fa7e8518fc270b0172acc2d48947fa404f657)
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
Very cool!
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!
It's been a while since I wrote (28.11.2016 (http://www.finescalerr.com/smf/index.php?topic=1424.300)):
QuoteThe 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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Metallkante_1_25mm_04.jpg&hash=36ddfd540f0cbcc7486b0a0c86886599df7fb9f2)
Metallkante_1_25mm_05 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Metallkante_1_25mm_05.jpg&hash=534c11a2de1172c528050edd5515ec9e29e1657e)
Gradually, the parts are positioned on the upper edges of the lock walls on a trial basis.
Metallkante_1_25mm_06 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Metallkante_1_25mm_06.jpg&hash=dcdce0e703f4f7e7376c3fc28b2bdff98ed192cd)
Metallkante_1_25mm_07 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Metallkante_1_25mm_07.jpg&hash=be43b7ac4d22ba0eb8b7d5109c64b1b4a160cec2)
Metallkante_1_25mm_08 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Metallkante_1_25mm_08.jpg&hash=3ae82069af3f8366a73f08476353d304268ef775)
Meanwhile, all brass profiles for the upper left edge are mitred ...
Metallkante_1_25mm_09 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Metallkante_1_25mm_09.jpg&hash=77f75cb88055b34940b07a9bff1010b7438ae5c1)
Metallkante_1_25mm_10 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Metallkante_1_25mm_10.jpg&hash=391c605d64ea8ed3468e3a10f2ba00fef2b293c0)
Metallkante_1_25mm_11 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Metallkante_1_25mm_11.jpg&hash=0e5095d30c6a44eb6bcb99705a08960390be8289)
... and tentatively placed.
A small milled subframe helped to solder the small brass profiles around the ladder.
Metallkante_1_25mm_12 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Metallkante_1_25mm_12.jpg&hash=e2cafa0cf0d2af8048c5297a9abba27dfe82d9b0)
Metallkante_1_25mm_13 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Metallkante_1_25mm_13.jpg&hash=f6a1b18d7982180f17c461f326f50a519a5b7bec)
Metallkante_1_25mm_14 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Metallkante_1_25mm_14.jpg&hash=c6dee6177d3729b2b30455958593f1fbaffc3795)
Metallkante_1_25mm_15 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Metallkante_1_25mm_15.jpg&hash=2bd30be84e8c839fbb770fc78cf96214d73b8d90)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Metallkante_1_25mm_16.jpg&hash=120ef90302cbd19323e92eb0a5d9b34d9e4bb2a8)
Metallkante_1_25mm_17 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Metallkante_1_25mm_17.jpg&hash=96ba02cf63d0bf6577a8b175c7a6b86e8cb81395)
Metallkante_1_25mm_18 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Metallkante_1_25mm_18.jpg&hash=988d8e75d1f1d4709c67e8c144779fd5ad5aa33d)
Metallkante_1_25mm_19 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Metallkante_1_25mm_19.jpg&hash=ede8deb83b7d899d7e8d26936c74ed4285791698)
Now the mill machine has to come into action.
Frithjof
As always, it is a pleasure to follow along with your progress on this project!
The precision and execution are beyond comprehension. -- Russ
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Metallkante_1_25mm_20.jpg&hash=33dc95d011ea6a07881198b655faf1d38c97932f)
Metallkante_1_25mm_21 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Metallkante_1_25mm_21.jpg&hash=75b688becf8bb88e015b0370d01777da33fea2be)
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.
How are you going to achieve the butt joints?
Always enjoy seeing your work.
Amazing just amazing - such precision
Barney
@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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Crop_Schleuse_Lbg_22_07_1959.jpg&hash=c9e6237533397727ae88cca7b97bbc42412d94c4)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Metallkante_1_25mm_23.jpg&hash=603616a6eb8a3e8bf2a6c91371419973d3a04daf)
Metallkante_1,25mm_24 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Metallkante_1_25mm_24.jpg&hash=1e8c94800b582a920609ff35ee8c744421d5822b)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903was_wird_das.jpg&hash=6fe18725a48fc8589ceb5f357a9c5319581841fb)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Leiter_01.jpg&hash=c0e24eb4d881ee3dd3347b0f7496aee2bf7696b6)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Leiter_03.jpg&hash=1b6081a23d269d1e4158be6a22b9fdc2796dbcbf)
Afterthen the two ladders were sandblasted.
Leiter_04 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Leiter_04.jpg&hash=96c8f62988fb64cb5dd3f99cf98fa9797e4d1faa)
Four 1.0 mm holes in the wall pick up the pins at the ends of the brackets.
Leiter_05 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Leiter_05.jpg&hash=670413819a9bfec5423ace4de6d991349ebb5cd1)
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!
Everything looks perfect. I find no room for improvement. Satisfactory. -- Russ
Once again a well-made jig proves its worth!
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Metallkante_1_25mm_028.jpg&hash=9dddde9a4cc3cea3b07342a426066f867315d71e)
Metallkante_1_25mm_025 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Metallkante_1_25mm_025.jpg&hash=1bc2b26e7f8cd661d6001f2a0a67411dd6219a62)
Metallkante_1_25mm_026 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Metallkante_1_25mm_026.jpg&hash=2c011d54abe263c6b0429d3dc077d3bd7da19a80)
great, what is the sound insulation for?
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Modul-Montage_017.jpg&hash=e907c9bccea441db8b0b72d4a7583ee91261c6e0)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Modul-Montage_019.jpg&hash=144ae46aeba60dcbf0ed326e7a085994ddb1a2a7)
The plywood wall plate left below the stairs was glued and fixed with Tesakrepp and aluminum weights to dry.
Modul-Montage_020 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Modul-Montage_020.jpg&hash=54d2fc0cf3260d2d08d8a7b7936d783baa8bc684)
Modul-Montage_021 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Modul-Montage_021.jpg&hash=ef93dd72b6439f9ba4d2316b574b9a5ed0b55138)
Modul-Montage_022 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Modul-Montage_022.jpg&hash=52b119087a17205ad74ba67ad1bac2e922b4bf5c)
Modul-Montage_024 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Modul-Montage_024.jpg&hash=209620a4e71f46d446798029c813ff578fc23cde)
Modul-Montage_025 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Modul-Montage_025.jpg&hash=a8debee15489f8d2edca9f388d1b2a38d024e5c3)
Impressive. -- Russ
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Modul-Montage_28.jpg&hash=42d7bbc7aec0bd5f8af45b50818a00b41870d54f)
... maybe with a little too big legs ....
Modul-Montage_29 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Modul-Montage_29.jpg&hash=e05e6f742a4af76f622a3e234d9160cf87751303)
... in principle, it's a kind of desk, but it should be used only twice.
Modul-Montage_26 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Modul-Montage_26.jpg&hash=39da881eaacd3dd4ee709f408aa179238dc90680)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Modul-Montage_27.jpg&hash=2f6edb478ab28be29f0e9f0b1c30e55b1532dd8c)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Modul-Montage_30.jpg&hash=f234aff0ebb61008d04fc56e3877624b602104e5)
Modul-Montage_31 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Modul-Montage_31.jpg&hash=a7bacf2fb41eb8f2886d07941abd22b4dbd8409d)
For better hold the two 1.8mm brass tubes while sandblasting, I pulled them onto a 0.3mm brass wire.
Modul-Montage_32 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Modul-Montage_32.jpg&hash=3e2c61827dd4b4b4a88c8a4d45a752df56a19aa3)
Then they were mounted with a new UV adhesive.
Modul-Montage_33 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Modul-Montage_33.jpg&hash=31642cfddf5ff0687c911e703f646c7af4a34d65)
Modul-Montage_34 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Modul-Montage_34.jpg&hash=14ca8ecf001ad41292cdc8b086126c7145dfbb93)
Modul-Montage_35 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Modul-Montage_35.jpg&hash=1d3a26cb6f68bce2022ad23edb3135855c024fc9)
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!
Good idea, Havard. Glad I thought of it! -- Russ
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
@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.
QuoteOn 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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Modul-Montage_36.jpg&hash=bcbe4863365420a8f176aaf9d441acbad48d48e1)
QuoteAbout 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.
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.
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
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Modul-Montage_37.jpg&hash=d8fc0944f2da8348a504a6d220a73d6fe317fa58)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9461%2F2903Spitzschute_1926_01.jpg&hash=7cebf2f1ae3319e00591a074cdc29dce32ae22a0)
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.
I will miss the red Lego boat when you return it. Still, I look forward to seeing how you build the dinghy. -- Russ
I wrote:
QuoteHowever, 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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Modul-Montage_38.jpg&hash=8fad0c007bf2ae1ae76ae170fdceb8de7a33d59c)
mounted on MDF boards and glued with superglue.
Modul-Montage_39 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Modul-Montage_39.jpg&hash=32f913b3a4842df4fdbc33323f6e7429235ed213)
Modul-Montage_40 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Modul-Montage_40.jpg&hash=dedbbf12878cbef4713f169c882d484088c9f870)
Now these pre-assembled parts have to be painted before they are glued to the bridgeheads finally.
Modul-Montage_41 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Modul-Montage_41.jpg&hash=ba03d8119fc964acde2d6fc1788970b59ec20ac1)
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
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."
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
@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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_07.jpg&hash=6a1a8d557f35f2dac6c23c02ea9ee0789eae1bb5)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_43.jpg&hash=48d32c3b31d2380245b9cb94dc01c84c213a4c33)
Schwimmer_44 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_44.jpg&hash=e3cbea4f9300b2595d86a8d2b8323263c97ce763)
Schwimmer_46 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_46.jpg&hash=af263211c5906eed97d819bfa82e249918983aff)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Hubbruecke_Portal_Detail-1.jpg&hash=e9b35b118b121570a3a267d2fb47accd01b2f951)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_52.jpg&hash=7764d634a5fe178d2aca1a22502293698131b86b)
Schwimmer_54 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_54.jpg&hash=a6470a4668e7c4bc72b6a2b2bfc38fb0cf265474)
The four guide rollers are not drawn yet.
Schwimmer_56 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_56.jpg&hash=1dfb7194ed8c9698b29f06f0c5515362f220497d)
Schwimmer_58 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_58.jpg&hash=40bf5720b37ebab5391200ed4cd8dc659b82d841)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_59.jpg&hash=07d43d7351acc4c28bd685c0ab8c728a27126076)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_60.jpg&hash=269b9febb40400f1295fa2d0b916bc6143674c1e)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_61.jpg&hash=3f6f03bcda6ff394956364c5822af715aefe4be7)
Excellent design and fabrication. Most satisfactory. -- Russ
In the meantime, the MDF panels for the shaft have been re-milled and assembled.
Schwimmer_70 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_70.jpg&hash=6390dda5c4eebd0aea0a13d6a38bc9d5fb70d726)
Now the new Plexiglas® cylinder also needs a new brickwork in the visible area!
Schwimmer_62 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_62.jpg&hash=c34b033011583afa2248ff6eb043e5017288ddc6)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_67.jpg&hash=4083b38d6018a72c434e8029cbb09efe827cf94a)
Schwimmer_68 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_68.jpg&hash=55f08a3e6a0deff53c9ed9763b76ad321d31e6fc)
Schwimmer_69 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_69.jpg&hash=16762daf8ae7200705ca3db9d8d99bbfdfcc5e6f)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_71.jpg&hash=06f53fae6e62096fead8b439b86504e233b023d2)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_72.jpg&hash=675edbe94b3bba2488dc604ad47c835208c087de)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_76.jpg&hash=08325bc5f2e289e4e7f16e70036b823434b6562e)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_75.jpg&hash=f7113a473443a82c8265041c3eab56a61792aed8)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_74.jpg&hash=e7ae83722edabf303f596da5d85588ca518c7e47)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Heber_16.jpg&hash=b0f8cb0ab50140fdb4dded0ef888e43e9b55d7fc)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Winde_25.jpg&hash=731dbe0450e89da6650d843de325ddf8ccd1227e)
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.
To a "normal" person like me such design, engineering, craftsmanship, and ingenuity is just amazing. -- Russ
Beautiful, especially that burnished piece.
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Hubbruecke_Anschlussbruecken_.jpg&hash=4f3b0b4fec90ce16fabd0d3962cec121df4e4c7e)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Modul-Montage_46.jpg&hash=5b4e84cebfae1f4ebccb772d7bff22c7e211c7c8)
The exact alignment was helped by a long aluminum profile and a few angle irons.
Modul-Montage_42 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Modul-Montage_42.jpg&hash=3fa87f81459d013c2573aecf4ecfb3d8426710a4)
Modul-Montage_43 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Modul-Montage_43.jpg&hash=8e2c9615b004fa276dbae7635ce34e1b0d818653)
Modul-Montage_44 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Modul-Montage_44.jpg&hash=465fcd032b7d9cc3da24c5089a5bd9f83c9d922d)
Modul-Montage_45 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Modul-Montage_45.jpg&hash=963e62ada340c97dce684975a8af7e2a594b9621)
I love what you are doing. Very creative and unique. -- Russ
Quote from: fspg2 on February 13, 2019, 12:50:58 AM
Thank you for your approval!
It is hard to express how much I enjoy this thread!
This is industrial archeology at its best.
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Modul-Montage_47.jpg&hash=5ed3d02da11b96969d7293f2966491e54626cf24)
The diving bell served as a counterweight to move the floodgate.
Tauchglocke_2 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Tauchglocke_2.jpg&hash=366192308c443b08301b8bd14e2f617c6b978fe9)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Tauchglocke_32.jpg&hash=e29fdd6526a5cef9408d83062481f9e8afae04af)
Let me see if the Faulhaber 2020 will be enough as a propulsion engine:?:
Tauchglocke_33 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Tauchglocke_33.gif&hash=b9f76c6d9c7d88561c3d320036d0354482d11974)
Nice. Those linear guides are interesting -- I might find have some uses for those.
Frithjof.
very cool love seeing it come together.
cheers
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.
@ 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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Gegengewicht_Schleusentor_2.jpg&hash=986c9322ea744169db5af935b43a79337c3faa59)
Since then, they were waiting for installation in the guide rails.
Gegengewicht_Schleusentor_1 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Gegengewicht_Schleusentor_1.jpg&hash=5d7fe57ed18cc94f112f70dec63b4ce23b029c01)
Gegengewicht_Schleusentor_5 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Gegengewicht_Schleusentor_5.jpg&hash=bb343b4385270b31be42498bbdec8673b3987f0c)
Gegengewicht_Schleusentor_7 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Gegengewicht_Schleusentor_7.jpg&hash=c308408b9ca29d66996bf83ae6c0d631102509c6)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Stemmtor_3a.jpg&hash=8849a5c8f513b00071185f6afba517325f0b8947)
Copyright: WSA-Lauenburg/Elbe
Stemmtor_4 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Stemmtor_4.jpg&hash=4ba3962c9b15640c06f884f4e2a6c861b16fdc63)
Copyright: WSA-Lauenburg/Elbe
Stemmtor_5 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Stemmtor_5.jpg&hash=1f73050bf74b9412dcad36849a3887aa645f047c)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Stemmtor_6.jpg&hash=4e3b48922e780cb4faf7bc23204ad30b94ae6900)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_28.jpg&hash=936113b04d94a3953325d53d4fd9f4fcabf893f9)
When I got the exact drawings, it looked a bit different! The positions shifted by 45°.
Hubbruecke_Portal_Detail-1 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Hubbruecke_Portal_Detail-1.jpg&hash=e9b35b118b121570a3a267d2fb47accd01b2f951)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_79.jpg&hash=ba1c37ba84a6b680c627326e1c67cbb8339e16ac)
Schwimmer_Laufrolle_01 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_Laufrolle_01.jpg&hash=8c3454b1f552082ddf0cee6e37f5974c419387a4)
Schwimmer_Laufrolle_02 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_Laufrolle_02.jpg&hash=a86ecf8a712bdb49bcfdf9dbb2076c1ed3bfbba5)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_Laufrolle_03.jpg&hash=c779b208ef13e340327c4b30029aba3e55402a99)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_Laufrolle_04.jpg&hash=30503b5b5d6fb91ca63ba0ac451516f007940a3b)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_Laufrolle_05.jpg&hash=6c499747fc960c9f2f63e03b1dd0a155f2b07cba)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_Laufrolle_06.jpg&hash=4553f5c9ea3738a347dc94c869e6827e1d0d8211)
Another inspirational post. -- Russ
Awesome!
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Bohrschablone-Rollenhalter_01.gif&hash=a19b7121b5df4f9fac8845a036372e2b2daa731e)
Bohrschablone-Rollenhalter_03 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Bohrschablone-Rollenhalter_03.jpg&hash=b4031f3fc916b56b598fb7e114cda247d2628857)
On the miniature vise, the jigs were always brought into the same position by a stop.
Bohrschablone-Rollenhalter_05 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Bohrschablone-Rollenhalter_05.jpg&hash=dbc74ae6af16feb771ace1b220b400cef60007e7)
Bohrschablone-Rollenhalter_06 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Bohrschablone-Rollenhalter_06.jpg&hash=ba63d382c9483e9699acef0571191e910cbf3467)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_Laufrolle_07.jpg&hash=a846675175a28149252b12d90dd39736c67e6a56)
Schwimmer_Laufrolle_08 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_Laufrolle_08.jpg&hash=0ff66d2bd27d4310ce82641ce13e34e08cbf18c1)
Schwimmer_Laufrolle_09 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_Laufrolle_09.jpg&hash=89a82d5726b7e18202cf126fdb8d9417447ca14b)
Schwimmer_Laufrolle_10 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_Laufrolle_10.jpg&hash=2bbe1b46c412bd2209447bbd01e8ee5077479faa)
As a precaution, the roller has some play on the side in its axis to compensate for any assembly errors.
Schwimmer_Laufrolle_11 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Schwimmer_Laufrolle_11.jpg&hash=fbed195e79d3c510aaa84b75546c6767db81770f)
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.
I doubt any other hobbyist on the planet is working on a comparable project. Satisfactory. -- Russ
This is so far, far, beyond amazing!
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.
I have to agree with Russ, this is truly outstanding.
Speechless big time !
Barney
very cool again.
Thanks a lot, guys!
After just under three weeks, the two small linear guides (MGN7H 7mm) have arrived from China today.
Tauchglocke_34 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Tauchglocke_34.jpg&hash=d40d06f184741c21ac86c32ebef1aafee0818044)
Tauchglocke_35 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Tauchglocke_35.jpg&hash=bd1c465d72b9f1286a476bfe21aee6c8ccc26b14)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Tauchglocke_36.gif&hash=a21690eeef4e6d99c4b727c9dbe5b10832e7c595)
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)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Hubmechanismus_01.jpg&hash=424f95dc3f4c800be279d4a9c57ee5455ec48a8e)
I have run out of hyperbolic expressions of praise. Forgive me. -- Russ
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.
Hello,
Russ it is forgiven! :)
Thanks to Kevin!
After a long time it goes a little further here.
A colleague from the German Buntbahnforum had linked a picture of the prototype from the ballast wagon from Glossen (http://www.buntbahn.de/fotos/data/7621/2854Schotterwagen_Glossen_360x480.jpg).
My started replica model (http://www.finescalerr.com/smf/index.php?topic=1424.375) (07/29/2018) was already some time in the cabinet and gazed me always, ...so I built a little bit further last weekend.
For the lower funnel end the square "box" was drawn as a flat pattern and milled out.
Feldbahn-Schotterwagen_17 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9406%2F2903Feldbahn-Schotterwagen_17.jpg&hash=e69b5acd477ffa8923f82ce8f42fefdcd7d0d507)
Feldbahn-Schotterwagen_18 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9406%2F2903Feldbahn-Schotterwagen_18.jpg&hash=498d4ee753666c2f49bff057c497dbb1a930d554)
A small 0.3mm nickel silver sheet was machined from two sides.
1) First, I milled a 0.5mm recess into a Pertinax plate.
2) Then the nickel silver sheet was glued with double-sided adhesive film (Gudy 870).
3) Four 2.0mm holes position the metal sheet when it is congruently machined from the back.
4) On the front, the two 1.0mm holes were drilled for the pivot axis of the flap and the three 0.14mm deep V-grooves were milled to bend the side walls.
5) The sheet was carefully removed from the bond and pasted the previously machined side with Gudy 870 and pressed with four 2.0mm rivets aligned.
6) The lower edge received a 0.15mm recess. This sits later during assembly inside the funnel.
7) Finally, the outer contour of the bending part was milled with a 0.5mm cutter.
Feldbahn-Schotterwagen_19 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9406%2F2903Feldbahn-Schotterwagen_19.gif&hash=a574da4be2e79ddf013974394a34746a3c3e5598)
Feldbahn-Schotterwagen_20 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9406%2F2903Feldbahn-Schotterwagen_20.jpg&hash=1f80c38e72f2b7b56c24aef22556ffe2c9f7a0ff)
A small assembly aid consisting of two 5.0mm Pertinax plates is used for exact alignment with soldering on the funnel.
Feldbahn-Schotterwagen_21 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9406%2F2903Feldbahn-Schotterwagen_21.jpg&hash=624a4d53ea574d92a04e6ee7498bdb2e3c879db5)
Before bending, the sheet was annealed with the flame.
Feldbahn-Schotterwagen_22 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9406%2F2903Feldbahn-Schotterwagen_22.jpg&hash=c0c540cd51c9ac024c52ebdfc96c3bc10b0d18e0)
The wagon frame was soldered from 5.0mm x 3.0mm U-profile.
Feldbahn-Schotterwagen_23 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9406%2F2903Feldbahn-Schotterwagen_23.jpg&hash=3ef8a457e3a8896713dc440e948c5311ccde164b)
I can only come up with WOW!, this is terrific! which is woefully inadequate to describe your modeling.
Yeah, it's adequate. -- Russ
Holy cow! Marvelous work!
Spectacular design and crafting!
So far, I had not finished the exhaust in my dust room.
It is still missing the suction shoe, which receives the chips directly at the spindle. The last stand is already almost 1 1/2 years back: klick (http://www.buntbahn.de/modellbau/viewtopic.php?t=6691&postdays=0&postorder=asc&highlight=staubraum&start=870)
(Sorry, I only reported about it in the Buntbahnforum at that time).
So it was drawn again a little bit :
P1-Montage_128 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9350%2F2903P1-Montage_128.gif&hash=5fbce706d17da5ce82aa1c49cb9efdf7df9215f1)
The gray drawn part is firmly connected to the movable spindle.
P1-Montage_129 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9350%2F2903P1-Montage_129.gif&hash=8a041522f3072e941dd59801b862eb23080b9d75)
The yellow parts in the drawing are held with neodymium magnets and can be easily disassembled to change the milling cutter.
Initially I have milled a first test of 10.0mm MDF boards.
P1-Montage_130 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9350%2F2903P1-Montage_130.jpg&hash=a4e0dfb789d5acaa2def42db6e18deca2799913b)
P1-Montage_131 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9350%2F2903P1-Montage_131.jpg&hash=22e40ab9a2765a0bee9373a60edeac34f4601f4e)
Firstly, I would like to see if the 5 provided magnets have too much holding power when changing. Maybe only three magnets are enough. Likewise it will show, whether the two intermediate layers with 20,0mm height are sufficient or if I pack another "slice" in between.
P1-Montage_132 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9350%2F2903P1-Montage_132.jpg&hash=9d8f52810731c36699a8103c6550acc9dc874ac1)
I have also ordered a round brush from the vacuum cleaner area (https://www.kaerchershop-schreiber.de/de/kaercher-rundbuerste.html). Maybe I can adapt them accordingly - and I do not have to stick them together with individual bristles.
I am sure you will come up with an elegant method of attaching the brush head to the assembly. Just think about it while having a cold beverage before bedtime, place a pad and pencil on the night stand and sleep on it. During the night there will be an AHA! moment, wake up take notes, and execute the remedy the next day. Some of my best solutions to problems have come after sleeping on them.
Once finished the exhaust hood needs to have the edges eased and be painted to match the rest of the mill. ;D
It probably is impossible to buy anything as good as what you build. -- Russ
Awesome as always Frithjof!
Franck
Once again I am in awe of your clever creativity and skillful work!
Thank you for the kind comments.
On vacation, I could continue with the suction shoe.
P1-Montage_133 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9350%2F2903P1-Montage_133.jpg&hash=e2102a2e11e82ded6e40d061f887422092f9a192)
Such a milling dust should be a thing of the past in the future. ;)
P1-Montage_134 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9350%2F2903P1-Montage_134.jpg&hash=758b4a4cb0fc8045bf692c666485c91fc5592970)
From the individual 10mm thick discs, the suction shoe is aligned with the help of 3.0mm brass tubes and glued together with superglue.
P1-Montage_135 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9350%2F2903P1-Montage_135.jpg&hash=0d907011bb0518a3accb812089d1baef7b2c8e6f)
P1-Montage_136 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9350%2F2903P1-Montage_136.jpg&hash=921392de69e38736fae6c2d9f078aa4c9379af26)
P1-Montage_137 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9350%2F2903P1-Montage_137.jpg&hash=7fdc0cfa471e1770ffafd21c898b5ae12bf9bb60)
.
P1-Montage_138 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9350%2F2903P1-Montage_138.jpg&hash=53fa2e13e5329da2dbcc7ce87f9dc538f8ad5fb2)
The dark hard PVC part is removable to change the milling cutters.
P1-Montage_140 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9350%2F2903P1-Montage_140.jpg&hash=fb6a889b981fd5798a04e8b88cef7d3cf90f6e52)
Now only the round brush strip is missing.
I hope I am not the only person here reeling in stunned disbelief. -- Russ
Yes Russ there is not only high-tech model making offered, but also the emergence of high-tech tools for this purpose is shown. Frithjof thank you very much for showing.
great Frithjof classy work.
You're not alone, Russ! It's amazing work!
After a long time I built something in the workshop again at the last weekend.
I have already spent several hours on my Böhler circular saw in the past 20 years and have been able to saw out some parts for my projects.
Boehlerkreissaege_mit_Hilfsanschlag (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7443%2F2903Boehlerkreissaege_mit_Hilfsanschlag.jpg&hash=b3cbec9baad88a05147521e7c1fa8ba5b04f21d5)
The sliding carriage helped immensely!
The motor power with 12 volts and the "low" cutting height of only 15mm made me look for something bigger and stronger.
There is no overly large selection of circular saws suitable for model making.
After seeing some examples on Youtube, I made my choice.
Since I often want to saw congruent parts and do not want to start the CNC milling machine every time for a quick cut, a table saw sled should be built again.
The woodworkers have plenty of ideas online: click (https://www.google.de/search?q=schiebeschlitten+kreiss%C3%A4ge&source=lnms&tbm=isch&sa=X&ved=2ahUKEwi7rb2p4LjnAhVL4aQKHQeDA80Q_AUoAnoECAsQBA&biw=1533&bih=1089). Many are similar, so I was able to adapt some things for myself.
It was drawn first.
Schiebetisch_01 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Schiebetisch_01.jpg&hash=bac47a3cde76f430e737b7286db7bbddd94fbce5)
Schiebetisch_02 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Schiebetisch_02.jpg&hash=2737e6354ebc2272a722e5bb14c6d5b5ae85eec8)
Schiebetisch_03 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Schiebetisch_03.jpg&hash=58a27c2f2155733a9acb6e0b6a350de2a918a040)
Schiebetisch_04 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Schiebetisch_04.jpg&hash=1de94f64cc9e79b2863afe83068787553947fa28)
Schiebetisch_05 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Schiebetisch_05.gif&hash=999f851218c43f899e50cd6a4cb97c3080778b02)
Schiebetisch_06 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Schiebetisch_06.jpg&hash=7a110400c110273218fd743a31b9c023fdeb9e55)
Schiebetisch_07 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Schiebetisch_07.jpg&hash=e5a2eb4395b9840bd04eb444cec47487c7733a0a)
Schiebetisch_09 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Schiebetisch_09.jpg&hash=359a4e22014957729e369e81e6ac944cd1aff1b4)
Schiebetisch_10 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Schiebetisch_10.jpg&hash=4d342403f172c8a2fd40242bb866f30aad3b82d5)
12mm aluminum is no problem with the new saw :D
With the help of the cross cut sled, the first parts for the adjustable stop were sawn.
Schiebetisch_11 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Schiebetisch_11.jpg&hash=4c6d4ac8b0554cfd289b6f4f7ae1e43d83699e44)
Schiebetisch_12 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Schiebetisch_12.jpg&hash=9085f88a42a3fe6bd5f5dd466c892bc6c9c85ab5)
Schiebetisch_13 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Schiebetisch_13.jpg&hash=ddec982460b37ae53451312b958f18e74e837359)
The self-adhesive steel tape measure with center "0" has been ordered.
Then a few projects can continue ;)
Why the effort with the sliding carriage:?:
Quite simply - for a number of parts that I still want to build for the lifting bridge module, I need very precise right-angled cuts in various materials (wood, plastic, brass, aluminum, ...
As already said, no problem with the milling machine ... with the saw some things go a little faster.
With the new circular saw I can cut 24.5mm high with an 85mm circular saw blade (with the Böhler it was 15.0mm).
So I can now quickly and individually adjust the remaining "limestones" to the masonry.
Recently I had found two nice little helpers for the circular saw on the web - or rather, I saw in videos how such parts can be made by myself.
A KERFMAKER is required for the production of exact grooves. There are plenty of examples: click (https://www.google.de/search?q=kerfmaker&source=lnms&tbm=vid&sa=X&ved=2ahUKEwjf_56L67_nAhWqQEEAHXlkBBkQ_AUoAnoECAwQBA&biw=1533&bih=1089)
One post (https://www.youtube.com/watch?v=uhPvanE9fnc) particularly appealed to me, so I built it last night, especially since I found all the parts I needed in my left-over boxes.
The beechwood board was provided with the necessary incisions on the router (14.0mm cutter).
Kerfmaker_01 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Kerfmaker_01.JPG&hash=75b4a9edb6fb72b5cd79b5f37a1ce4b7f1930c06)
At the rip fence on the circular saw, the remnant board was sawn to the required width and for length I used the sliding carriage.
Kerfmaker_03 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Kerfmaker_03.JPG&hash=815bea65e1fda0c8d773b93751639613ce8abc37)
The small screws for adjusting the saw blade thickness are still missing on the last photo.
In order to safely guide the wooden strip at the rip fence, I drew a FEATHERBORD that fits the saw in size.
There are also a number of examples: click (https://www.google.de/search?q=featherboard&source=lnms&tbm=isch&sa=X&ved=2ahUKEwiPnvvJ7r_nAhVOXMAKHVl1Bi4Q_AUoAnoECBAQBA&biw=1533&bih=1089)
Featherboard_02 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Featherboard_02.jpg&hash=0851c5c22368c688b47d16e0b65998c5200a358b)
Then two parts were milled together with a 2.0 mm one tooth cutter.
Featherboard_03 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Featherboard_03.JPG&hash=3c3dbb8c44baf3a8d06689562e7c6c251d239925)
With the cross cut sled I separated the two parts.
Featherboard_04 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Featherboard_04.JPG&hash=effcd820f985f4b2a27068952e5bcba190774bc4)
The inserted 3.0 mm wooden strips ensured that the individual combs were not damaged when they were cut.
Featherboard_05 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Featherboard_05.JPG&hash=581688ab7ec1cbf0e9263e8ddd865afb0cc3af94)
Featherboard_06 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Featherboard_06.JPG&hash=2160dafe4288cd0b6a18a0dcfe35672819a28f4a)
As desired, the comb now ensures a clean pressure on the bar.
Featherboard_07 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Featherboard_07.JPG&hash=69a1aeb3b6df7faf60aba1298728eeb13f2d1690)
Featherboard_08 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Featherboard_08.JPG&hash=d9fe02f7ef28a25b0e2266f9652ac1c786e3794d)
Time required for drawing: approx. 30 minutes and around 40 minutes for milling.
Very fine work as always!
Just over an hour for all that? Astounding! But what about the time you spent thinking and designing before you drew the plans?
I am extremely impressed by this and by so many of you geniuses on this forum. I wish people I deal with in other fields (like doctors, businesses, and even musicians) were as competent.
Russ
Frithjof, this is as always extremely interesting, instructive and inspiring.
Bernhard
@Ray, Russ, Bernhard
Thanks!
QuoteBut what about the time you spent thinking and designing before you drew the plans?
This happens while sleeping ;-)
Yesterday I was able to continue building on the sliding carriage.
For this purpose, the metal tape measure was glued in position with the center zero.
The HPL profile (High Pressure Laminate) for the two adjustable zero markings were installed from the bottom with three M2.0mm screws in the sliding block.
Schiebetisch_14 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Schiebetisch_14.jpg&hash=74da6dc67562456ed397aad0ce1b7eef22dab9bc)
For the two zero markings, an old plexiglass lid was made a little lighter.
Schiebetisch_15 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Schiebetisch_15.jpg&hash=3c1e923727bc60a28346e7200a6cb8d459fdfce4)
Schiebetisch_16 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Schiebetisch_16.jpg&hash=4fed026b9f7e18296faad39f06abc5f77a8e8e73)
Both parts were milled twice ... if one breaks off, a replacement is existing.
Schiebetisch_17 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Schiebetisch_17.jpg&hash=ead57ab6122eee55f5fe9b7c4735b7310417b51e)
The 0.35mm deep V-groove is located on the underside so that the line can be read closer to the measuring tape.
It was colored red with a waterproof felt pen. Before everything was dry, I cleaned the surface with kitchen paper.
Only a small red line remained in the recess.
Through the elongated holes, the two plexiglass plates can be adapted to the respective thickness of the saw blade.
Schiebetisch_18 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Schiebetisch_18.jpg&hash=cc9c23a48ee2b22d5be8d320ec6d89834e266d8a)
Schiebetisch_19 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Schiebetisch_19.jpg&hash=6da4fcede91f05548f84a7ae23406c4b6f711ffa)
So now the sliding table is ready for the next challenges.
In addition to the Kerfmaker and sliding carriage, I found many useful tools on the WWW while browsing various woodworking sites, which can also provide useful help on a small circular saw.
So you can set a value with the enclosed angle stop on the Proxxon saw ... but it is a matter of luck whether you also reach the set angle. Depending on how you press the T-slot in the guide groove of the table, you get different results.
See also here (http://p-sails.blogspot.com/2014/07/proxxon-fet-winkelanschlag.html).
But what do you need for precise miter sawing?
Within the sliding table, I can achieve 45 and 90 degree cuts with a triangle. However, the size of the sliding table is limited here.
There is a possible solution to see here (http://www.metallmodellbau.de/KS230_Umbau.php)
So I particularly liked the following Tablesaw CrossCut Sled (https://www.rockler.com/tablesaw-crosscut-sled) especially since I can also saw longer strips at any angle.
Since the original should be a bit too big for my small saw, I had to build it myself again. It was drawn and the range of degrees extended to 90 degrees. For the miter sawing of strips, 45 degrees would have been enough (you can also guide the strip for 60 degrees from the other side with 30 degrees on the guide rail.
However, I want e.g. it is not always possible to make a miter cut on a component that has already been assembled.
Here are the first steps to reduce the size of the replica.
Gehrungsbrett_01 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Gehrungsbrett_01.jpg&hash=3d52bc6e4d7d330557928d2aa159022869ccc476)
Gehrungsbrett_03 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Gehrungsbrett_03.jpg&hash=9ab8686525be9b20ac8e41d2439e213e8995e10a)
Gehrungsbrett_04 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Gehrungsbrett_04.jpg&hash=b2a25ede06cf82fba5075840915c118b739d24cd)
Gehrungsbrett_05 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Gehrungsbrett_05.jpg&hash=9e287742e711d53fcf1f8bdba461a689d367ead6)
Gehrungsbrett_06 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Gehrungsbrett_06.jpg&hash=fa6b954c97504d8f45028dfd1479a1761dfe32ce)
Gehrungsbrett_07 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9521%2F2903Gehrungsbrett_07.jpg&hash=09d045cb985cc98ea38894bc625926ec9322211e)
That is absolutely beautiful! Did you photo-etch the protractor into the aluminum plate? -- Russ
No, I dinˋt used an aluminium plate.
It is a 6.0mm HPL plate.
All slots are engraved with a V-Router Bit like here (https://www.sorotec.de/shop/Cutting-Tools/sorotec-tools/Routing-Tools/V-Router-Bit-164/)
The figures are 0.2mm deep, the lines 0.3mm.
Nice clean work!
Bernhard
"All slots are engraved with a V-Router Bit"
That is even more impressive.
Russ
It looks as good as something you'd buy from a manufacturer, and probably more accurate!
Before I will continue to work on my actual projects, I would like to add a few helpers to the workshop.
So far, I used Gudy 870 (https://www.leha-webshop.de/aufziehfolie-gudy-870?number=642200&gclid=EAIaIQobChMI6sfkooj65wIVA0QYCh0vgwtYEAYYAiABEgLvovD_BwE) to glue the board material onto 22mm MDF boards.
These were attached to the milling table with clamps (http://www.buntbahn.de/fotos/showphoto.php?photo=113739&size=big&password=&sort=7&thecat=9409).
Over the years, over 30 plates with brass, nickel silver, plastic, Pertinax, aluminum, various woods, etc. have accumulated, many only contain small remnants.
In the future I want to machine many parts on a vacuum table.
Since I mill through most of the parts, it will not be a grid, but rather a perforated grid vacuum table.
So something was drawn again:
Vakuumtisch_auf_Fraese_01 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9350%2F2903Vakuumtisch_auf_Fraese_01.jpg&hash=c4f4e8a231ba421f5397492283d0a54bf3ae0667)
Vakuumtisch_auf_Fraese_02 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9350%2F2903Vakuumtisch_auf_Fraese_02.jpg&hash=2faff093385d4b64ff46b2d1e48035a37cf88559)
Vakuumtisch_auf_Fraese_03 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9350%2F2903Vakuumtisch_auf_Fraese_03.jpg&hash=2aa4ce64a3dfbc2b4d6f3eda8190b84ca1403dd2)
Then it went to the milling machine.
A 360.0mm x 360.0mm x 10.0mm Makrolon board was glued to the face-milled MDF board with Gudy 870. (received as residual material for € 5.00)
The work steps were:
1) Drill 9 mounting holes with a 5.0mm cutter (296sec.)
2) screw the Makrolon onto the MDF board in these holes with wood screws so that the board does not bend when milling the holes later (120sec.)
3) Drill 1080 holes (diameter = 6.0mm - 6.0mm deep) with the 6.0mm milling cutter (3100sec.)
4) Drill 1080 holes (diameter = 0.5mm - 11.0mm deep - starting from 6.0mm) with the 0.5mm drill (4655sec.)
5) Milling the outer contour to 350mm x 350mm with 5.0mm milling cutter in several passes in total 10.5mm deep (495sec.)
Vakuumtisch_auf_Fraese_04 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9350%2F2903Vakuumtisch_auf_Fraese_04.jpg&hash=52ee2e4c85cabd341391ce288a33efc0f87e9cc4)
Vakuumtisch_auf_Fraese_05 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9350%2F2903Vakuumtisch_auf_Fraese_05.jpg&hash=62a2af5eb0e1ce54461014dd38e3ebc90ca41f93)
Vakuumtisch_auf_Fraese_06 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9350%2F2903Vakuumtisch_auf_Fraese_06.jpg&hash=cd430c0d415bb2bc59491bb08619f4f58b550368)
It will soon be the turn of the base plate.
Before I processed the base plate, the MDF clamping plate was face milled 0.5mm deep. Repeated milling had left several traces.
Vakuumtisch_auf_Fraese_07 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9350%2F2903Vakuumtisch_auf_Fraese_07.jpg&hash=241106c03996bc49f94df90e7f6a53ea42b5af37)
Then a 20.0mm thick 400mm x 400mm large PVC plate was fixed with clamps.
The plate was machined in several milling passes:
A small mobile phone video shows the processing with a 5.0mm single tooth cutter: click (https://vimeo.com/395016194)
After almost two hours, the board was just unscrewed from the MDF board.
Vakuumtisch_auf_Fraese_08 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9350%2F2903Vakuumtisch_auf_Fraese_08.jpg&hash=a10c138be7ca335f26b820ef377e83bf4ff2380d)
Gorgeous. -- Russ
Thanks for the detailed step by step Frithjof, that's also something I need for my cnc.
With such a CNC machine you can do really nice things.
Hello,
I hope you are all doing well in this strange time !
I haven't been able to do anything in my lift bridge project for a long time.
The winch was constructed well two and a half years ago (http://www.finescalerr.com/smf/index.php?topic=1424.285).
In the meantime, a slightly crumbled side part appeared, but it was a bit unstable to build the winch out of it.
Winde_25 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Winde_25.jpg&hash=731dbe0450e89da6650d843de325ddf8ccd1227e)
Winde_25 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Winde_25.png&hash=446578fe6f580fe1a1bb4c1883fea80b03413198)
Since the winch is supposed to be functional, I did not dare to just solder rivets on both sides.
The parts should now be printed out of nickel silver.
Within a week, two perfectly dimensioned side parts came from the foundry today: D
Winde_26 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Winde_26.jpg&hash=a7ab7fd0a54399791600b01dfe8fe214d84dab43)
Two "sand-lime stone bases" were milled from a 4.0 mm piece of brass. These later give a secure connection to the base plate. The airbrush will provide the right color impression.
Winde_28 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Winde_28.jpg&hash=93519ab10e1365d6063dfaa268098eb79d4e6a24)
Winde_29 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Winde_29.jpg&hash=2298ef13f3f7209d7525ea9ad4c3f8c63d8834c5)
Winde_30 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Winde_30.jpg&hash=bfacddcc0ec93a30a5853bd5ced45078c9b85143)
Winde_31 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Winde_31.jpg&hash=b762581b569fabc4c63e6d0a5f5a2de3d8482e2b)
After the winch side parts were freed from the sprues, sandpaper files with increasingly fine grains were used.
In order to get a small impression, I have loosely put together the parts of the winch that have been finished so far.
Winde_32 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Winde_32.jpg&hash=892fb85bd084a24e67243b1085a18730a874610d)
Several small parts are still missing on the winch, e.g. the brake/locking mechanism, a few connecting profiles and rods, the hand crank ...
It will take some time before the entire bridge is finally assembled, but the pension is in sight.
Stay healthy :!: :!: :!:
More top notch work. I like your brass "sand-limestone" bases. I don't think I have ever seen stone modeled with brass before.
What happened to the crumbled side part?
Yet another example of your outstanding craftsmanship. -- Russ
Awesome!
Many months have passed again in which I couldn't really make progress on the lift bridge. I hope to be able to continue building here with a little more concentration soon.
In between I was looking for something where my little light rail locomotives could be parked.
I have a small four to five-seater open shed with a transfer platform in mind.
The search in the Buntbahn-Forum showed a nice little rotary sliding table from the Frankfurt Feldbahnmuseum:
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F663%2F75620050911-0367.jpg&hash=9d4f4733fc51014217907b358b92d92f22360371)
[size=11] The photo is from Thomas Heyl and can be found here:
http://www.buntbahn.de/fotos/showphoto.php?photo=21975&size=big&sort=7&thecat=663[/size]
After Marcel provided me with further pictures and a sketch, I could draw. Thank you Marcel
Dreh-Schiebebuehne_01 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_01.gif&hash=0808ca2922e445b3df706dc2456d88eedff5b68c)
At first I wanted the platter to turn on 2.2mm ball bearing balls ...
Dreh-Schiebebuehne_02 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_02.jpg&hash=2656a6661fa1dd3a5e54399cb43be24b4521ab99)
Dreh-Schiebebuehne_04 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_04.jpg&hash=eaca3f93d800c0f1edcff0b63e766266f57d64c3)
Dreh-Schiebebuehne_05 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_05.jpg&hash=1a72fe49b8736b07f8bedcaa629018b352582090)
... in an attempt without balls, however, the disk turned just as easily!
Dreh-Schiebebuehne_07 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_07.jpg&hash=300e8cc70bb2d174f7701d4cd2f7bd5d7f6e2e87)
So the parts for a second pane were adjusted in height and milled again - here they are loosely put together.
Dreh-Schiebebuehne_08 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_08.jpg&hash=ca527f7ffd5aa89360d896bbb0a661faaa5b58d7)
For the exact alignment of the 1.0mm base plate and the round lower part of the turntable, 2.0mm holes were drilled afterwards - one hole would have been enough!
Dreh-Schiebebuehne_09 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_09.jpg&hash=4904c5f5978abbdc9d1395f7a172e80a76c5d26d)
Dreh-Schiebebuehne_06 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_06.jpg&hash=98de98afc8f69d3f3ad9a6df94e1691208a1a93f)
I have adjusted the rail profiles in the rounding in a small gauge.
Dreh-Schiebebuehne_10 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_10.jpg&hash=66bd6bec4b1a7b2f285452b3d3ce1b7f20450537)
Dreh-Schiebebuehne_12 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_12.jpg&hash=65f094c0d09814df8593fd0b76537cb540f63002)
Dreh-Schiebebuehne_13 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_13.jpg&hash=3336c677f4fdad4659ab6a21867a0804d2270b26)
The base plate and the lower part of the turntable were coated with some solder paste and S39. A 2.0mm rivet was (briefly) inserted into one of the side holes for precise alignment. According to Volker's tip (Merci for it :)), all of this was fixed between two plates with clamps. Don't be surprised that the saw blade had a broken point!
The soldering was done with a large flame.
Dreh-Schiebebuehne_14 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_14.jpg&hash=adfe5182578338b2a167ed1a1c1b0a19d457a0bf)
After cooling, the residues of the S39 were rinsed off with soap and water. After the sandblasting everything looked a little better.
Dreh-Schiebebuehne_16 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_16.jpg&hash=0fb8300a15248d12cab5dd51c4a3d4595dcd0ddd)
This stuff belongs in a museum so, a century from now, people still can admire it. -- Russ
"WOW" Things just get better
Barney
Animated computer drawings now, I'm still at the pencil and ruler stage!
Les
It's amazing that when progress on your lift bridge project stopped for a time, you started a second project that is already looking very good.
Very cool! I think that's the first time I've seen a transfer table that also includes a turntable.
Thank you all for the accolade!
The turntable still needs small parts, which on the one hand lock the disc ...
Dreh-Schiebebuehne_21 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_21.jpg&hash=00c642055ae6da84eab3b9cdc61bd82f895ec15f)
Dreh-Schiebebuehne_22 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_22.jpg&hash=f8e1c1f0cd79f5a3447bd16b87ae5252793f23c8)
Dreh-Schiebebuehne_23 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_23.jpg&hash=ebba9f8132269b4541efccbfe4ec2e0424a2fff8)
... and on the other hand prevents the rolling of the field railway tipper. Needless with small light rail locomotives, they have their own brake.
Dreh-Schiebebuehne_17 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_17.jpg&hash=5b6eede8b42ef7fff7ee1af711033aa1c7360801)
Dreh-Schiebebuehne_19 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_19.jpg&hash=90ab7a78f4a854348f4ab31625d669d703e760fe)
Dreh-Schiebebuehne_20 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_20.jpg&hash=4d46dcfb6c6b25e0266b641f6f75db09840baec9)
Hi Frithjof.
Always a great pleasure to see your very clever models they are truly inspiring.
cheers Kim
Your drawings always are excellent but the metal parts your produce are nothing short of superb. -- Russ
Thanks Kim, thanks Russ!
The locking of the turntable consists of two parts , in which the two outer guides need a 0.5mm hole.
I milled two small guide gauges (yellow) from 2.0mm MS58. They are pushed over the part to be drilled like shoes and fixed in a further gauge made of HPL in a small vice. Now the 0.5mm drill can be positioned exactly.
Dreh-Schiebebuehne_24 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_24.jpg&hash=92789201926fecd9723a403b2a6c5de1ebe2289d)
Dreh-Schiebebuehne_26 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_26.jpg&hash=468adcefec1550572633c038b975bfc8e9a76357)
Dreh-Schiebebuehne_27 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_27.jpg&hash=2035b4cb02714af692cfc884a02bc9601abcb2a9)
Later the rotary transfer table will run in a brick pit on two rails and transport the small locomotives rotated by 90 ° into an open shed.
Dreh-Schiebebuehne_28 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_28.gif&hash=0ec3ad12cda39ab511f6b458c62c4eb4f5e6b750)
Dreh-Schiebebuehne_29 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_29.jpg&hash=a5e9801a579a11add57bc58277b04a99cb3ccaa3) :?:
The wheels with a diameter of approx. 9.5mm will come from Steiner Modellwerke (https://www.steiner-modellwerke.de/produkte-spur-1/feldbahn/radsatz/) - but unfortunately I have to wait 3 months until they are available again.
Considering your own skill, you probably could turn better wheels yourself and also avoid a three month delay. -- Russ
@ Russ
Then I would have to do 3D turning with the lathe - and I can't (yet) do that.
The bricked edge of the turntable/sliding platform was modified a little.
The side parts of the walls were milled from a 10.0mm MDF board.
First, the joints in the upper row of stones were drilled vertically into the slab with a 0.5 mm drill (green). Then the side stone joints were milled 0.5mm deep with a 0.5mm cutter (blue). Finally I machined the outer contour with a 2.0mm milling cutter (red). The milling cutters ran on the respective lines.
Dreh-Schiebebuehne_35 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_35.jpg&hash=b1748975bc6892455ab103084afe1e439d8de33e)
Dreh-Schiebebuehne_31 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_31.jpg&hash=07ef96c7bcfbdf40f1365f7e1eb4888433a309ce)
Dreh-Schiebebuehne_32 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_32.jpg&hash=73ab74d05fb1232483bb912e1db848de0421b369)
Dreh-Schiebebuehne_33 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_33.jpg&hash=f85fc477746237e780a955e6f93507adc41b045d)
Impressive work again and again!
Bernhard
Thank you, Bernhard :)
It went a little further - currently I have the following solution:
Dreh-Schiebebuehne_40 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_40.jpg&hash=df32e8593cb0e7466c04a6e9feaacdb09632ccee)
Dreh-Schiebebuehne_41 (fspg2)
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Dreh-Schiebebuehne_42 (fspg2)
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A loose rehearsal of the already milled parts gives this picture:
Dreh-Schiebebuehne_43 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_43.jpg&hash=6d0e5d2a4df889cccc453aa7d01e95e366b19955)
That's nothing less than inspirational. -- Russ
Hi Frithjof.
AS always very cool it does not need to be painted just seeing the bits is enough.
I was having trouble seeing your photos but it has been fixed very clear.
cheers
Very cool!
@Kim How did you manage to see the photos again?
In the last few days the locomotive shelter went a little further.
Dreh-Schiebebuehne_49 (fspg2)
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Dreh-Schiebebuehne_50 (fspg2)
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Dreh-Schiebebuehne_51 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_51.jpg&hash=dbcdc4666393db55bfa534959ee03c315ff23e0a)
The inner and outer parts of the wall were milled out of HDF.
Dreh-Schiebebuehne_48 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_48.jpg&hash=2d88ff8f26e868ff02d92d913b01020fec4b5ff6)
After the 0.5mm cutter had milled the 0.5mm deep grooves, I sanded the upstanding wood fibers with a sandpaper file and swept the grooves free with an old toothbrush.
Dreh-Schiebebuehne_47 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_47.jpg&hash=cb79580842a8e89869a8f8596fac977eff360baa)
Because of the HDF board is 5.2mm thick, I had to reduce the material thickness a little for the interlocking. This was done on the Proxxon circular saw.
Dreh-Schiebebuehne_52 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_52.jpg&hash=5053612ed84167c84ca495d145af76e8d87bafc8)
Now the remaining "teeth" have the same material thickness as the 1/2 stones and match the rest of the milling pattern.
Dreh-Schiebebuehne_56 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_56.jpg&hash=fd442e9768095211ceaff65fcb5673dab0a7e3f9)
I still have to expose the horizontal grooves, as shown here:
klick (http://www.buntbahn.de/fotos/showphoto.php?photo=102576&size=big&password=&sort=7&thecat=7452)
Dreh-Schiebebuehne_53 (fspg2)
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That is depressingly excellent. -- Russ
Thanks, Russ :)
I've drawn a little and now ended up here:
Dreh-Schiebebuehne_60 (fspg2)
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I will do without diagonal bracing. The respective double rafters are screwed with a continuous threaded rod and external nuts and should give the small shelter with the corrugated iron roof enough stability ... ... and if the next storm does cause damage after all, it could result in a wonderful scene where tradespeople start repairs.
Dreh-Schiebebuehne_61 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_61.jpg&hash=a456695bd3d5e1bf6d5f0d81499e46f8d49250ab)
Yesterday there was an order for the sawmill to saw the wooden beams. Hazelnut "trunks" were used that had been waiting for a sensible use in a drawer for a good 10 years.
Dreh-Schiebebuehne_54 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_54.jpg&hash=384179a7ef96e8293595b666de9db0b79d9287c1)
First straight sections were sawn oversized on four sides ...
Dreh-Schiebebuehne_57 (fspg2)
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and brought to the final dimensions of 5.8mm x 5.8mm in a further sawing process.
Dreh-Schiebebuehne_58 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_58.jpg&hash=4d49b8dfb5a9c6ba79b59b6b3bc52a08f2f97369)
Now there are enough bars waiting for the Kerfmaker.
Dreh-Schiebebuehne_59 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_59.jpg&hash=f4aa0bcbc71e3f9f87867e657f4efb0bc14a1d11)
I like the authentic production of the beams.
Bernhard
I agree with Bernhard. Very few modelers actually mill their own wood. But that is typical of Frithjof and one reason his modeling is so perfect. -- Russ
I'm curious about the Hazelnut wood. The heartwood is very pronounced. Is it harder or softer than the sapwood and being a different colour, do you know how it will react to future staining and weathering?
That wall is amazing!
Very neat workmanship - but Im lost in this world computerised stuff - but saying that Im struggling some times with a sheet of Plastic Card and a pack of Evergreen !!
but very nice stuff just keep it coming
Barney
Thanks to all!
@Paul
QuoteI'm curious about the Hazelnut wood. The heartwood is very pronounced. Is it harder or softer than the sapwood and being a different colour,
Hazelnut is moderately hard, easy to split and extremely elastic and can be turned very well.
The darker heartwood feels significantly softer than the outer sapwood.
Quotedo you know how it will react to future staining and weathering?
I can't comment on that yet, it's the first time I've used hazelnut.
After I got a few helpful ideas at Buntbahnforum (http://www.buntbahn.de/modellbau/viewtopic.php?t=6691&postdays=0&postorder=asc&start=970) for a more stable construction of the wooden beams, I redesigned a little further.
Dreh-Schiebebuehne_67 (fspg2)
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Dreh-Schiebebuehne_68 (fspg2)
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Dreh-Schiebebuehne_69 (fspg2)
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Dreh-Schiebebuehne_71 (fspg2)
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The individual "bars" were cut to size on my small circular saw, respectively the corresponding mitres were cut.
Dreh-Schiebebuehne_73 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_73.jpg&hash=c1f396b83903d80cb86f4ea9817fe18f85d31c5b)
Dreh-Schiebebuehne_74 (fspg2)
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A teaching helped adjust the individual pieces of wood.
Dreh-Schiebebuehne_75 (fspg2)
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Dreh-Schiebebuehne_76 (fspg2)
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You have challenged me to try to replicate rough sawn timber. I will probably try it with Crepe Myrtle as it is straight in the sizes I need.
You need to throw the first attempt away (you can send the wood to me) and start over. With all of the work you are doing I would expect that the braces would be made with mortise and tenon joints not butt joints. Just teasing!!!
Save the slab wood you cut off and use it to create a shed by a back woods shack.
I like this project. -- Russ
very nice - and well thought out
Barney
Very nice framing... it's a pleasure to see some proper half-lap joints. The remaining bark here and there is a nice touch, very effective.
Thanks for your approval
@ Lawton
QuoteSave the slab wood you cut off and use it to create a shed by a back woods shack.
Yes that is a good idea!
A few adjustments were made.
So I sawed continuous frames from hazelnut wood. If necessary, these will get scratched overlays.
The individual wooden parts for the back and front wall were glued with a little wood glue in the teaching. Then 0.8mm holes for the "wooden nails" were drilled in the same setting.
Dreh-Schiebebuehne_77 (fspg2)
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A casual rehearsal gives an idea of the shed.
Dreh-Schiebebuehne_78 (fspg2)
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Dreh-Schiebebuehne_79 (fspg2)
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The rafters were rounded at the front. For this purpose, the individual slats were placed in a small gauge and processed with a 1.0mm milling cutter.
Dreh-Schiebebuehne_80 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_80.jpg&hash=4b3ee4ce8667432ba43114367888ff5c49a5077a)
Beautiful work. -- Russ
I agree with Paul, the connection of the beams is perfect. Likewise the wooden nails.
Bernhard
Interesting work. Take a look at a site which discusses timber framing. The wooden pegs pin the joints together so that no metal is needed in assembly.
Recently on the BBC's news site there were a pair of pictures of a shipwreck discovered off the east coast of England where the hull was held together with wood pegs. Estimated to be over 200 years old and still being held together.
Looks great so far!
Fantastic - looks great
Barney
Corrugated iron is provided for the roof.
Marcel had made these parts himself out of mustard tin sheet about three years ago: klick (http://www.feldbahn-modellbau.ch/search/label/4.71%20Tutorial%20-%20Wellblech%20aus%20Senftuben)
I have planned 0.1mm thick Copper sheet from the roll (https://www.ebay.de/itm/Kupferblech-Platten-99-9-Reines-Kupferblech-0-1-0-2-Kupferfolie/302927228694?var=601849002121&hash=item4687deaf16:g:CRQAAOSwoA1bVUwn).
This was cut into 72.0mm x 50.0mm pieces and burned out with the flame.
Dreh-Schiebebuehne_86 (fspg2)
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Dreh-Schiebebuehne_87 (fspg2)
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Some time ago there was still that Fiskars crimper (https://www.youtube.com/watch?v=kUAFXc-c1TA), which seems to be sold out everywhere at the moment!
These waves generated are 2.5mm in size - but for the replica of an 80mm prototype wave it should be 3.55mm here.
So I milled grooves 1.5mm deep in two HPL panels with a 3.5mm ball end mill. The distance to each other is 5.6mm.
Dreh-Schiebebuehne_91 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_91.jpg&hash=e6eb48d3993a1abb614e39d099ec30abcb1abe8a)
I glued 3.4mm thick wooden sticks into these grooves with superglue.
Dreh-Schiebebuehne_82 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_82.jpg&hash=50324c1134059ec77ed946c0a1aa5ef5590531e5)
The copper sheet will be pressed with the help of these two stamping plates.
Dreh-Schiebebuehne_81 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_81.jpg&hash=a326084cdcc7723db8b194e8aadf88d809a46e2b)
After the first wave has been pressed, only the next one comes in turn. So the sheet metal still has enough reserve to expand. Pressing all the shafts at the same time does not produce a convincing result.
Dreh-Schiebebuehne_88 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_88.jpg&hash=ad5c87ca8a2af4cc112f0b1e45bd6434bb54db76)
The raised edge is used to align the copper plate at right angles when pressing the first shaft.
Dreh-Schiebebuehne_85 (fspg2)
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Dreh-Schiebebuehne_83 (fspg2)
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Dreh-Schiebebuehne_89 (fspg2)
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Dreh-Schiebebuehne_90 (fspg2)
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Some guys locally here 3d printed their own crimping rollers for corrugated iron.
Probably not a tool that's going to last too long, but certainly good enough for 1 or 2 projects and easy to make/remake.
Your corrugated panels turned out perfectly.
I wonder how long a 3-d printed press or roller would work for corrugating cardstock.
Russ
That turned out nice.
Quote from: finescalerr on March 14, 2021, 03:42:25 PM
Your corrugated panels turned out perfectly.
I wonder how long a 3-d printed press or roller would work for corrugating cardstock.
Russ
Really well I imagine. Despite doing a lot of 3d printed models, I feel one of the best uses for the technology is jigs, fixtures and tooling. Such things are quick to do.
That is an excellent process for creating corrugated panels, well done. Definitely going to make an attempt to replicate your fixture for 1:48.
@ Paul
Good luck - please report about it!
In the meantime, I have punched all of the corrugated sheet metal appropriately for attachment to the roof battens. To do this, I milled grooves again on the milling machine and glued in round bars. This gave me precise positioning and counter pressure when drilling.
Dreh-Schiebebuehne_95 (fspg2)
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Dreh-Schiebebuehne_93 (fspg2)
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Dreh-Schiebebuehne_94 (fspg2)
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In addition, I made a few small experiments to give the corrugated iron sheets a little color.
Dreh-Schiebebuehne_96 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_96.jpg&hash=694105b9feeef6df2feb057a3786d741d7315242)
The three plates above are used for practice and will be further maltreated.
Let's see how I get things rusted through ...
Excellent. -- Russ
Well thought out workmanship - and so many ideas to help us all
Barney
I tried something sort of like this but my method didn't work very well, and I had to go with a much more labor-intensive way to make corrugated sheet. But this is giving me some new ideas. I'll have to do some experimentation and see if I can adapt your technique using the limited tools I have.
Quote from: Ray Dunakin on March 20, 2021, 09:47:17 PM
I tried something sort of like this but my method didn't work very well, and I had to go with a much more labor-intensive way to make corrugated sheet. But this is giving me some new ideas. I'll have to do some experimentation and see if I can adapt your technique using the limited tools I have.
Ray, I don't want to hijack Frithjof's thread. I think there's a solution for limited tools as well; take a look here: http://www.finescalerr.com/smf/index.php?topic=1983.msg64925#new (http://www.finescalerr.com/smf/index.php?topic=1983.msg64925#new)
That is more suited to my rudimentary skill set. -- Russ
At the beginning of January 2017 I looked in vain for Plakafarbe no.25 (brick red) (https://www.pelikan.com/pulse/Pulsar/en_US.Store.displayStore.221730./the-plaka-paints-by-pelikan).
According to information from Pelikan (https://www.pelikan.com/pulse/Pulsar/de_DE.Store.displayStore.211440./die-plaka-farbe-von-pelikan) this color has been removed from the range taken and should not be reissued.
Over the past few years I've tried Google every now and then ... always without success ... until recently. A dealer had, declared as a special item, two small glasses with the desired color. So ordered yesterday and received by DHL today - it was almost like Christmas, I can give a few parts of the wall the same color as the remaining parts.
Plaka_Ziegelrot_25_ (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7443%2F2903Plaka_Ziegelrot_25_.jpg&hash=3eda8842f8609b029836f4d6829ffe52dda3dcf6)
Among other things, the walls of the small locomotive shed and the border of the transfer platform will be treated with a paint roller after a gray primer - similar to the one shown
in the post from 07/14/2008 (http://www.buntbahn.de/modellbau/viewtopic.php?t=6691&postdays=0&postorder=asc&start=100) gezeigt.
The border of the transfer platform was re-milled with upright stones and should now see color.
Dreh-Schiebebuehne_98 (fspg2)
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Dreh-Schiebebuehne_99 (fspg2)
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It went a little further - albeit a little slower than I would like! My second cataract operated eye still has to get used to me a little. But it's getting a little better every day.
Dreh-Schiebebuehne_100 (fspg2)
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All holes of the rafters and the roof battens were drilled with a 0.5mm drill on the router.
0.5mm wires prevented them from being pulled together by the moisture during the first pickling process.
Dreh-Schiebebuehne_101 (fspg2)
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A polystyrene gauge was used to assemble the individual elements. Additional holes were drilled here to connect the rafter holes through the roof battens.
Dreh-Schiebebuehne_102 (fspg2)
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At first I drilled through the existing rafter holes with a 0.5mm drill (with a 1/8-inch shaft) into the roof battens underneath.
After the first drill, which was carefully turned by hand, broke off, I had taken a thinner "auxiliary rafter" as a drilling aid ... this drill also broke off very quickly :o
Fortunately I found some 0.5mm HSS drills with 0.5mm shank in a small, forgotten bag. Clamped into a pin block, all remaining holes could now be drilled without any further problems.
Dreh-Schiebebuehne_103 (fspg2)
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Then everything was pinned with short 0.5mm brass wires ...
Dreh-Schiebebuehne_104 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_104.jpg&hash=571daf9bd88c0743cab0a050b4f8ce9b490a5f39)
... and brought into the wood with light hammer blows. The wire got a little thick head.
Dreh-Schiebebuehne_105 (fspg2)
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So that the superglue only bonds to the wood and not to the polystyrene gauge, the knot areas had a circular cutout in the gauge.
Dreh-Schiebebuehne_107 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_107.jpg&hash=43b661cbae77188c5d792cc3e8378a5ec6d74075)
Dreh-Schiebebuehne_108 (fspg2)
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As a test, the rafter framework was laid loosely.
Dreh-Schiebebuehne_109 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_109.jpg&hash=3200ad96bdf1798c1c99a4a823de7f59ae18d74b)
There will be further aging with stain, pigments and various Prismacolor Premier-Farbstiften (https://farbstifte.net/prismacolor/?language=de).
Beautiful. -- Russ
I like your method of assembling the rafters!
It got a little dirty:
Dreh-Schiebebuehne_110 (fspg2)
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After superglue had been applied to the edges of the roof battens on both sides with a thin wire, I pressed the area briefly and forcefully and dusted it with tile mortar.
The resulting thickenings are later darkened even further and reflect the dirt accumulated there. However, it will only be visible on the front and rear long edges under the corrugated metal sheets on top.
You don't necessarily need a milling machine to build such gauges. Such aids can also be glued together using "boards" that have been sawn out accordingly. in the meantime there were only a few small steps, so the rails on the edge of the stage were soldered to an L-profile. Small gauges ensured the right-angled alignment.
Dreh-Schiebebuehne_111 (fspg2)
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The floor was also treated a little. As a basis I again applied Molto-Holz-Reparaturspachtel (https://www.molto.de/produkt/molto-holz-reparatur-spachtel/). It was made supple by adding a little water and pressed on the wooden surface with the fingers in a wavy manner. The advantage over plaster is the slight flexibility after drying. On the modules built in 2007, I haven't got any cracks or chipping on the edges or edges to this day.
Dreh-Schiebebuehne_112 (fspg2)
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A short rehearsal with the loosely laid tracks took place here.
Dreh-Schiebebuehne_113 (fspg2)
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The floor of the shed was provided with several layers of earth, sand and stone meal one after the other.
Dreh-Schiebebuehne_114 (fspg2)
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Each layer was sprayed with a landscape and construction adhesive that was unfortunately no longer available.
Alter_Lagerschuppen_200 (fspg2)
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The advantage of this glue compared to wood glue is that all parts glued with it can be stained afterwards and the brightness of the color is retained after drying
:D
So much for today - the walls and tracks will still retain a number of signs of aging ...
Dreh-Schiebebuehne_115 (fspg2)
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Excellent!
Do you know what type of material that discontinued landscape and construction adhesive was made of?
It looks like it was perfect for staining areas that accidentally had some glue residue on them.
Outstanding, inspirational, and satisfactory. -- Russ
Looking good!
Amazing! I´m always excited when I see that there is an update to this thread.
But this project is so complex I have totally lost track of how everything is supposed to go together in the final layout. Have you ever arranged all the components to show how everything fits together? I would love to see that picture.
That brickwork is a "Augenschmanckerl"!
Inspiring!
FG H
I thank you for your approval!
@Bill
QuoteExcellent!
Do you know what type of material that discontinued landscape and construction adhesive was made of?
It looks like it was perfect for staining areas that accidentally had some glue residue on them.
Unfortunately, I couldn't get any precise information about the composition of the landscape and construction adhesive, except that it is based on acrylic.
@Hauk
QuoteBut this project is so complex I have totally lost track of how everything is supposed to go together in the final layout. Have you ever arranged all the components to show how everything fits together? I would love to see that picture.
Have a look on page 16 - post from 08-09-2015:
click (http://www.finescalerr.com/smf/index.php?topic=1424.225)
Here you can see the dimensions (in centimeter) of the modules:
Module_Abmessungen (fspg2)
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Module_12_06_08_1 (fspg2)
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Module_12_06_08_3 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Module_12_06_08_3.jpg&hash=111778c0c76d87a7b92a6b10ec9a7c3aa473c9fc)
Module_12_06_08_5 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7452%2F2903Module_12_06_08_5.jpg&hash=f026d86db0e8681130829070dde58196196d1b03)
Modul-Montage_43 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Modul-Montage_43.jpg&hash=8e2c9615b004fa276dbae7635ce34e1b0d818653)
Modul-Montage_44 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Modul-Montage_44.jpg&hash=465fcd032b7d9cc3da24c5089a5bd9f83c9d922d)
Modul-Montage_45 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F7473%2F2903Modul-Montage_45.jpg&hash=963e62ada340c97dce684975a8af7e2a594b9621)
There are also many other small projects, such as the Kemna Gigant 8 roller (http://www.finescalerr.com/smf/index.php?topic=2872.0), the Gmeinder 10-12 light rail locomotive (http://www.finescalerr.com/smf/index.php?topic=1358.0).
There are now a lot of projects for which I, as a pensioner, will now have more time - at least I hope so!
A little bit of progress has been made on my loco shed, so the previously loosely laid tracks in the shed were fastened with Old Pullman nails.
Dreh-Schiebebuehne_116 (fspg2)
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To do this, holes had to be pre-drilled with a 0.8mm drill, otherwise the small wire pins would bend immediately. I used to have the same nails of a significantly harder quality!
Dreh-Schiebebuehne_117 (fspg2)
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The angle profiles that are soldered on lie on the edge of the wall. They still have to be fitted with small hexagonal screws.
Dreh-Schiebebuehne_118 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Dreh-Schiebebuehne_118.jpg&hash=65d07dc7407365609466adde127e8ac72fb0ae9d)
Dreh-Schiebebuehne_119 (fspg2)
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All tracks and their nails will later be significantly aged.,
Dreh-Schiebebuehne_120 (fspg2)
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The wooden beams have been pretreated with various stains and have so far gone through several stages of aging with pastel pencils and various stone powders ...
but more powder is scattered. I sprayed the intermediate steps with the landscape and construction glue every now and then.
Likewise, some diagonal struts have to be installed and further imitation wooden dowels glued in.,
Dreh-Schiebebuehne_121 (fspg2)
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The corrugated sheets were placed here loosely - as an experiment - in order to get a small preliminary impression.
Dreh-Schiebebuehne_123 (fspg2)
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Stay healthy!
Frithjof
I love the whole concept of your layout as much as the individual models. -- Russ
I enjoy the appearance of decay in the weathering of the wood beams and ties. If I close my eyes I can almost hear the wood rot.
The level of your craftsmanship would be stunning for a single diorama.
Building a layout consisting of 10-15 dioramas is just flabbergasting.
Thanks for sharing!
now Hi Frithjof.
After all these years following the pieces now seeing it coming together great.
But the sleepers in the yard are special.
cheers Kim.
I just spent three days reading every post of this thread.
All I can say is(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.kingstonemodelworks.com%2Femoji%2Fwow.jpg&hash=5c07d4c9adf08f7b820e7cd013b67fb17f9471e0)
Frithjof what an excellent presentation of your work. I have never seen such excellent "model engineering" work done on a model forum. I like how you show the use of jigs and fixtures to produce beautiful models. I've picked up a few ideas that I will be able to apply to model work in the future. Having metal working tools is a great asset to model building.
I can't wait to see more post from you.
Regards,
Bernd
@Russ, Lawton, Hauk, Kim, Bernd
Thanks for your kind words!
Today four small axle bearing brackets for the rotary slide table were milled out of a 3.0mm thick MS58 plate.
Two pieces to "practice". It happens again and again, if I just do the exact number I need, strangely enough, a part disappears without a trace ...
28_FFM (fspg2)
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Drehschiebebuehne_128 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Drehschiebebuehne_128.jpg&hash=1ac6ebd526bbb0865764c24c748228768925fc4f)
Drehschiebebuehne_129 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Drehschiebebuehne_129.jpg&hash=2df6ab2e6ae29779f233e97747a12d2cc6fa8d04)
Drehschiebebuehne_130 (fspg2)
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To drill the 2.0mm blind hole for the stub axle, I clamped the milled parts in a 4.0mm collet and mounted it on the small Emco Unimat 3.
Drehschiebebuehne_131 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Drehschiebebuehne_131.JPG&hash=117def28d1bec87e127b2e416ce19a0838649c5e)
One after the other, 1.5mm and 1.9mm were pre-drilled ...
Drehschiebebuehne_132 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Drehschiebebuehne_132.JPG&hash=4a3529dea401ba818aa73933b0495d33929f232f)
... and then rubbed down to the final size with a reamer.
Drehschiebebuehne_133 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Drehschiebebuehne_133.JPG&hash=c52316417cf5d0c54d36d009d5441c99e798acce)
Drehschiebebuehne_134 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Drehschiebebuehne_134.JPG&hash=3205b0c4f2e57dd58eea9c2ec34bb23b8fb84215)
Drehschiebebuehne_135 (fspg2)
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The length will be shortened by 5.0 mm. I had placed the retaining bar at the flatter end while milling.
Drehschiebebuehne_136 (fspg2)
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Nice detail, Frithjof. I always find valuable ideas for fabricating parts in your posts.
Bernhard
That traveling turntable is pretty cool.
Another example of perfect fabrication. Ho-hum .... -- Russ
@Bernhard
I am happy when some ideas are helpful!
Looking for wheels (diameter of the running surface = 10.5mm) for the rotary slide table I found diese Webseite (https://www.steiner-modellwerke.de/produkte-spur-1/feldbahn/radsatz/) found.
It's almost like the semiconductor chips ... ordered on Feb 6. 2021 - delivery came at the end of September!
The profiling of the wheel centers on both sides was important to me.
Even if the wheel width is much narrower on the prototype, I'll use it first.
Let's see, maybe I'll have them 3D printed accordingly later.
I wanted to insert the wheels into the four axle bearings with the inner stub axles shortened to 5.5mm.
A befriended model builder came up with the idea for attaching the wheels mounted in this way, which I was able to implement successfully.
Drehschiebebuehne_137 (fspg2)
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For this purpose, the axle was provided with grooves on both sides and shortened to length with a cutting disk.
Drehschiebebuehne_138 (fspg2)
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During assembly, a small, appropriately shortened, M0.8mm screw from the underside of the axle bearing will secure the axle stub against slipping out. From the bottom because there is a little more material for the tap (0.8mm compared to 0.3mm on the top).
Drehschiebebuehne_140 (fspg2)
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Drehschiebebuehne_139 (fspg2)
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ITS INCREDIBLE AND VERY NICE
Barney
Thanks Barney :)
I used a 4.0mm ER20 collet for the bore.
If I had clamped a 3.0mm x 3.0mm square, the 2.0mm hole would have been made exactly centric.
The bottom of my small parts was only 2.5mm wide, so the drill hole is offset upwards.
When setting up the four axle bearings, I made sure that the lower edge was aligned in the same way with the same lamella of the collet (see picture above: Drehschiebebühne_134).
As a result, all parts got their holes in the same position ... just not in the middle from bottom to top - the distance on the sides was then identical.
Today there was a trial session:
Drehschiebebuehne_141 (fspg2)
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Drehschiebebuehne_142 (fspg2)
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Drehschiebebuehne_143 (fspg2)
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The wheel width is quite thin compared to the original! :(
That is as perfect as fabrication gets. -- Russ
Nice, good progress!
Bernhard
Looks awesome to me!
The little turntable got a bed today.
To do this, several layers of 1.0mm aircraft plywood were glued together so that a 2.0mm deepening was created in the central axis.
The water can then run off in the middle, should it rain. :)
Drehschiebebuehne_144 (fspg2)
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Drehschiebebuehne_145 (fspg2)
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Drehschiebebuehne_146 (fspg2)
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Drehschiebebuehne_147 (fspg2)
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Not bad. -- Russ
too clean.
The audience is watching in awe.
Nice!
Sometimes it's the little things that take a little more time ...
For the locking blocks the wheels on the turntable, I needed about 2.5 hours for drawing, creating the three milling files, milling out and soldering the individual parts.
First a 2.7mm wide U-profile with a wall thickness of 0.34mm was milled from a 4.0mm brass plate. Thereby it received a 0.6mm recess for inserting the middle plate.
The 1.5mm thick insert plate received a lateral recess of 0.2mm on the back. On the top, 0.9mm was milled off on both sides.
Drehschiebebuehne_148 (fspg2)
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Drehschiebebuehne_149 (fspg2)
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Drehschiebebuehne_150 (fspg2)
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Both parts were soldered together in a correspondingly milled groove, placed tightly in an HPL panel and glued with a crepe adhesive strip.
Drehschiebebuehne_151 (fspg2)
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Those parts were strung on a thin wire and sandblasted.
Drehschiebebuehne_152 (fspg2)
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Drehschiebebuehne_154 (fspg2)
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The turntable is slowly being equipped with the individual parts ...
Drehschiebebuehne_153 (fspg2)
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I wish the world were as perfect as your models. -- Russ
@Russ
With a model, I can be "king" and certainly make the world a little more "perfect" for me ;)
I sketched the drilling of the 0.5mm hole in the base body on February 12, 2021: click (http://www.finescalerr.com/smf/index.php?topic=1424.480)
After the hole was drilled, the protruding sides of the base plate were cut off on the sheet metal cutting machine and the sides smoothed on 400 grit sandpaper. After sandblasting it could be installed.
Drehschiebebuehne_155 (fspg2)
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The rivet will be replaced by a hexagon screw.
Drehschiebebuehne_156 (fspg2)
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Drehschiebebuehne_157 (fspg2)
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Actually, a few more parts should be milled out ... just a minute ... but unfortunately things went much slower - Win suddenly had problems with the WiFi on the milling computer - Grrrr!
Now I have reset the last update and restarted the computer, now it seems to work ... let's see how long!
Has anybody noticed how more and more things depend on wi-fi and the Internet ... but both the Internet and wi-fi are only semi-reliable? If they go down, they leave us absolutely helpless. I love high-tech stuff but really dislike the direction the computer and software industries are going. -- Russ
Frithof, I always enjoy seeing your work, never fail to learn something from your working method. Outstanding work.
Quote from: finescalerr on October 19, 2021, 12:52:39 PM
Has anybody noticed how more and more things depend on wi-fi and the Internet ... but both the Internet and wi-fi are only semi-reliable? If they go down, they leave us absolutely helpless. I love high-tech stuff but really dislike the direction the computer and software industries are going. -- Russ
Agreed Russ... there is far too much co-dependence, risk of failure, and exposure to potential corruption/hacking. I suspect in the not-too-distant future that even operating systems will be dependent upon active internet connections to function either in whole or in part.
A lot of work for these beautiful little parts! When I hear about your computer problems I am again quite happy with my manual milling machine.
Bernhard
Hi Frithjof.
As usual great, I have always liked how your models work with visible mechanical components in miniature.
cheers
Hi there,
First of all, thank you for your statements!
There are always two sides - advantages and disadvantages: with or without a computer, with CNC or hand milling machines., ...
Even though I now mill a lot of things with the CNC, small parts are also cranked by hand.
"You can see better with the second!" or if you look twice, you discover something that was overlooked the first time.
So when I compared it with a prototype photo, I suddenly saw that the two guides for locking the wheels on the model seemed a bit too bulky and a small part was missing (see red arrow).
Drehschiebebuehne_158 (fspg2)
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Drehschiebebuehne_159 (fspg2)
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Drehschiebebuehne_160 (fspg2)
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All parts were redrawn and milled - mostly a few more than needed ... sometimes something so small disappears.
Drehschiebebuehne_161 (fspg2)
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All square edges are shortened at one end before the final assembly. There were two retaining bars there, because otherwise the small brass squares would have been damaged during milling.
Drehschiebebuehne_162 (fspg2)
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For comparison: on the left the first guides (inside 2.0mm x 2.0mm) - on the right the new ones with an inside dimension of 1.5mm x 1.5mm.
You are a real perfectionist! Anyone else would have just left the first version, because no one looks that closely anyway.
Bernhard
You're right, as small as the changes are, new version looks even better than the first.
Silly me. I thought the first one was perfect .... -- Russ
@Bernhard
Sometimes things go a little more perfect. It is not important to me to finish as quickly as possible ... I would also be annoyed if I had finished something half-heartedly.
@Bill
Sometimes it's the little things that make a big difference.
@Russ
To err is human ;-)
Some parts have already been put together for testing ...
Drehschiebebuehne_163 (fspg2)
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I still don't like the wheels - they are being redrawn and printed. The tread is simply too narrow!
Then a few fiddly jobs followed,
Drehschiebebuehne_164 (fspg2)
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Drehschiebebuehne_165 (fspg2)
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... I shortened the M0.6mm screws before assembly. Once again, a 0.5mm thick sheet metal helped, in which 0.5mm holes were drilled and then the 0.6mm thread was cut.
After the required hexagon screws with a 0.3mm thick washer each had been mounted, the threads on the back of the sheet were cut off and sanded flush on a sandpaper tray.
Now all threads have a length of 0.8 mm and could be screwed into the axle bearings and soldered without the axles being obstructed.
Drehschiebebuehne_166 (fspg2)
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When it comes to the braking system, I want to see whether I can make it work.
When comparing some of the prototype photos it was noticed - again only at the "second look" - that I had milled the base plate on the brakeman's side a little too short to fit all the small parts with reasonable distances.
Drehschiebebuehne_167 (fspg2)
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The wheels are markedly oversized in the picture above. They are later turned to final dimensions with a steel section.
So the base plate gets an artificial extension of 1.0mm. For better durability, I milled the part on the underside with two protruding surfaces from a 2.0mm MS58 from two sides.
Drehschiebebuehne_168 (fspg2)
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The guide block for the brake lever will follow!
Drehschiebebuehne_169 (fspg2)
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Those bolts are pieces of jewelery!
Unglaublich! -- Russ
I love watching your progress on this project. The precision and attention to detail is fascinating.
"Incredible"
Barney
The main thing that bothers me about the wheels is the width of the wheels. Especially since the brake pads on the original have significantly more contact surface.
Drehschiebebuehne_175 (fspg2)
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Drehschiebebuehne_176 (fspg2)
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The retaining tabs of the brake yoke were milled from 0.4mm nickel silver.
The respective kinks were milled in on both sides with a 92˚ box graver 0.2 mm deep. click (https://shop.vhf.de/articleGroups/Kistenstichel-W_G_GSK.htm#)
The four 2.0mm rivets ensured the exact positioning of the two sides.
Drehschiebebuehne_170 (fspg2)
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The retaining tabs were pressed into shape with the help of a small brass gauge.
Drehschiebebuehne_171 (fspg2)
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Drehschiebebuehne_172 (fspg2)
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Drehschiebebuehne_173 (fspg2)
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Drehschiebebuehne_174 (fspg2)
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Superb. -- Russ
The parts are slowly coming together.
The axle bearing of the brake lever was put together from 3 small milled parts and the side limit stop was soldered on from a 2.0mm half-round rod.
Drehschiebebuehne_183 (fspg2)
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Drehschiebebuehne_177 (fspg2)
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The brake lever crossbar still required two lateral 0.5mm and 0.8mm holes. For this purpose, the rod was inserted vertically into a corresponding cutout and fixed with adhesive tape.
Drehschiebebuehne_178 (fspg2)
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The small brake lever consists of a milled base body into which the 1.5mm axle and a rivet with a head diameter of 3.4mm were soldered.
Drehschiebebuehne_184 (fspg2)
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Then all finished parts were sandblasted, cleaned under soapy water with a toothbrush and dried on the heater. Then the browning took place.
The proportions seem to fit.
Drehschiebebuehne_179 (fspg2)
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In order to facilitate the precise alignment of the tracks for driving over from the turntable to the siding, I milled a 0.5mm recess on the underside of the transfer platform (Fig. 177).
A 6.0mm neodymium magnet is glued in here.
Drehschiebebuehne_180 (fspg2)
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Magnets have also been glued into a central groove under the rail bed.
Drehschiebebuehne_181 (fspg2)
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For the exact positioning of these four lower magnets, the transfer platform was fixed with a track gauge and the corresponding magnet was inserted into the longitudinal groove. The exact positioning was made by the magnet already glued into the stage. Glue did the rest.
If I now move the transfer table with slight pressure from the side, the next track can be reached precisely.
Drehschiebebuehne_182 (fspg2)
(https://www.finescalerr.com/smf/proxy.php?request=http%3A%2F%2Fwww.buntbahn.de%2Ffotos%2Fdata%2F9575%2F2903Drehschiebebuehne_182.jpg&hash=4d40833a03a5a6c256d11baafc4cc64fc8a905a4)
Using magnets for the precise alignment is an excellent solution.
Clever and gorgeous. -- Russ
This is absolutely outstanding work Frithjof... it's like watching George Daniels build a watch.
Quote from: Bill Gill on November 15, 2021, 05:39:48 AM
Using magnets for the precise alignment is an excellent solution.
I agree -- it's very clever!
Hi, everyone,
Since my CNC milling machine is currently defective, it was very convenient for me that Volker created a 3D file for a Schottel sloop recently. Thank you again for that!
Schottel_Schaluppe_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7452/medium/Schottel_Schaluppe_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131279)
Through a tip from a model building friend, I came to an Italian supplier who offers interesting graduated prices.
The price varies depending on the desired delivery date!
Although I had chosen the longest time (approx. three weeks) and therefore the cheapest price, the package arrived from Italy today - after only six days!
The hull has been chosen for 3D printing in natural gray with brackets.
Gray resin ABS like was used as the material.
Bildschirmfoto_2022_02_10_um_14_20_22 (fspg2)
(https://www.buntbahn.de/fotos/data/7452/medium/Bildschirmfoto_2022_02_10_um_14_20_22.png) (https://www.buntbahn.de/fotos/showphoto.php?photo=131282)
(Click on each image to enlarge it!)
If I had ordered today, I would have paid almost €2.00 less. Postage and German VAT will then be added!
Bildschirmfoto_2022_02_10_um_14_31_44 (fspg2)
(https://www.buntbahn.de/fotos/data/7452/medium/Bildschirmfoto_2022_02_10_um_14_31_44.png) (https://www.buntbahn.de/fotos/showphoto.php?photo=131283)
The model was separated so that the resin can drain out of the cavities under the front and rear "metal plates" during printing.
Once the two "tin plates"...:
Schottel_Schaluppe_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7452/medium/Schottel_Schaluppe_02.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131280)
...and the body:
Schottel_Schaluppe_03 (fspg2)
(https://www.buntbahn.de/fotos/data/7452/medium/Schottel_Schaluppe_03.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131281)
A day later, after uploading, a warning message came from the vendor because some of the printed parts had a wall thickness of less than one millimeter: (some only 0.4 mm, 0.6 mm and 0.98 mm).
I was given the choice of uploading a modified new file or printing at my own risk.
It was worth the risk :)
Now the many small retaining bars must be separated carefully and the attachment points lightly sanded.
Schottel_Schaluppe_04 (fspg2)
(https://www.buntbahn.de/fotos/data/7452/medium/Schottel_Schaluppe_04.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131277)
Schottel_Schaluppe_05 (fspg2)
(https://www.buntbahn.de/fotos/data/7452/medium/Schottel_Schaluppe_05.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131278)
So the first ship has arrived to live up to the title of the thread ;)
Oh, by the way, I'm not related to the manufacturer... - I'm just enthusiastic about the speed and the quality :)
That will need some very delicate work but the result will be outstanding. -- Russ
That looks very good and extremely thin and fragile. But it does look like the risk of trying to print it was worth it.
If you squint and look at the photo it could be a small ship on the ways preparing for launching.
Hi Frithof.
Impressive, Volker did a very good job with the drafting and I am sure that you will do a great job but it is so thin.
cheers Kim
Volker really did a great job :)
Some parts are very thin indeed - although the scale is 1:22.5. A wall thickness of 1.0mm in the model is already 2.25cm thick at the prototype! The small boat must have been very heavy then :-)
By the service provider for 3D printing, I could have also chosen a version "without brackets", but then the print would have been about €20.00 more expensive.
So I only started with a small cutting disc to separate the holding webs. However, it was too dusty for me, so I quickly grabbed a small, wade-free side cutter and clipped through what felt like around 300 thin bars from below, piece by piece carefully.
Then I got on board to rehearse:
Schottel_Schaluppe_06 (fspg2)
(https://www.buntbahn.de/fotos/data/7452/medium/Schottel_Schaluppe_06.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131294)
The casts, which are still visible, were then carefully sanded with 240-gauge wet sandpaper.
Schottel_Schaluppe_07 (fspg2)
(https://www.buntbahn.de/fotos/data/7452/medium/Schottel_Schaluppe_07.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131295)
My left hand held the camera for the above shot. I usually hold the object to be sanded in my hand so that I can better control the pressure with the sandpaper.
That boat is a perfect example of why every serious modeler in the future will need a 3-D CAD program and a 3-D printer. Look at the beautiful results! -- Russ
Yes, excellent work, Volker and Frithjof. I know how difficult it is to model objects with such freeform surfaces in 3D.
Bernhard
Amazing that such a thin-walled object could be printed!
Hello everyone,
a few sheet metal parts have been milled again in the last few days - it is a pleasure that the control of the milling machine could be repaired again
As a friend said: "There is life without a milling machine... but it would be more pointless - at least a little!"
0_4mm_Blech_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/0_4mm_Blech_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131725)
Knotenblech_Gruppe_4_fach (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Knotenblech_Gruppe_4_fach.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131724)
...and drilled many holes in L and U profiles (of different lengths).
The individual U- and L-profiles of a portal side wall were lined up with a distance of 2.2mm and saved as a file.
For the U-profiles, 1.4mm grooves were milled into an MDF board and 3.0mm x 1.5mm U-profiles were inserted and fixed with masking tape. Then 1.2mm holes were drilled and the individual parts were cut to length with a 2.0mm cutter. This was done four times for each side wall.
Traeger_Montage_40 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_40.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131697)
Traeger_Montage_41 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_41.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131687)
The 3.0mm x 3.0mm L-profiles were placed back to back in pairs in an 1.0mm wide and 3.2mm deep groove. Since the legs are 0.45mm thick, I inserted a 0.1mm sheet metal strip between the legs. After that, maskig tape came to the rescue again.
The two sides of the thigh were drilled and milled differently. Then the two legs were exchanged with each other and the opposite side was machined. A small brass stop was milled into the MDF board on one long side so that the two profiles could also be processed congruently.
Traeger_Montage_44 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_44.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131690)
After the 404 L- and Ui-profiles were ready, the MDP panel looked like this:
Traeger_Montage_52 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_52.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131726)
The profiles that belong together were sorted into small boxes and labeled.
Traeger_Montage_50 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_50.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131722)
I will start with the assembly of the four inner side parts of the portal.
Traeger_Montage_48 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_48.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131710)
The lifting bridge will reflect the riveted condition of 1901.... so the consideration was whether it would make sense to use real brass rivets.
However, this would result in several disadvantages:
On the one hand, 50 rivets cost around €5.30 with a minimum purchase of 1000 pieces. Since I need 2712 pieces (+ quite a few more, which are distributed somewhere in the room during assembly...), that would be around €300.00.
Secondly, one side would have a wonderful semi-circular head, the opposite side would have a significantly smaller diameter after rounding with an appropriate hollow cutter (also finishing cutter) - e.g.: head = 1.3mm and the shank only 1.0mm.
Volker had shown an ingenious way with his Oesterbrücke: click (http://www.finescalerr.com/smf/index.php?topic=2257.msg61212#msg61212) (scroll down further in this post!)
Advantage: with this amount of rivets required, I come to 18.00 €
Disadvantage: both sides have to be wounded... there are only 5424 ends.
First attempts with existing wire and finishing cutters made me doubt whether my wire was perhaps too soft (MS63?). The hollow cutter immediately clogged.
New MS58 wire was ordered... and the first test gives me courage. Likewise, Volker had also achieved great results!
The first few meters of wire were cut into 5.0mm long pieces on the sheet metal cutting machine.
Due to the bevel, the 1.2mm thick wire pieces should "slide" more easily into the 1.2mm holes, which works well in some cases......
...but, the wire has slightly different diameters due to the manufacturing process. Threading in at 1.22mm next to 1.19mm is not always fun.
Traeger_Montage_54 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_54.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131728)
This can be remedied by a conical square reamer, which has been given a stop limiter by a tube that has been pushed on, so that I don't ream the holes too far.
Traeger_Montage_53 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/Traeger_Montage_53.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131727)
There is again a Pertinax gauge for easier assembly. At the points where the wire pins are pressed in, 2.0mm deep holes with a diameter of 1.3mm are drilled so that the pin has enough length on the underside for later rounding.
Traeger_Montage_51 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_51.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131723)
All of us must be very glad that your milling machine works again because it is so satisfying to see your designs turn into reality. -- Russ
Hi Frithjof.
How did you survive without your milling machine, you use it so well.
The fabrication is coming along very well great update about the rivets.
Cheers, Kim.
I'm very happy to see that you are once again making progress on this great project!
What a Sisyphean task! But perfect and instructive as always.
Bernhard
Thank you for the kind words
Even if it's like a Sisyphean task, it's just fun to make some progress with the lifting bridge project.
Clicking on the individual images will take you to the gallery. Another click is enough to enlarge the image!
So I was able to solder the first two parts together in soldering jigs.
Traeger_Montage_55 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_55.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131786)
Traeger_Montage_57 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_57.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131792)
Front and back of outer main beam panel. Some rivets were pressed with the rivet stamping machine to make assembly easier later.
Traeger_Montage_56 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_56.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131791)
Traeger_Montage_58 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_58.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131793)
To make things a bit more varied, I can start by twisting the rivet heads in addition to assembling the other side parts.
Traeger_Montage_59 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_59.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131794)
I am always fascinated by these elegant old riveted construction, which are, after all, mainly made of sheet metal and angle profiles. Great implementation, Frithjof.
Bernhard
Good to see that the mill is up and running again!
The results are fantastic as usual.
@Bernhard
QuoteI am always fascinated by these elegant old riveted construction, which are, after all, mainly made of sheet metal and angle profiles. Great implementation, Frithjof.
Thank you Bernhard - When I saw this rivet construction for the first time, I was blown away!
These few sheet metal plates, L- and U-profiles alone are surprisingly stable when they are soldered together.
@Hauk
Thank you!
At first I didn't quite succeed in twisting the soldered wire pins.
I had tried to finish the pins - without shortening them - with the finishing cutter. Apart from the fact that it took a long time to get the protrusions of up to 2.5mm to 0.6mm head height, quite a lot of heat was generated and the small milling cutter clogged up very quickly, so that it no longer showed any abrasive effect. Grrrr....
A small wooden stick every few roundings, which I pressed vertically against the milling cutter to clean, helped.
Also quite tedious and unsatisfactory when I think of the rivet heads still ahead of me....
The next attempts went much better when I shortened the wire ends freehand with the fordless side cutters.
However, the respective remaining lengths were slightly different in length, so that some millings were quite quick, but others - the longer the wire end was - more tedious.
In the end, various 0.3mm and 0.5mm thick spacer sheets were milled, which were drilled with 2.0mm holes in some places to allow the wire ends to pass through.
I put these sheets in the appropriate places as a test and the side cutters grabbed....
Traeger_Montage_63 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_63.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131801)
With 0.5mm sheet metal, the wire ends are still too long!
Traeger_Montage_64 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_64.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131802)
I got the best result with the thinner sheet metal, although the required rivet head height is 0.6mm.
Traeger_Montage_65 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_65.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131803)
Now it only takes a few seconds and the rivet head is rounded without me having to use the wooden stick to clean it up.
Traeger_Montage_66 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_66.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131804)
Traeger_Montage_67 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_67.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131807)
In between, the work was examined with a magnifying glass and a few spots were marked in red so that the hollow milling cutter can be used again.
From time to time the sheet metal was scratched a bit, but this is no longer noticeable after sandblasting.
Traeger_Montage_68 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_68.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131808)
The five rivets of the right strap on the lower diagonal are not visible with the naked eye, only the photo shows the part mercilessly :) - well, I'll have to go there again.
Miniature engineering of the best
Barney
Inspirational. -- Russ
impressive work.
Very impressive!
Thank you all!
Clicking on the individual images will take you to the gallery. Another click is enough to enlarge the image!
For easier assembly of the lower side parts, a left and a right laminated paper template were milled into which the gusset plates are placed in the corresponding recesses.
Traeger_Montage_69 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_69.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131828)
[size=85](Die Ausrichtung der lose aufgelegten U-Pofile ist auf dem Bild noch verdreht)[/size] ;-)
After all the brass pins and profiles were positioned, everything could be soldered together.
Here, too, the pins were shortened with the side cutter, whereby I achieved the different lengths of the wires with three brass templates of different thicknesses (0.3mm - 0.5mm - 0.7mm).
Traeger_Montage_76 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/Traeger_Montage_76.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131835)
Then the ends were only slightly rounded.
Traeger_Montage_71 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_71.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131830)
The rounded wires have different lengths because they are inserted into the corner profiles, for example, and the rivet head must still be visible on the inside.
Traeger_Montage_72 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_72.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131831)
Traeger_Montage_70 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_70.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131829)
Now I was able to put the inside and the lower left side part together loosely to check the height of the rivet heads that were pushed through.
Traeger_Montage_73 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_73.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131832)
Traeger_Montage_74 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_74.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131833)
Heads that were too high were marked red and had to be put under the finishing cutter again.
Traeger_Montage_75 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_75.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131834)
Using the hard paper templates ensures that all four towers are identical before I can solder them in pairs to the cross members then.
But it will still be many hours before the individual prefabricated sheets and profiles are soldered to the wire pins...
You can NEVER have too many rivets! Lovely work!
Your components always look as good as finished models. Beautiful work. -- Russ
I love the look of this style of construction, and your work perfectly duplicates it in miniature!
Thanks a lot!
Because the control of my milling machine failed again, I drew a little further.
For the two lateral portal supports I want to mill out a common base plate soon in order to put the entire lifting mechanism on a secure footing.
Portal_Bodenplatte_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Portal_Bodenplatte_01.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131849)
Portal_Bodenplatte_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Portal_Bodenplatte_02.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131850)
Traeger_Montage_mit_Schacht_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_mit_Schacht_01.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131853)
Traeger_Montage_mit_Schacht_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_mit_Schacht_02.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131854)
In the meantime I soldered together all the individual parts (except for the roof) for the first portal and shortened the wires and rounded them on both sides.
Traeger_Montage_77 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_77.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131848)
Traeger_Montage_78 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_78.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131855)
Since I can alternately solder, shorten, round off and also draw again, the missing milling machine doesn't distract me at the moment.
However, now I have to go a little more closely to investigate the causes of why the same axis is always no longer working the way I want it to.
Nobody would think you had any kind of problem, from the mill or anything else, because of the perfection of your work. -- Russ
Hubbruecke_LEA_Ausschnitt (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hubbruecke_LEA_Ausschnitt.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131871)
Copyright: Lauenburger Elbschiffahrtsarchiv
Since most of the individual parts for the two main portals have been soldered and the rivets wound, now I can free my floor from the around 5000 wire ends that have been pinched off so far.
In the meantime I have started to look more closely at the drawings for the main bridge.
Hauptbruecke_Grundskizze_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbr_cke_Grundskizze_01.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131864)
Hauptbruecke_Grundskizze_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbr_cke_Grundskizze_02.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131865)
Hauptbruecke_Grundskizze_03 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbr_cke_Grundskizze_03.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131866)
Then I created a 3D view from the three individual sketches - mind you, only half the length of the bridge is shown here. The total length of the movable main bridge segment is 112.44 cm in the model.
Hauptbruecke_Grundskizze_04 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Grundskizze_04.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131870)
I started with the page display (Hauptbruecke_Grundskizze_02).
I scaled this drawing to the model length with Photoshop and used it as a background for the first basic sketch.
I converted the original dimensions and drew in auxiliary lines for all the necessary elements.
I cheated a bit with some dimensions, so I drew an angle profile with the original dimensions of 100mm x 65mm (arithmetically at 1:22.5 this results in 4.44mm x 2.89mm) now with 4.5mm x 3.0mm, since there are corresponding profiles to buy
However, I was shocked by the prices from individual suppliers, e.g. a 1000mm/4.5mm x 4.5mm L-profile gross at a Provider (https://www.wilmsmetall.de/?page=bin/productview&data=NjM4ITY1Mg%20==) even cost €19.43.
Hauptbruecke_Montage_A (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbr_cke_Montage_A.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131949)
Hauptbruecke_Montage_B (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbr_cke_Montage_B.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131950)
Hauptbruecke_Montage_C (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbr_cke_Montage_C.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131951)
Hauptbruecke_Montage_Knotenbleche_Animation (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbr_cke_Montage_Knotenbleche_Seite_01.gif) (https://www.buntbahn.de/fotos/showphoto.php?photo=131952)
Most of you should know it: With a click on the respective picture you get to the corresponding gallery - a further click results in an enlargement, where you can see the details better.
Mad. But in a good way ;)
Absolutely Mad but just excellent in all ways
Barney
Your bridge will be too big to fit in my workshop! And based on the high price of materials, I think worldwide inflation is beginning to affect our hobby. Maybe you should redraw the plans in N scale .... -- Russ
Brilliant work as usual, always amazed at your engineering and machining skills.
Perfect design work.
I purchase almost all profiles from hassler-profile.li (http://hassler-profile.li). They are a lot cheaper. U- and I-profiles also have tightening on the legs like the original.
Bernhard
Bernhard,
That is a great source! I wonder if they will ship to the US?
Paul, I will ask him. But he is absent until May 28.
Bernhard
@all
Thanks very much!
@Russ
Good idea.... But N scale, my eyes are a bit too old for that
@Bernhard
Most of the profiles I have used so far are from Mr. Hassler. In some cases, he also made special profiles for me according to my wishes. You can call him - he is very helpful!
Time flies when you draw. It's hard to believe how much information is hidden in the three floor plans.
Some dimensions, which appear to be missing in the side view, arise automatically when assembling the individual parts.
Also, some dimensions are not always logical and are dimensioned differently in the different partial views.
You can see the current status in the following views:
Hauptbruecke_Montage_I (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montage_I.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131989)
Gruppe_Traeger_Bruecke_06 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Gruppe_Traeger_Bruecke_06.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131993)
Gruppe_Traeger_Bruecke_08 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Gruppe_Traeger_Bruecke_08.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132000)
Gruppe_Traeger_Bruecke_09 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Gruppe_Traeger_Bruecke_09.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132001)
Gruppe_Traeger_Bruecke_11 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Gruppe_Traeger_Bruecke_11.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132005)
Next, the guide rollers and their holders are reconstructed - with the help of the detail enlargements it should work. ;)
Fuehrungsrolle_Hubbruecke_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Fuehrungsrolle_Hubbruecke_01.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131991)
Fuehrungsrolle_Hubbruecke_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Fuehrungsrolle_Hubbruecke_02.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=131999)
Fuehrungsrolle_Hubbruecke_03 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Fuehrungsrolle_Hubbruecke_03.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132003)
Fuehrungsrolle_Hubbruecke_04 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Fuehrungsrolle_Hubbruecke_04.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132004)
The side roll holders and rollers are drawn and fit.
Rollenhalter_Gruppe_Druck_4x (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Rollenhalter_Gruppe_Druck_4x.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132009)
Let's see what comes out of 3D printing at Shapeways...
The holes for the fastening screws are only 0.3mm deep in the model and will be drilled out later.
Fuehrungsrolle_Hubbruecke_05 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Fuehrungsrolle_Hubbruecke_05.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132006)
0.3mm of air is enough on the side, so that nothing stands in the way of vertical movement, at least in terms of the drawing. :D
Fuehrungsrolle_Hubbruecke_06 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Fuehrungsrolle_Hubbruecke_06.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132007)
When I tried lifting, I could see a problem in the CAD for the later assembly.
Hauptbruecke_Montage_N_ (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montage_N_.gif) (https://www.buntbahn.de/fotos/showphoto.php?photo=132016)
Once the rollers are installed, the main bridge will not slide onto the two side rails.
The upper edges of the bridge are already touching the head, while the rollers are still below the respective upper edge of the rails.
A later assembly of one roller each would probably be feasible, but is ruled out due to difficult accessibility!
Fuehrungsrolle_Hubbruecke_07 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Fuehrungsrolle_Hubbruecke_07.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132008)
The solution will be a bit antithetical, but it does the job. I'm going to bevel the top tips of the guide rail slightly.
Hauptbruecke_Montage_M (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montage_M.JPG) (https://www.buntbahn.de/fotos/showphoto.php?photo=132014)
In order to get a small overview of the dimensions of the entire bridge, there is a drawing of an assembly.
Hauptbruecke_Montage_J (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montage_J.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132010)
Next, the missing profiles in the main bridge are drawn. Then the derivation of the many small gusset plates, L and U profiles can take place, so that the milling machine gets work to do again.
I ordered an external power amp (https://www.sorotec.de/shop/Stepper-motor-endstage-Leadshine-DM556EU-Digital.html) for the defective, permanently installed power amp on the mainboard of the milling machine.
Hauptbruecke_Montage_K (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montage_K.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132011)
Hauptbruecke_Montage_L (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montage_L.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132012)
This is more than just a model. It is truly a "miniature". -- Russ
Hey, Fridtjof!
Could you build me a 1/24 model of the Eiffel Tower? You seem to be up to the task!
Seriously, this is the most enjoyable modelling thread I have ever followed.
Thank you both!
@Hauk
Well, certainly the Eiffel Tower would have its appeal :),
only the lift bridge is a little closer to me....
Just looking at the number of rivets on the Eiffel Tower... I haven't counted them yet, but there are quite a few! ;)
For my bridge construction, I consider which rivets I will press or which I will replicate with rounded wire pins.
I also have to think carefully beforehand about the order in which the individual parts should be assembled.
The finishing cutter can no longer reach many small corners once the parts have been soldered.
Hauptbruecke_Montage_O (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montage_O.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132032)
Hauptbruecke_Montage_P (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montage_P.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132033)
Hauptbruecke_Montage_Q (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montage_Q.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132034)
Now the long beams and the cross connectors for the rails are missing.
Likewise the wooden boards, the handrails and many small mounting brackets, which I will gradually add to.
Hauptbruecke_Montage_R (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montage_R.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132035)
With a click on the respective picture you get to the corresponding gallery - a further click results in an enlargement, where you can see the details better.
Why not try shaping the ends of hard to reach rivets prior to pressing into place on the difficult end of the sub-assembly? A fixture would limit its penetration and the pieces could later be added to the larger assembly. Use the Carr's series of different temperature solders working from the highest temp to the lowest as you work outward. with the tiniest amount of solder needed to hold the parts in place.
Have you ever tried to solder sub-assemblies in the oven? Just hold it in a fixture based on a jeweler's heat resistant pad, bake it in the oven until the solder flows (best done with solder/flux mix applied with a syringe), and allow to cool before proceeding. Can do the same thing when working with surface mount semiconductors using a cast iron skillet on the stove's burner.
Just trying to figure out how to install all those rivets, and what sequence to install them, must be quite a mind-bending puzzle.
QuoteBernhard,
That is a great source! I wonder if they will ship to the US?
Yes Paul, he confirmed to me that he would also deliver to the USA.
Bernhard
@Lawton
QuoteWhy not try shaping the ends of hard to reach rivets prior to pressing into place on the difficult end of the sub-assembly? A fixture would limit its penetration and the pieces could later be added to the larger assembly.
Thank you, I will go this way!
Since I work with a resistance soldering device, I can easily connect all parts with the same solder without the neighboring solder joints coming loose again.
@Ray
Quote...must be quite a mind-bending puzzle.
I'll have to solve that. ;)
The reel seats arrived from Shapeways after just 14 days:
Rollenhalter_Gruppe_Druck_4x_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Rollenhalter_Gruppe_Druck_4x_02.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132065)
Many small gusset plates, brackets and the first profiles have now not only been drawn, but also milled.
Traeger_Montage_80 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Traeger_Montage_80.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132040)
The handrails require small brackets made of 2.5mm x 2.5mm L-profile:
Hauptbruecke_Montage_V (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montage_V.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132049)
As shown earlier, I inserted the legs of two L-profiles in opposite directions into a groove milled into the MDF and fixed them with masking tape.
Profile_fraesen_04 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Profile_fraesen_04.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132059)
On the following picture you can see the milling sequence:
Profile_fraesen_03 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Profile_fraesen_03.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132052)
After one pass, the two profiles were turned over so that the upper legs, which had already been machined, were inserted into the groove - and the game repeated. In the end I got a lot of small brackets:
Profile_fraesen_05 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Profile_fraesen_05.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132060)
The vertical Z-profiles also received their drill holes:
Profile_fraesen_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Profile_fraesen_02.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132051)
It is hard to believe how many parts such a relatively small bridge actually consisted of. But that's what comes of counting the rivets :lol:
In comparison with the insane number of individual parts that were made to fit e.g. when constructing the Empire State Building - without a computer - the replica of the lifting bridge is probably child's play:wink:
By the way, here are two great films about the construction of the Empire State Building: klick (https://www.youtube.com/watch?v=EdDECW5FLAM&t=1158s) and the Golden Gate Bridge: click (https://www.youtube.com/watch?v=FKU1PTyHtbM)
The upper end of the two side parts are formed by small flat bars that extend in a zigzag shape over the entire length.
Hauptbruecke_Zick_zack (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbr_cke_Zick_zack.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132193)
Hauptbruecke_Montage_Y (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montage_Y.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132189)
I milled left and right bands out of 0.3mm nickel silver. The dividing lines between the individual angled parts were milled 0.1mm deep with a V-milling cutter.
Hubbruecke_Zick_zack_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Zick_zack_02.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132194)
To prevent the individual 2.2mm wide strips from buckling or breaking at the V-groove, they were carefully removed from the plate with a 0.2mm thick sheet of brass. The remaining adhesive film (GUDY® 870) could then be rubbed off the back.
Profile_fraesen_07 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Profile_fraesen_07.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132188)
Since I milled the outer contour with a 1.0mm milling cutter, the 90° corners still have to be filed a little.
Profile_fraesen_08 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Profile_fraesen_08.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132192)
Finally for today an animation of the raising of the bridge:
Hubbruecke_komplett_Animation_1 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hubbruecke_komplett_Animation_1.gif) (https://www.buntbahn.de/fotos/showphoto.php?photo=132191)
In the enlargement there is a cleaner process!
Always great,
Amazing how much passion we manage to pour into constructing obscure corners of history!
Inspiring stuff.
Lawrence
An impressive amount of detail !
Very cool!
Thank you all!
My storage is slowly filling up.
The gusset plates shown in the following two overviews I milled for the side parts 4 times...
Knotenbleche_aussen_innen_0,4mm_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Knotenbleche_aussen_innen_0_4mm_01.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132217)
and 1 time for the underside:
Knotenbleche_Boden_0,4mm_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Knotenbleche_Boden_0_4mm01.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132218)
Knotenbleche_Vorrat_0,4mm_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Knotenbleche_Vorrat_0_4mm_01.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132222)
The side legs of the Z-profiles were additionally drilled with 1.0mm holes for the outer and inner gusset plates.
Two opposing Z-profiles were placed in a correspondingly milled groove in an MDF board.
Profile_fraesen_06 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Profile_fraesen_06.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132187)
Profile_fraesen_07 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Profile_fraesen_071.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132213)
Profile_fraesen_08 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Profile_fraesen_081.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132214)
A 2.0mm brass stop ensured congruent alignment. In addition, a small wooden stick and the crepe tape gave a secure hold when drilling.
Profile_fraesen_09 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Profile_fraesen_09.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132216)
Profile_fraesen_10 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Profile_fraesen_10.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132219)
Because my stock of 3.0mm sheet brass was no longer sufficient for 4 identical roller guides on the portals,
I milled the base plate from 2.0mm. This received a 2.0mm wide and 0.4mm deep groove in the middle.
The 2.0mm x 1.5mm thick square rods that are soldered into the groove now give me the required thickness of 3.1mm.
Rollenfuehrung_fraesen_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Rollenfuehrung_fraesen_01.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132220)
Rollenfuehrung_fraesen_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Rollenfuehrung_fraesen_2.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132221)
What a complicated model! -- Russ
As always, absolutely perfect and inspiring.
Bernhard
This is beyond modeling...it's more like engineering in miniature!
A work of art! Beautiful work and the patience to go with it!!
Jerry
@Russ
There are certainly more complicated things.
Although I often think that I have interpreted everything correctly so far, I keep discovering new things in the original scans that I had previously overlooked or incorrectly drawn in later, in supplementary CAD drawings.
@Bernhard, @Ray, @Jerry
Of course, I could certainly get to a result much faster if I didn't take accuracy so seriously.
Unfortunately, there are enough examples in many other forums that look great at first glance, but when you take a closer look, e.g. at an exhibition, the first impression is unfortunately often put into perspective. I don't want to offend anyone, it's a hobby - and it should be fun. Only I personally feel sorry for the time and the material, if I could have done it better.... with a little more patience. I don't have to be finished tomorrow, the journey is the reward :)
It went a little further now, so I have the four weights
Gewichte_15 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/2903Gewichte_15.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=106952)
built into the main bridge and which checks the position of the deflection rollers. I had already converted and drawn these in 2016 according to the original drawings.
Gewichte_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/2903Gewichte_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=106836)
Now that the main bridge has been drawn, I had to move two pulleys sideways by 0.8mm so that the ropes are exactly aligned.
Rollenmontage_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/2903Rollenmontage_02.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=106972)
Seilfuehrung_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/2903Seilfuehrung_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=106989)
Hubbruecke_komplett_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hubbr_cke_komplett_02.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132230)
In order to mount the longitudinal and transverse girders of the movable main bridge,
Hauptbruecke_Montageschblone_Bodengruppe_06 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montageschblone_Bodengruppe_06.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132259)
I drew an assembly template...
Hauptbruecke_Montageschblone_Bodengruppe_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montageschblone_Bodengruppe_01.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132253)
... and milled in MDF. The respective grooves are 2.5mm deep:
Hauptbruecke_Montageschblone_Bodengruppe_10 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montageschblone_Bodengruppe_061.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132269)
In the following picture you can see different colored gusset plates (half each as right and left version). These are milled from 0.4mm and 0.5mm MS58 sheet metal.
Hauptbruecke_Montageschblone_Bodengruppe_05 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montageschblone_Bodengruppe_05.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132258)
The gusset plates are saved as a copy and are given a radius of the respective material thickness + 1/1000mm on the outside edge and a radius of 1/1000mm on the inside.
Knotenblech_praegen_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Knotenblech_praegen_01.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132270)
An unrolling is generated from this. At the bend edge (between the red dashed lines) a groove of half the material thickness is then created on the router with a V-milling cutter (here a 91° box graver).
Knotenblech_praegen_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Knotenblech_praegen_02.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132271)
Knotenblech_praegen_03 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/Knotenblech_praegen_03.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132272)
Knotenblech_praegen_04 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Knotenblech_praegen_04.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132273)
After milling out, the small gusset plates were annealed with a gas burner so that the rivet head does not press out when the rivet is stamped.
Knotenblech_praegen_05 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Knotenblech_praegen_05.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132274)
The milled parts were then positioned under the embossing stamp with the help of a milled sheet of brass and some transparent adhesive film. In doing so, I used the tip to touch the points previously punched 0.2mm deep on the back with the V-milling cutter.
Knotenblech_praegen_06 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Knotenblech_praegen_06.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132275)
The adhesive film had to be changed after about three passes.
Before the subsequent bending, the slightly crooked parts are straightened again.
Adequate indeed. -- Russ
Tomorrow, small "frogs" (here shown here in red), whose original dimensions are about 40mm x 40mm, will be milled out of 2.0mm x 1.0mm L-profile to fasten the rail profiles on the movable bridge.
Hauptbruecke_Montageschblone_Bodengruppe_06 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montageschblone_Bodengruppe_06.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132259)
Hauptbruecke_Montageschblone_Bodengruppe_07 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montageschblone_Bodengruppe_07.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132260)
The screws are M0.6mm, with a wrench size of 1.0mm... there are 136 of them... sure, that may be crazy, but you'll see them later.
Hauptbruecke_Montageschblone_Bodengruppe_08 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montageschblone_Bodengruppe_08.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132261)
By the way, the rails are not insulated because I will be driving with a battery.
Hauptbruecke_Montageschblone_Bodengruppe_09 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montageschblone_Bodengruppe_09.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132262)
In addition to the gusset plates, I milled the outer longitudinal beam elements from 5.5mm x 2.0mm U-profile.
They received 0.15mm deep markings on the outside with the V-milling cutter - these are later used to position the rivet embossing stamp.
Profile_fraesen_11 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Profile_fraesen_11.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132306)
Profile_fraesen_12 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Profile_fraesen_12.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132310)
The ends that grip the insides of the cross members have been shortened 0.7mm deep. So they are flush with the top. In the MDF gauge, I work overhead to make it easier to achieve this conciseness.
Profile_fraesen_13 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Profile_fraesen_13.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132311)
Frithjof, you are what we would call an "advanced modeler" and your work is satisfactory. -- Russ
Frithjof, "advanced" as in !!!!!!!!!!!!!!
We're talking museum quality work here. Absolutely amazing!
Stuart
Well, don't overdo it - it's just a bit of modeling :)
I need the gusset plates in 5 different variants, in which both the height and the rivet pattern differ.
Today I milled out new gusset plates from 0.5mm nickel silver and pressed the rivets. However, I left the individual gusset plates with retaining bars on the plate. This made positioning under the embossing stamp much easier.
Knotenblech_praegen_07 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Knotenblech_praegen_07.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132331)
The remaining fluff from the adhesive film is washed off with spirit before the parts are bent.
Knotenblech_praegen_08 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Knotenblech_praegen_08.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132330)
In the meantime I have milled the mounting board again on the back....
First I have to solder the rivets on the vertical Z-profiles in connection with the crossbeams and round the wires, because later I can no longer get between them vertically with the finishing cutter.
However, the Z-profiles now needed through-holes through the MDF board. In addition, the inserted wooden limit rods had to be moved outwards on both sides by 0.65mm (wall thickness of the Z-profiles + 5/100th of the air). This allows the Z-profiles to protrude downwards through the plate when I solder the crossbeams to the solebars and the gusset plates.
I machined the through holes in the board on both sides with a 10.5mm long 2.0mm milling cutter, since the MDF board is 19mm thick.
Hauptbruecke_Montageschblone_Bodengruppe_11 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montageschblone_Bodengruppe_11.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132315)
Hauptbruecke_Montageschblone_Bodengruppe_12 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montageschblone_Bodengruppe_12.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132317)
The recesses in the mounting plate are slowly filling up... a few gusset plates are still missing...
Hauptbruecke_Montageschblone_Bodengruppe_13 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montageschblone_Bodengruppe_13.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132332)
That probably took more than a couple of minutes to complete. -- Russ
Very impressive! Planning and building the assembling jigs certainly takes the same amount of time as manufacturing the individual parts.
Bernhard
@ Russ, @ Bernhard
You are right! Each process often takes much more time than you think. But I think it will be worth it in the end. I'm currently trying to finish at least one more part every day.
I make some parts several times if errors become apparent during assembly.
So after I had bent the first gusset plates in the plate bending machine, ...
spitzer_Winkel_2 (fspg2)
(https://www.buntbahn.de/fotos/data/7443/medium/2903spitzer_Winkel_2.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=44406)
...the two rivet heads of the narrow leg are pressed flat again.
The clearance was just too narrow on the 45° side of the punch.
Knotenblech_praegen_091 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Knotenblech_praegen_091.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132346)
So I made the gusset plates, after punching all the rivet points with the V-cutter,
Knotenblech_praegen_09 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Knotenblech_praegen_09.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132342)
drilled out on the narrow leg side with a 1.0mm drill. The previously carried out markings helped to achieve an exact drill hole.
There is also a new mounting template for precisely mounting the eight different gusset plates with the cross members.
Hauptbruecke_Montageschblone_Traegergruppe_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montageschblone_Traegergruppe_02.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132340)
Hauptbruecke_Montageschblone_Traegergruppe_03 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montageschblone_Traegergruppe_03.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132341)
After the first cross member was equipped, there was a fitting test in the MDF assembly template.
Hauptbruecke_Montageschblone_Traegergruppe_04 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montageschblone_Traegergruppe_04.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132344)
It seems to fit.
Hauptbruecke_Montageschblone_Traegergruppe_05 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montageschblone_Traegergruppe_05.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132345)
When all crossbeams are soldered to the gusset plates, they will positioned in another hard paper assembly jig and also soldered.
Hauptbruecke_Montageschblone_Traegergruppe_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montageschblone_Traegergruppe_01.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132339)
A large crew built the original full size bridge. You are building the entire thing by yourself. They earned a living for their work while you are spending part of your life savings on the model. Logically, then, you must be as insane as the rest of us. But your construction and progress are quite satisfactory. -- Russ
I love this stuff.
From time to time introspection can cause one to wonder if one is going a bit far with some detail or other. A quick look at this thread restores balance and convinces you that you are not going anywhere near far enough!!
keep it up.
Lawrence
Hi Frithjof,
I've been following your build both as a Guest and as a member of the forum. I was a member at one time a long time ago. I retired from a job in the machine tool industry of 30 years and am familiar with CNC machines. That is what attracted me to this thread. I have a Sherline CNC mill and recently added a second CNC router/engraver to my machine shop.
I really like your presentation of how you go from a drawing to the finished part. Your assembly fixtures are very interesting. I'm always looking forward to a new post on your project. Keep up the great work. I'm enjoying it immensely.
Bernd
Hello Frithjof.
Great, it is really refreshing to see how the members of this forum are such individuals.
Apart from the subject I really like the jigs that you use for assembly.
Regards.
@Russ, Lawrence, Bernd, Kim
Thank you - I will continue, even if I have to take a day off sometimes. Designing and building an individual part is still fun... But if the same work steps have to be done over and over again, I get bored.
Here are three more pictures of the construction of the lift bridge:
Copyright: Lauenburger Elbschiffahrtsarchiv (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/2903Hubbr_cke_LEA-431-nah.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=40353)
Feldbahn-Hubbrücke Ausschnitt vom Süden gesehen
Copyright: Lauenburger Elbschiffahrtsarchiv (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/2903Hubbr_cke_LEA-431.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=40352)
Blick vom Süden linke Brücke = Staatsbahnbrücke
Hubbruecke_Bau_1900_1 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/2903Hubbruecke_Bau_1900_1.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=50251)
Copyrigth: Slg_Frenzel/Oppermann
In order to make sure that all inserted profiles really stay in their position when soldering, I milled a pair of "combs" out of 8.0mm Pertinax.
Hauptbruecke_Montageschblone_Traegergruppe_06 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montageschblone_Traegergruppe_06.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132347)
Then they were placed tightly in a 3.0mm recess in an MDF scrap board and three 3.5mm holes were drilled.
Hauptbruecke_Montageschblone_Traegergruppe_07 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/5156A0BB_65CB_4EF8_9CE4_CE5DD45D756D.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132348)
The MDF mounting plate had already received corresponding 2.0mm holes for the fastening screws.
Hauptbruecke_Montageschblone_Traegergruppe_09 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/41F4FBCB_4F15_44D6_9AF9_A03607575488.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132350)
At the following picture you can see a very clear difference between the four pressed and the two wounded rivet heads.
Although I had carefully pre-sorted the 8 different gusset plates in small, labeled plastic boxes (the outer longitudinal members each have a height of 5.5mm, but the two inner members are 6.0mm), I misassigned the gusset plates to one of the cross members. I will file down the two bevels of the outer gusset plates from 6.0mm to 5.5mm. The two inner (too short) knots will stay that way. It's the underside that you won't see later. And I hope no one will betray me.
Hauptbruecke_Montageschblone_Traegergruppe_10 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montageschblone_Traegergruppe_10.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132417)
After I did not get convincing results with the existing 0.8mm and 1.0mm brass wire when rounding with the corresponding finishing cutters, I ordered MS58 brass wire... and lo and behold, it works. My first wire was probably just the soft MS63 variant.
Hauptbruecke_Montageschblone_Traegergruppe_11 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montageschblone_Traegergruppe_11.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132418)
The first two of 10 cross member units are soldered. It's going on slowly.
Perfect!
Stuart
It occurs to me that the bridge would make a lovely model 'under construction'.
Plenty of interest, an excuse for figures, and no need to do all of the rivets!
Not that it isn't lovely now of course.
If this were a university, you would not be even a graduate student; you would be a full professor. -- Russ
Just Fantastic
Barney
As always: I am very impressed.
We certainly don't tell anyone about the swapped gussets! On my models you can sometimes find such small spots as well.
Bernhard
If you build a miniature in exactly the same way as the prototype, its going to look exactly the same as the prototype. Just amazing work.
Quote from: Bernhard on May 12, 2022, 01:55:34 PMPerfect design work.
I purchase almost all profiles from hassler-profile.li (http://hassler-profile.li). They are a lot cheaper. U- and I-profiles also have tightening on the legs like the original.
Bernhard
They do not respond to my email and their website seems to be down. Are they still operating?
Lawrence, I was just in contact with them about this. They seem to have a problem with the website, but are working on fixing it.
Bernhard
Thanks Bernhard, I appreciate that.
Thank you all for the friendly comments.
@Lawrence
Your suggestion to present the bridge as built is quite appealing.... But then I can't drive over the bridge with my vehicles.....
Let's see how far I get ;)
At the four corners of the movable lift bridge are the holders for the guide rollers
Rollenhalter_Gruppe_Druck_4x_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Rollenhalter_Gruppe_Druck_4x_02.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132065)
attached to the mounting shafts for the weights.
Vorne_rechts_Gruppe_10 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Vorne_rechts_Gruppe_10.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132463)
The eight castings had only 0.5mm recesses printed for the holes of the mounting screws.
They served as orientation for the drill.
In each case four M0.8mm x 3.0mm hexagon screws were inserted with a small socket wrench (wrench size = 1.3mm) from below through the 0.4mm nickel silver plate and the roller holders, while the nut was mounted laboriously (with some spit on the finger). Assembly time per plate long between five to last three minutes.
Vorne_rechts_Gruppe_04 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Vorne_rechts_Gruppe_04.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132457)
Then I rounded the first forty of three hundred and twenty 1.0mm wire pins (6.0mm long) on one side on the Emco Unimat 3 with the finishing cutter - this took about twenty minutes.
Nietkopf_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Nietkopf_01.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132426)
Nietkopf_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Nietkopf_02.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132427)
They are soldered into the vertical 5.0mm U-profiles at the ends of the lift bridge in the legs from the outside.
Vorne_rechts_Gruppe_05 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Vorne_rechts_Gruppe_05.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132458)
The rounded ends are butted one after the other (first for one leg, then for the second) against two inlaid Pertinax strips of different widths so that the rivet heads do not protrude too far inside the profile.
A later wounding would not have been feasible.
Vorne_rechts_Gruppe_1 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Vorne_rechts_Gruppe_1.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132428)
Vorne_rechts_Gruppe_2 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Vorne_rechts_Gruppe_2.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132429)
Vorne_rechts_Gruppe_3 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Vorne_rechts_Gruppe_3.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132430)
Vorne_rechts_Gruppe_06 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Vorne_rechts_Gruppe_06.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132459)
n the picture above you can see at the edge of the nickel silver plate what happens when the resistance solder is set a little too high - the material simply shrinks. After all, it's an old bridge, so that can happen.
Vorne_rechts_Gruppe_07 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Vorne_rechts_Gruppe_07.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132460)
Vorne_rechts_Gruppe_08 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Vorne_rechts_Gruppe_08.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132461)
Vorne_rechts_Gruppe_09 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Vorne_rechts_Gruppe_09.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132462)
When all other parts and the rivet pins are soldered in place, the protruding ends are shortened to approx. 1.0mm with a wadless side cutter and then further wound with the finishing cutter.
Your Pertinax solution is elegant.
I think your vehicles may some day drive over this bridge.
Engineering in miniature - in total excellence - way way beyond myself !!
Barney
Inspirational. -- Russ
Your progress, as always, is fascinating!
As always, impeccable execution. I am already eager to see the finished structure.
Bernhard
Thanks a lot!
I had soldered the lateral four receiving shafts with 5.0mm x 3.0mm brass profiles. After the front had got the 0.4mm nickel silver sheets and diagonal struts (except the upper, laterally projecting sheet) soldered on, the U-profiles were laterally trimmed, since the U-profiles have a leg width of only 2.5mm.
To do this, the parallel-aligned fence was set up on my small Böhler circular saw to match the existing width of the soldered mounting slot, which is now still too wide by 1.0mm. The first side was slowly fed along the 2.0mm wide saw blade with an intermediate 0.5mm brass strip in two height settings. The first cut separated only the lower leg, while the second saw cut the full height of the profile.
Then it was the turn of the opposite side - here I now inserted two 0.5mm brass strips. This way, I can successively bring all four parts to the same dimension without having to adjust the lateral stop.
I took the following photo afterwards, because I had forgotten it during the sawing.
Profile_trimmen (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Profile_trimmen.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132512)
A weight has already been inserted as a test.
Vorne_links_Gruppe_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Vorne_links_Gruppe_02.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132507)
The lateral thickness of 5.0 mm must later be ground down to 4.9 mm, otherwise it would chafe in the 5.0 mm wide shaft.
Vorne_links_Gruppe_03 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Vorne_links_Gruppe_03.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132508)
The front 9.0mm x 3.0mm crossmember profiles (dark green) are connected via 0.4mm thick nickel silver sheets (light green) and 3.0mm x 3.0mm L-profiles (yellow).
Vorne_links_Gruppe_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Vorne_links_Gruppe_01.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132506)
The 1.0mm brass pins, rounding on one side, were pressed tightly into the pre-drilled holes in the nickel silver plate using small flat-nose pliers. A hard paper template with corresponding 1.0mm deep holes served as a depth stop.
Vorne_links_Gruppe_04 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Vorne_links_Gruppe_04.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132510)
After I had soldered the first two connecting plates, a positioning test with the cross member revealed a small problem.
The distance between the two nickel silver sheets was too narrow by 0.3mm.
I had used an older data file when drilling the L-sections, which still had the corresponding holes offset by 0.15mm.... 2 x 0,15mm... there was the mistake.
So there was a new attempt with the newer file... and the cross member fit.
Vorne_links_Gruppe_05 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Vorne_links_Gruppe_05.jpeg) (https://www.buntbahn.de/fotos/showphoto.php?photo=132511)
It is relief to know that, along with the usual perfection, you are human enough to make a rare mistake. -- Russ
It's a real watchmaking work !
Good morning,
First of all, I wish everyone a peaceful and healthy new year!
Unfortunately I can't show you any physical construction progress today.
When I wanted to mill out a few parts for the lifting bridge again after a long time, a pungent smell came from the control switch box shortly after the milling computer started and I saw the mess:
Fehlermeldung_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Fehlermeldung_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133472)
This time the output stage for the Z-axis was submerged on the control board... grrrrrr......
Last time an external Leadshine output stage solved the problem, now all axes are to be equipped with the same external output stages. Steffen kindly agreed to help again.
Fehlermeldung_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Fehlermeldung_02.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133473)
In the meantime I continued to draw a bit.
The portal cross member was equipped with various angle profiles, rivets and the two supports for the side bridges.
Portal_Querträger_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Portal_Quertr_ger_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133469)
westl_Bruecke_Seitensicht_Auflager_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/westl_Bruecke_Seitensicht_Auflager_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133470)
westl_Bruecke_Seitensicht_Auflager_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/westl_Bruecke_Seitensicht_Auflager_02.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133471)
From the individual sketches above I could see the respective dimensions..
Hauptbruecke_Montage_Portal_001 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montage_Portal_001.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133455)
Hauptbruecke_Montage_Portal_002 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montage_Portal_002.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133456)
Hauptbruecke_Montage_Portal_003 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montage_Portal_003.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133457)
Hauptbruecke_Montage_Portal_004 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montage_Portal_004.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133458)
Hauptbruecke_Montage_Portal_005 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montage_Portal_005.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133459)
Hauptbruecke_Montage_Portal_006 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montage_Portal_006.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133460)
Hauptbruecke_Montage_Portal_007 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montage_Portal_007.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133461)
Hauptbruecke_Montage_Portal_008 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montage_Portal_008.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133462)
Hauptbruecke_Montage_Portal_009 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montage_Portal_009.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133463)
The central auxiliary suspension for the floating cylinder was drawn also.
Hauptbruecke_Montage_Portal_010 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montage_Portal_010.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133464)
Hauptbruecke_Montage_Portal_011 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montage_Portal_011.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133465)
Hauptbruecke_Montage_Portal_012 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montage_Portal_012.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133466)
Hauptbruecke_Montage_Portal_013 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montage_Portal_013.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133467)
Hauptbruecke_Montage_Portal_014 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montage_Portal_014.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133468)
So now a few 100 rivet heads should be wounded again.... really boring, but necessary work.
Hello Frithjof.
Love your drawings, I can see how you can get lost in them, Happy New Year to you too.
Hello Kim,
Today there are a few more pictures.
On the existing black and white photos of the old lift bridge, the color of the time can only be guessed at.
Hubbrücke_LEA_264_coloriert (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hubbr_cke_LEA_264_coloriert.gif) (https://www.buntbahn.de/fotos/showphoto.php?photo=133485)
Copyright: Lauenburger Elbschiffahrtsarchiv
So Photoshop's AI (Neural Filters) was questioned... and this is what came out:
Hubbrücke_coloriert_2 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hubbr_cke_coloriert_2.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133486)
Copyright: Lauenburger Elbschiffahrtsarchiv
Even if the color of the masonry was not matched in any way, I believe that the bridge itself was grey.
Other small individual parts were drawn so that they can be milled out once the milling machine is up and running again.
This is how the connecting rods between the two floating cylinders and the lifting bridge were prepared.
Verbindungsstange_Schwimmer zu Hubbrücke_1 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Verbindungsstange_Schwimmer_zu_Hubbr_cke_1.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133476)
Verbindungsstange_Schwimmer zu Hubbrücke_2 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Verbindungsstange_Schwimmer_zu_Hubbr_cke_2.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133480)
The unit above consists of 170 individual parts, it is required four times.
Verbindungsstange_Schwimmer zu Hubbrücke_3 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Verbindungsstange_Schwimmer_zu_Hubbr_cke_3.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133481)
Verbindungsstange_Schwimmer zu Hubbrücke_4 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Verbindungsstange_Schwimmer_zu_Hubbr_cke_4.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133482)
Verbindungsstange_Schwimmer zu Hubbrücke_5 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Verbindungsstange_Schwimmer_zu_Hubbr_cke_5.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133483)
Judging from the drawings and photos alone I expect your model to be astoundingly good. -- Russ
@Russ
You could be right :)
Today we are talking about the supports of the secondary and lifting bridges.
westl_Nebenbrücke_Brückenlager (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/westl_Bruecke_Br_ckenlager.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133567)
Both ends of the west side bridge can be seen in the view above. In each case (circled in red) on the left the fixed bearing and on the right the suspected roller bearing.
But in the following drawing I don't see a roller bearing but a "bolt" in the middle....was that enough to compensate for the longitudinal movement of the secondary bridge :?: :?: :?:
Auflager_Nebenbrücke_03 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Auflager_Nebenbr_cke_03.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133563)
Auflager_Nebenbrücke_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Auflager_Nebenbr_cke_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133564)
The bearings for the secondary bridges resting on the two portals (shown as a red roller on the left) are soldered together from several milled brass sheets. Appropriate pins and grooves are provided for precise mounting. Similar to here (https://www.buntbahn.de/fotos/data/8181/medium/2903Muenzel-Kran_128.jpg) at the harbor crane.
Auflager_Nebenbrücke_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/Auflager_Nebenbr_cke_02.gif) (https://www.buntbahn.de/fotos/showphoto.php?photo=133562)
The red base plate has a size of 15.7mm x 10.0mm.
The four replicas of the lift bridge's original cast bearings are created as 3D printed parts.
Auflager_Nebenbrücke_04 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Auflager_Nebenbr_cke_04.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133565)
As a combined block of four, they are a about €10 cheaper than four individual parts (despite the bulk price).
Auflager_Nebenbrücke_05 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Auflager_Nebenbr_cke_05.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133566)
The brass parts should be ready in fourteen days - much faster and a little cheaper bit than a well-known competitor from Holland.
Fascinating work, Frithjof. I have also found that making individual brass castings is cheaper than placing multiple parts on a sprue. Apparently weight also has a significant effect on price. Holes, for example, make a part more complicated, but also lighter and therefore cheaper.
Can you tell me where you have your parts made?
Bernhard
My casting supplier levies a fixed charge depending on the volume of the part plus a metal charge of NZD 0.40/g (for silicon bronze). For a casting this size probably NZD 8.00 or so for the fixed charge. All up probably less that $20 - which is about EUR 12.
That does not include printing the 'wax' which I do myself. The wax prints can be expensive if the caster does them.
It pays to make any modelled sprue as small as possible and have the caster add wax sprue - which they will remove after casting and thus not charge for.
Fascinating and inspiring as always!
The comments are as interesting as the design. -- Russ
Thanks you for the comments!
@BernhardQuoteCan you tell me where you have your parts made?
I ordered the parts here: https://i.materialise.com/de
The following zooming shows a small but important part for leveling the movable lifting bridge.
Nivelliereinheit_Gruppe_04 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Nivelliereinheit_Gruppe_04.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133626)
I assume that the lifting bridge was brought into the appropriate position with the help of the two floating cylinders and the counterweights in order to align the rail joints with the side bridges.
Then the movable wedges were pushed into position and fixed to the base bodies with the nuts.
When lowered, the lifting bridge had a fixed support on the portal now.
However, I'm not sure whether the two contact surfaces were corrugated on the original, you could guess it from the sketch. I won't reproduce it in the model.
Nivelliereinheit_Gruppe_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Nievelliereinheit_Gruppe_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133624)
Nivelliereinheit_Gruppe_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Nievelliereinheit_Gruppe_02.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133617)
Nivelliereinheit_Gruppe_03 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Nievelliereinheit_Gruppe_03.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133618)
It's amazing how many individual parts have to be installed in this portal carrier unit.
Portalträger_Einheit_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Portaltr_ger_Einheit_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133623)
If you count, you will come up with about 185 parts.
The STL file has two extra parts... you never know where such a small, unique piece will go.
Nivelliereinheit_Gruppe_Druck_10x_1 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Nievelliereinheit_Gruppe_Druck_10x_1.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133622)
In 3D printing, the 1.0mm threaded rods are not printed, they are soldered in individually later.
Please be sure to post photos of the printed assembly when it's ready. -- Russ
The detail and extent of accuracy you are expending on this project is phenomenal!
Stuart
Thanks for the info Frithjof.
I have another theory about the contact surface of the wedges: the upper wedge is guided on both sides in a groove. The broken line is the invisible contact surface. The line drawn above it is the upper edge of the lateral guide. The lower part is wider than the upper.
This is how I would have built it as a designer.
Bernhard
@Russ
will be done!
@StuartThis "rivet counting" is certainly sometimes exaggerated - but why shouldn't I build something as precisely as possible with my skills, especially since many detailed representations are possible on this scale (1:22.5).
With 3D printing, there is a minimum material thickness, which on smaller scales would reproduce the original far too strongly.
@BernhardThank you very much for your hint! Volker had similarly considered this possibility.
So I adjusted the leveling unit accordingly:
Nivelliereinheit_Gruppe_06 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Nivelliereinheit_Gruppe_06.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133629)
The new lateral guide has a height of 0.2mm (0,00787402 ") and a width of 0.4mm (0,015748 ").
Nivelliereinheit_Gruppe_07 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Nivelliereinheit_Gruppe_07.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133630)
Nivelliereinheit_Gruppe_08 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Nivelliereinheit_Gruppe_08.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133631)
The four brass supports arrived today.
Auflager_Nebenbrücke_06 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Auflager_Nebenbr_cke_06.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133715)
When measuring, there was a minimal shrinkage of 0.6% - 0.9% - I can live with that. For the future I will print similar sized parts at 101%.
Because I had only planned one approach on the underside in the middle, the lower surface became slightly round. After cutting off the 1.5mm round attachment bars with a fretsaw, I was able to smooth the four supports on a sandpaper board so that everything appears flat again.
For the following similar parts, however, I will provide several bars accordingly, even if the fretsaw then gets more work.
Since my milling machine is not running at the moment, I used the time to draw other parts.
In addition, some of the many prefabricated individual parts are soldered. But the mountain is only slowly getting smaller.
Hubbrücke_komplett_09 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hubbr_cke_komplett_09.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133713)
Träger_Montage_mit_Schacht_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Tr_ger_Montage_mit_Schacht_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133710)
Träger_Montage_mit_Schacht_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Tr_ger_Montage_mit_Schacht_02.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133711)
Träger_Montage_mit_Schacht_03 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Tr_ger_Montage_mit_Schacht_03.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133712)
Finally, there is a colored view of the lifting bridge during the construction period around 1899:
Hubbrücke_LEA-431_400-coloriert (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hubbr_cke_LEA_431_400_coloriert.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133632)
Copyright: Lauenburger Elbschiffahrtsarchiv
(By clicking on the picture you get to the gallery. A second click enlarges everything.)
The castings look terrific, even if they are very slightly undersize. The bridge itself will be a standout model, something beyond the ability of most of us but always an inspiration. -- Russ
Originally, I had planned to permanently install the lifting mechanism together with the portals on the module.
The module is built on a door leaf (202cm x 82cm) and will have a height of approx. 79cm with the portals.
Modul-Montage_43 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/2903Modul-Montage_43.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=117382)
lift-bridge-operation-principle_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7452/medium/2903lift-bridge-operation-principle_02.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=86946)
Schwimmer_61 (fspg2)
(https://www.buntbahn.de/fotos/data/7452/medium/2903Schwimmer_61.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=117090)
However, to protect the portals in case of a possible transport, I will make them demountable now.
So once again something was drawn.
Träger_Montage_mit_Schacht_12 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Tr_ger_Montage_mit_Schacht_111.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133729)
A box made of 5.0 mm HDF boards is firmly glued around the first version (see picture above). A 1.0mm MS58 sheet metal is then used as the basis for the portal. On the side, two 30mm x 15mm brass brackets are soldered to the sheet metal as a support.
Träger_Montage_mit_Schacht_08 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/Tr_ger_Montage_mit_Schacht_08.gif) (https://www.buntbahn.de/fotos/showphoto.php?photo=133725)
Next, another box (now 6.0mm poplar plywood to save some weight) is glued firmly to the module as a guide. This also gets two brass brackets as support for the removable gantry box.
Between the two boxes, there will be 1.0mm of air all around the sides to compensate for any expansion.
Träger_Montage_mit_Schacht_09 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Tr_ger_Montage_mit_Schacht_09.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133726)
Träger_Montage_mit_Schacht_11 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Tr_ger_Montage_mit_Schacht_11.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133728)
On the module itself, space was created and some already glued partition walls and Styrodur panels were cut out again.
Träger_Montage_mit_Schacht_06 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Tr_ger_Montage_mit_Schacht_06.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133722)
Well, then, it looks like the whole bridge should be finished in about half an hour! -- ssuR
Not that its one of the most fantastic piece of micro engineering I have seen in years or a life time - But Im completely lost and lost for words - but don't let me put you off just keep the Fantastic workmanship up - just looking at the workmanship that's going into to it - I surrender and I shall get on with my Lego blocks
Barney
I'm with you Barney. This project is completely beyond me in scope and magnitude. When completed, it will be more than impressive. I'll go back now and stand in my corner.
Stuart
This project is insane in a very postive way!
And maybe the most insane thing is that the model is probably way better engineered than the prototype.
It is always fascinating and inspiring to look at your posts.
Bernhard
fspg2, This continues to be an incredible build. I can only wonder in awe what the fantastic outcome would be if you and Bernhard ever collaborated on a model.
Bill, Frithjof, of course, that would be a great honor and a great pleasure. However, I expect to be busy with my l'an project for the next couple of years. I must also confess that I have already learned a lot from Frithof's posts.
Bernhard
Thanks to Russ, Barney, Stuart, Hauk, Bernhard, Bill,
I´m glad to get your approval. But it is all learnable. I still remember my beginnings and the gradual increase, which I could not have achieved without the help of friends and also many posts in forums.
One goal is always not to settle for the first best when I could do better. So in the course of time quite a few beginnings have also ended up in the tons.
@Bill
A joint project with Bernhard would be appealing to me, but I also see my started projects waiting (lift bridge, Gmeinder 10-12, Demag ML15, Kenna Gigant8, old storage shed, harbor crane, Diema DL8, ballast wagon, old scale, old fire station, ...).
Even if I make the gantry together with the inner wooden box removable for possible transport, it means a lot of effort. Both the four counterweights with the lifting ropes have to be unthreaded, as well as the movable 110cm long main bridge and the floating container with the lifting rods have to be disassembled.
However, I don't want to do that too often!
Should I have to lubricate the mechanical lifting elements, which are permanently mounted on the door leaf, with grease, I will have to find another solution!
Even if I implement a friend's tip to use lithium saponified grease, I still want to be able to service the jack screw and ball cages later if needed.
Hubeinheit_Traeger_Montage_17 (fspg2)
(https://www.buntbahn.de/fotos/data/7452/medium/2903Hubeinheit_Traeger_Montage_17.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=91497)
So cutouts are milled in the lower part of the right side panel.
Träger_Montage_mit_Schacht_13 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Tr_ger_Montage_mit_Schacht_13.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133847)
Träger_Montage_mit_Schacht_14 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Tr_ger_Montage_mit_Schacht_14.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133848)
In the door leaf, on which the whole module is built, there is also a recess to gain access to the jack screws.
Träger_Montage_mit_Schacht_16b (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Tr_ger_Montage_mit_Schacht_16b.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133893)
I discarded my initial consideration of making the mechanical part removable along with the gantry and shaft. By permanently mounting the two drives on the door panel, I don't have to dismantle the toothed belts or their emergency switches. The weights and the lift bridge would also have to be removed in this case.
Hubeinheit_Traeger_Montage_31 (fspg2)
(https://www.buntbahn.de/fotos/data/7452/medium/2903Hubeinheit_Traeger_Montage_31.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=92258)
In the meantime - until the router is fully functional again - I'm in the process of creating the routing files.
So all the HDF/plywood panels were converted from 3D view to DWG to DXF to job and finally to tap files that will eventually go onto the router.
Likewise, the support plates for the winch drive motor were prepared.
Träger_Montage_mit_Schacht_18 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Tr_ger_Montage_mit_Schacht_18.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133888)
I had described the principle here on October 20, 2016 here (https://www.buntbahn.de/viewtopic.php?t=6691&hilit=winde&start=310). Sorry, it's in German - please use the translation function of your browser.
The four ropes of the weights in the two gantries are guided to the winch via pulleys.
This ropes are passed twice around the pulley (principle of a capstan) and then down through four corresponding holes in the floor. A second pulley with flanged Faulhaber 22B - 243:1 winds up the ends of the ropes. The motor makes one revolution in about 50 seconds at 1.5Volt.
It now takes a good 140 seconds to make the 9cm lift (just under 3 turns of the pulley). The hand crank of the winch makes about 120 revolutions thereby, which was needed to lift the four weights completely. So I have 1.2 crank revolutions per second in the model - in the prototype, however, the process took about 10 minutes for the 120 revolutions of the hand crank.
I can live with this compromise, because who wants to watch for 10 minutes when the bridge lifts so slowly?
Otherwise I could use a higher reduction Faulhaber (I don't have one) ... or even put a gearbox between the lower pulley and the existing motor.
Träger_Montage_mit_Schacht_20 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Tr_ger_Montage_mit_Schacht_20.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133890)
Träger_Montage_mit_Schacht_22 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Tr_ger_Montage_mit_Schacht_22.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133892)
The nice thing about this is it makes the 'insane' things that I do seem commonplace and normal ;)
Inspirational.
The elegant, sophisticated design suggests you probably majored in something other than music when you were in school. -- Russ
Frithjof, It is exciting to see this project progressing so methodically.
I think your compromise on the time it takes to lift the bridge is a good idea. There is a small bascule bridge here in the village that just had a celebration for its 100th anniversary. Before the bridge can open the bridge tender must perform a sequence of operations: lower the vehicle gates, lower the pedestrian gates, raise the vehicle barrier girder, blow the whistle, then raise the bridge.
That sequence is repeated in reverse order when lowering the bridge. Tourists on foot find it "picturesque" the first time they watch all that, but those in cars find the interval almost unbearable. The bridge opens for boat traffic every hour between 8am and 8pm during the summer as well as any other time of the day for commercial or emergency vessels, so the local residents try to time their driving through the downtown area between openings to avaid the long lines of cars that wait for the bridge.
One hot summer the bridge opened for the passage of the museum's annual antique boat parade. The open leaf was in the sun for almost 90 minutes while the fixed roadway was in the shade. The moveable leaf expanded enough from the heat of the sun that it could not close completely. the fire department had to come and spray river water on the section until it cooled enough to close properly. You can imagine how "excited" everyone was to wait and watch all that, so the 140 seconds it takes to raise your bridge sounds just right.
This is an astounding project Frithjof, an inspiring blend of engineering, machining mastery, and creativity. Really looking forward to seeing all the elements come together.
I agree with all a "fantastic project"
Barney
@Lawrence, Russ, Bill, Paul, Barney,
Many, many thanks - I'm starting to blush with embarrassment now though.
@Bill
Thank you for the nice bridge story with the fire department too!
Puh.... Six weeks without a milling machine, that's when the real withdrawal symptoms set in.
The new output stages for the X, Y and Z axes were installed in a second control box and connected to the corresponding motor cables.
neue_Enstufen_1 (fspg2)
(https://www.buntbahn.de/fotos/data/9350/medium/neue_Enstufen_1.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133915)
neue_Enstufen_2 (fspg2)
(https://www.buntbahn.de/fotos/data/9350/medium/neue_Enstufen_2.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133914)
Now only the new power amplifiers had to be connected to the control signals of the motherboard....
... but which contacts now had to be tapped on the board?
Fortunately, Steffen knew how to perform the "open heart surgery"!
OP_am_offenen_Herzen_2 (fspg2)
(https://www.buntbahn.de/fotos/data/9350/OP_am_offenen_Herzen_2.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133904)
Even though the enameled copper wires are very thin, they are perfectly adequate for the control signals.
OP_am_offenen_Herzen_3 (fspg2)
(https://www.buntbahn.de/fotos/data/9350/medium/OP_am_offenen_Herzen_3.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133905)
Now the milling machine is running again and I could mill out the first parts for the mounting shaft of the lift bridge.
Träger_Montage_mit_Schacht_23 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Tr_ger_Montage_mit_Schacht_23.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133907)
Small retaining webs on the underside prevent the individual parts from shifting during the final milling pass and thus possibly being damaged by the milling cutter. They were cut with a cutter blade and the edges smoothed with sandpaper.
Träger_Montage_mit_Schacht_24 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Tr_ger_Montage_mit_Schacht_24.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133906)
The four side panels and the two intermediate shelves are inserted into the corresponding recesses and glued at the end with super glue. This results in a stable rectangular box.
Träger_Montage_mit_Schacht_25 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Tr_ger_Montage_mit_Schacht_25.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133908)
Träger_Montage_mit_Schacht_26 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Tr_ger_Montage_mit_Schacht_26.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133909)
The individual parts for the motor mount were also milled out. The two side parts (drawn red and green transparent) for the pulley were modified a bit and a 1.0mm brass plate was added to the upper side.
Träger_Montage_mit_Schacht_31 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Tr_ger_Montage_mit_Schacht_31.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133916)
The four small elongated holes (light yellow) are used for rope guidance and allow the 0.25mm thick ropes coming through corresponding elongated holes on the base plate (red) of the winch to roll up neatly.
Träger_Montage_mit_Schacht_28 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Tr_ger_Montage_mit_Schacht_28.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133911)
Träger_Montage_mit_Schacht_30 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Tr_ger_Montage_mit_Schacht_30.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133913)
Good to see that your machine is working again. I am already curious about the further progress.
Bernhard
Perfect components. You must be overjoyed to have your mill working again. -- Russ
Awesome!
In the meantime I was able to mill out a few more parts.
Since there is no U-profile with the dimensions 13.0mm x 4.0mm to buy, I had already received 15.0mm x 4.0mm profiles from Hassler (http://www.hassler-profile.li/ ) in 2016 and separated them in the middle with a 1.5mm cutter.
Quertraeger_trennen_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/2903Quertraeger_trennen_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=106484)
Quertraeger_trennen_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/2903Quertraeger_trennen_02.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=106483)
Quertraeger_trennen_05 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/2903Quertraeger_trennen_05.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=106497)
After I soldered the two bent halves back together with the help of small holding blocks, I got a height of 13.5mm.
Quertraeger_trennen_06 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/2903Quertraeger_trennen_06.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=106848)
However, when I recently tried to slide the four profiles into the side gantry beams on a trial basis, the corresponding openings were unfortunately too narrow by 0.5mm.
Hauptbruecke_Montage_Portal_009 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Hauptbruecke_Montage_Portal_009.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133463)
What could I do?
a) cut the parts that are too wide again in the middle with a 0.5mm milling cutter,
b) order new profiles and cut them in the middle with a 2.0mm cutter,
C) Mill out the required profiles from a 4.0mm MS58 flat material.
I chose the third option. Even if the lateral bevels of the two profile legs and the roundings are missing, it will hardly be noticeable afterwards, as they are covered by the bridge parts.
As I recently wrote:
So all the HDF/plywood panels were converted from 3D view to DWG to DXF to job and finally to tap files, which eventually go onto the router.
...I was asked what you can imagine by that.
Two portal cross member profiles (yellow) were arranged in a 3D file so that they fit on the 250.0mm x 40.0mm x 4.0mm MS58 flat material (green) and had space for a 2.0mm milling cutter all around .
This file was placed in a DWG drawing and colored the different edges and holes with different colors. So I got different layers for the tap file derived from this, to which I could assign the corresponding drills and milling cutters with the respective parameters (diameter, speed, feed, immersion depth and immersion type, starting point, direction, holding webs,...).
Portalträger_05 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Portaltr_ger_05.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133921)
Portalträger_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Portaltr_ger_02.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133918)
Portalträger_03 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Portaltr_ger_03.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133919)
Portalträger_04 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Portaltr_ger_04.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133920)
The milled parts were first straightened out a little after the small retaining bars had been separated.
Now a few 0.8mm and 1.0mm mounting holes were missing on the upper thigh surfaces.
A milled groove (cyan) with two cross stops (blue) in a HPL scrap sheet and two additionally inserted brass profiles helped to align the profiles at right angles.
Querträger_Portal_Löcher_Schenkel_oben_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Quertraeger_Portal_L_cher_Schenkel_oben_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133923)
In addition, I inserted a 3.0mm thick flat profile to avoid wobbling while drilling.
Querträger_Portal_Löcher_Schenkel_oben_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Quertraeger_Portal_L_cher_Schenkel_oben_02.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133925)
Querträger_Portal_Löcher_Schenkel_oben_03 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Quertraeger_Portal_L_cher_Schenkel_oben_03.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133926)
That's what I call uncompromising model making!
Bernhard
@Bernhard Sometimes I try to get as close as possible to the prototyp, even if it's not the fastest way to get to the goal.
Next, a number of details for the two portal cross members have to be made.
Querträger_Details_04 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Quertr_ger_Details_04.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134003)
As in the animation already shown recently,
Auflager_Nebenbrücke_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/Auflager_Nebenbr_cke_02.gif) (https://www.buntbahn.de/fotos/showphoto.php?photo=133562)
the four supports for the secondary bridges were milled from six individual parts each and soldered together. Instead of the red roller in the animation, I milled a fixed bearing block with a 3.0mm hole. Corresponding bolts on the underside of the two adjacent secondary bridges will be securely positioned here later.
Auflager_Nebenbrücke_07 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Auflager_Nebenbr_cke_07.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133928)
Also here I have made one part more, you never know ;)
Auflager_Nebenbrücke_08 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Auflager_Nebenbr_cke_08.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133929)
Auflager_Nebenbrücke_09 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Auflager_Nebenbr_cke_09.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133962)
Today, the eight (+1) U-profiles connecting the two portal cross beams were added.
Querträger_Details_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Quertr_ger_Details_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133999)
Querträger_Details_03 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Quertr_ger_Details_03.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134002)
Querträger_Details_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Quertr_ger_Details_02.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134001)
Even if the work steps are always similar, every small angle of the two portal crossbeams has different lengths and drill hole spacing.
Here four 3.0mm x 3.0mm and 3.5mm x 3.5mm L-profiles were milled several times as right and left versions.
As before, the legs were inserted into a 1.0mm wide and 3.6mm deep groove back to back.
Since the legs of the 3.0mm x 3.0mm profile have a thickness of only 0.4mm (instead of 0.5mm for the 3.5mm x 3.5mm profile), a 0.2mm sheet metal strip was inserted tightly between them. In the milling drawing it had been considered accordingly, so that the 1.0mm holes were also drilled at the correct position.
After the first leg was drilled, the two profiles were swapped and the second leg received its deviating holes.
Querträger_Details_05 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Quertr_ger_Details_05.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134004)
Querträger_Details_06 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Quertr_ger_Details_06.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134005)
During the first positioning test with the 19.3mm long connecting U-profile, there was nothing to complain about.
Querträger_Details_07 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Quertr_ger_Details_07.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134006)
Slowly the box is filling up with the details for the two portal beams.
Querträger_Details_08 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Quertr_ger_Details_08.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134007)
Now the leveling units have to come from the 3D printer first, before I can solder the four short connecting U-profiles to the two cross beams, otherwise the M0.8mm connecting screws cannot be mounted. The 1:22.5 scale is sometimes a little small after all :)
Nivelliereinheit_10x_Druck_101% (fspg2)
(https://www.buntbahn.de/fotos/data/7473/Nivelliereinheit_10x_Druck_101_.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134009)
On the following picture, the rivets at the left support of the side bridges are not yet rounded.
The M0.8mm screws have a wrench size of 1.3mm... I needed the headband magnifier for that ;)
Querträger_Details_09 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Quertr_ger_Details_09.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134008)
Satisfactory. And I hope visitors, who may not belong to the forum but see your work, truly appreciate it. -- Russ
As always, absolutely precise and perfect work.
Bernhard
If the dictionary had a photo for an example of "Scracthbuilding" your work would be it.
it really is impressive to follow along.
Impressive as always!
Thanks to all
@Bill
It goes on with the ,,scratchbuilding".
The next part will be the connecting rod between the float cylinder and the lift bridge.
Verbindungsstange_Schwimmer zu Hubbrücke_1 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Verbindungsstange_Schwimmer_zu_Hubbr_cke_1.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133476)
Verbindungsstange_Schwimmer zu Hubbrücke_2 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Verbindungsstange_Schwimmer_zu_Hubbr_cke_2.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133480)
For this I was able to persuade the milling machine to spit out a number of small parts in the last few days.
Verbindungsstange_Schwimmer_zu_Hubbrücke_04 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/Verbindungsstange_Schwimmer_zu_Hubbr_cke_04.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134011)
After the required parts were milled out of 0.3mm and 0.5mm nickel silver sheets, they were freed from the remains of the adhesive foil on the back.
With the help of a homemade sandpaper file (wooden stick with clad 1000 sandpaper) I then removed the slight degree formation that occurs when drilling and milling through on the underside.
Verbindungsstange_Schwimmer_zu_Hubbrücke_05 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Verbindungsstange_Schwimmer_zu_Hubbr_cke_05.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134012)
The connecting rod consists of two lateral 6.0mm x 3.0mm U-profiles that are connected to the diagonal braces with wire pins.
To do this, 100 rivet imitations must be fitted for each of the four connecting rods.
As before, I clamped a 0.8mm MS58 wire in the Emco lathe and rounded it on one side with a Twincut hollow cutter and then cut off pieces about 5mm long in each case (as shown here (https://www.buntbahn.de/fotos/data/7473/Nietkopf_02.jpeg)).
Verbindungsstange_Schwimmer_zu_Hubbrücke_07 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Verbindungsstange_Schwimmer_zu_Hubbr_cke_07.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134014)
In order to allow the resulting rivet heads on the inside of the U-profiles to dip evenly with only the rounded end, two different stops were milled from 5.0mm HPL sheets. The first stop inserted into the U-profile allows the rivet heads to dip by 0.4mm.
For the opposite side, the second stop has a corresponding cutout on both sides.
Verbindungsstange_Schwimmer_zu_Hubbrücke_08 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/Verbindungsstange_Schwimmer_zu_Hubbr_cke_08.gif) (https://www.buntbahn.de/fotos/showphoto.php?photo=134015)
Verbindungsstange_Schwimmer_zu_Hubbrücke_09 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/Verbindungsstange_Schwimmer_zu_Hubbr_cke_09.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134016)
Verbindungsstange_Schwimmer_zu_Hubbrücke_10 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Verbindungsstange_Schwimmer_zu_Hubbr_cke_10.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134017)
Verbindungsstange_Schwimmer_zu_Hubbrücke_11 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Verbindungsstange_Schwimmer_zu_Hubbr_cke_11.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134019)
Very impressive - I just love it
Barney
Frithjof is a virtuoso. -- Russ
It goes a little further step by step.
You can hardly believe how long just the small parts require time.
The four small curved holders for the floating cylinder suspension served as an example.
Schwimmzylinder_Aufhängung_08 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Schwimmzylinder_Aufh_ngung_08.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134043)
They were milled out of a 3.0mm brass flat in pairs - one more pair to be on the safe side.
Schwimmzylinder_Aufhängung_04 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/Schwimmzylinder_Aufh_ngung_04.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134024)
Two 20.0mm x 23.0mm Pertinax half-shells with a center-milled 1.0mm slot are used to accurately position a 1.0mm drill.
Schwimmzylinder_Aufhängung_05 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Schwimmzylinder_Aufh_ngung_05.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134026)
Schwimmzylinder_Aufhängung_06 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Schwimmzylinder_Aufh_ngung_06.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134027)
Thus, the upper hole was drilled at both ends.
Schwimmzylinder_Aufhängung_07 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Schwimmzylinder_Aufh_ngung_07.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134028)
Then the parts prepared in this way were placed tightly in a recess with stops on both sides and the 1.2mm holes were drilled. A 1.5mm cutter then separated the two holders.
Schwimmzylinder_Aufhängung_09 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/Schwimmzylinder_Aufh_ngung_09.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134044)
One holder each is later attached to the mounting bracket of the float cylinder.
Schwimmer_80 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Schwimmer_80.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133717)
Schwimmzylinder_Aufhängung_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Schwimmzylinder_Aufh_ngung_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134020)
Schwimmzylinder_Aufhängung_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Schwimmzylinder_Aufh_ngung_02.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134021)
The mounting brackets are now waiting to be soldered together.
Schwimmzylinder_Aufhängung_03 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Schwimmzylinder_Aufh_ngung_03.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134022)
Schwimmzylinder_Aufhängung_10 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Schwimmzylinder_Aufh_ngung_091.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134047)
Ten days after ordering, the 3D-printed brass leveling units arrived yesterday.
After I sanded the slightly visible layer steps with a sandpaper file, the sandblasting gun smoothed out the rest.
Nivelliereinheit_10x_Druck_101%_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/Nivelliereinheit_10x_Druck_101_02.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134025)
A scroll saw was used to cut off the bottom casts and smooth the bottoms on 400-grit sandpaper.
Nivelliereinheit_10x_Druck_101%_03 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Nivelliereinheit_10x_Druck_101_03.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134045)
The fiddling work now consists of installing the M0.8mm screws and nuts and the many 1.0mm rivet pins. Patience will be required here.
Nivelliereinheit_10x_Druck_101%_04 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/Nivelliereinheit_10x_Druck_101_04.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134046)
The smallest parts always seem to require the most time. As for the results: Satisfactory. -- Russ
And again a few more perfect parts!
Bernhard
I think the only prototype thing you have not replicated is mining and refining the metal.
The care and the precision you take with all the processes of your work is outstanding and the result is very evident ithroughout the entire model.
Small parts are fiddly and almost always take more than their share of time.
Each piece is in itself a jewel. Utterly fantastic work and I wag my head in disbelief with each posting you make.
The time with the rivets is usually very monotonous, so I always switch to other sections. There are more than enough of them fortunately :)
So the parts for the inner and outer wooden boxes of the portal beams were milled out of MDF and poplar plywood.
Träger_Montage_mit_Schacht_09 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Tr_ger_Montage_mit_Schacht_09.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=133726)
Träger_Montage_mit_Schacht_32 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Tr_ger_Montage_mit_Schacht_32.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134060)
Here is the inner removable box on which the gantry is permanently mounted.
Träger_Montage_mit_Schacht_33 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Tr_ger_Montage_mit_Schacht_331.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134121)
The inner shaft has already been loosely inserted as a test and the surrounding individual parts checked for accuracy of fit before the outer wooden frame will be firmly glued in place.
Träger_Montage_mit_Schacht_34 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Tr_ger_Montage_mit_Schacht_33.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134124)
The original idea of later servicing the lifting mechanism through a cutout from below (https://www.buntbahn.de/fotos/data/7473/medium/Tr_ger_Montage_mit_Schacht_16b.jpg) was discarded. During trial assembly, after lifting out the inner unit, I was able to get to the mechanism after all in such a way that greasing from above would be quite convenient.
So the right outer side panel was re-milled - now without a side access hole.
Träger_Montage_mit_Schacht_35 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Tr_ger_Montage_mit_Schacht_35.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134123)
That looks as though it will be a rather large model when it is complete. -- Russ
It is always a pleasure to see how this model grows.
Bernhard
Today a small continuation, so that the model continues to grow.
After I could get more accurate original drawings of the shaft of the lift bridge in 2019, I had re-milled the plexiglass base body.
Here still the old state:
(https://www.buntbahn.de/fotos/data/7452/2903Schwimmer_46.jpg)
Contrary to initial assumptions, the guide rollers of the floating cylinder were rotated exactly 45°.
(https://www.buntbahn.de/fotos/data/7473/2903Hubbruecke_Portal_Detail-1.jpg)
For the new version, the wall parts for the lateral inspection shaft were missing until now.
Shaft_01 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Schacht_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134139)
In order to be able to look through the side opening into the inspection chamber, the right side wall was only indicated.
Schacht_02 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Schacht_02.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134140)
Schacht_03 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Schacht_03.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134150)
Schacht_04 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Schacht_04.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134148)
The ladder was soldered in an already existing Pertinax gauge.
Schacht_05 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Schacht_05.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134151)
The lateral protruding wire ends were carefully cut off with a 0.5mm thin saw blade on the Böhler circular saw and the side surfaces smoothed on fine sandpaper.
Schacht_06 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Schacht_06.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134152)
Schacht_07 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Schacht_07.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134153)
Before the parts can be glued into the shaft, I want to treat them with color now.
Schacht_08 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Schacht_08.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134157)
fspg2, It is always a pleasure to see and read about your progress with this project.
Frithjof, if you are going to show off such beautiful brick walls and brass ladders, it is only fair that you also make them for the rest of us. -- ssuR
Thank you Bill! :)
Thanks Russ, but then I'm sure I'll never be finished with all my many projects. ;)
In the last days I could do only little, so today comes only a small update.
On the inside of the only indicated side wall of the inspection chamber, I sawed a 1.0mm wide slot diagonally to get a secure guide for the curved back wall.
Schacht_09 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Schacht_09.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134158)
Before final installation in the module, the inspection shaft is glued together as a complete unit with wood glue. In the process, I discovered that the left side wall, where the ladder will later be mounted, was unfortunately milled 1.0mm too narrow. Although I had taken the right number of stones, I hadn't considered the outward slanting to the round main shaft.
So I milled a small wall strip from 1.0mm waterproof aircraft plywood and glued it to the slanted side. After a slight overhang was adjusted to the wall surface with a sandpaper file, a 0.5mm thick saw blade helped to cut the wall joints free.
After painting, the transitions will no longer be visible.
Schacht_12 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Schacht_12.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134204)
The 1.0mm holes for fixing the ladder are still missing.
Schacht_13 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Schacht_13.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134205)
A few more small parts milled from MDF, should show the wall structure in the visible area of the shaft - more about that later.
Schacht_10 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Schacht_10.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134201)
Schacht_11 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Schacht_11.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134203)
First of all, a peaceful and healthy New Year 2024 to everyone!
Today I'm going to tell you a little about why I haven't posted a report here since April 2023.
After my control card for the CNC milling machine failed three times in a row and Steffen was able to repair it twice, three new output stages were installed in a second control box (https://www.buntbahn.de/fotos/data/9350/medium/neue_Enstufen_1.jpg) in February. After that, everything worked as usual for the last four years, until the software suddenly started giving error messages and stopped in the middle of the milling process. :'(
Now began a somewhat annoying troubleshooting process to find the cause.
Dozens of milling passes (1 cm above the milling plate) were carried out, whereby the various possible sources of interference were switched off one after the other (cooling water pump of the spindle, LED lighting for the milling cutter, height sensor, vacuum cleaner, ...) - unfortunately the error message came up again and again.
:'( :'( :'(
USB_Fehler (fspg2)
(https://www.buntbahn.de/fotos/data/9350/medium/USB_Fehler.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137342)
Steffen (he helped me a lot with the installation of the CNC router) then asked whether the power cable and the USB cable from the computer to the control box were housed in a common cable duct and could thus generate interference signals....
That was the case - although no error has occurred in recent years... - but why all of a sudden now?
So a new cable duct was laid to separate the power and USB cables.
At the same time, a 15m LAN cable was laid through three rooms to get the data from the server to the milling computer. Until now, I had been using the WLAN network.
Now I was curious..... Trial milling operations with cutter/drill changes in the air were now carried out without any problems.
... until I looked at the milling machine again after about 30 minutes: The test milling job had been completed as usual, the milling spindle had been moved to the rest position, the vacuum cleaner had been switched off...
...and a new error message appeared: "NO RETURN MESSAGE"
The software no longer allowed any movement. Only after a restart could I continue.
After another attempt ended the same way, I gave up in frustration :( :(
As I was and still am very busy with long renovation work on our house, the hobby took a back seat for the time being.
After I had milled out the last parts for the lift bridge shaft in April, the milling machine didn't want to continue.
Schacht_14 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Schacht_14.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=134265)
Schacht_15 (fspg2)
(https://www.buntbahn.de/fotos/data/7473/medium/Schacht_15.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137343)
Since then I have made a few drawings for the boom of the Münzel crane only.
Getriebe_Ausleger_03 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Getriebe_Ausleger_03.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=136248)
Getriebe_Ausleger_04_1 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Getriebe_Ausleger_04_1.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=136249)
Getriebe_Ausleger_05 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Getriebe_Ausleger_05.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=136250)
Getriebe_Ausleger_06 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Getriebe_Ausleger_06.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=136251)
Getriebe_Ausleger_09 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Getriebe_Ausleger_09.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=136449)
Getriebe_Ausleger_10 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Getriebe_Ausleger_10.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=136450)
Getriebe_Ausleger_11 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Getriebe_Ausleger_11.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=136451)
The boom was raised and lowered using a rack and pinion, which was protected against the weather by interlocking (sliding ?) protective tubes.
There was a double rack and pinion variant on this larger crane: former crane in Dortmund (https://www.wirindortmund.de/wp-content/uploads/2023/06/06-2023-Portaldrehkran-Restaurierung-JK-5-scaled.jpg)
As the mechanics of this crane were located inside the housing, there were no telescopic protective tubes here.
Initially, I wanted to use the green pulley on the gearbox shown in my previous design for a drive chain (or rope?) between the gearbox and the drive motor in the crane housing. A model could be here: Kran Hamburger-fotoarchiv.de (https://historische-bilder.com/photo/holthusenkai-norderelbe-verstauen-hafenarbeiter-papierholz-offene-bahnwaggons-Q9trt2Pfi7)
Unfortunately, I don't have any other pictures that document this function in more detail.
In the later version shown below, I still have no idea what function this box on the left of the gearbox had... was an electric motor hidden here ???
Muenzel_Kran_LEA_02 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/2903Muenzel_Kran_LEA_02.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=113310)
Münzel-Kran_Lauenburg (Copyright W.Hinsch-LEA)
Getriebe_Ausleger_08 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Getriebe_Ausleger_08.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=136302)
Münzel-Kran_Lauenburg (Copyright W.Hinsch-LEA)
Here is another picture of the crane (older condition) without side box but with an upper black block (tube ?).
The function is also unknown to me.
Getriebe_Ausleger_07 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/Getriebe_Ausleger_07.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=136301)
Münzel-Kran_Lauenburg (Copyright W.Hinsch-LEA)
Back to troubleshooting (NO RETURN): Between the holidays, I had another idea:
I started the milling computer and deactivated the WLAN connection - after all, there is a LAN cable.
Another milling attempt in the air was made without any further problems now ... and after a long wait: no more error messages either.
In the next few days I will hopefully be able to start a proper milling and then get some milling work done that has been a long time coming.
Happy New Year!
The mill machine problems sound very frustrating. Hope it is finally corrected and you can continue the project.
I don't have any equipment with electronic controls, just manually operated small hand tools and sometimes I also get 'mental error messages' that are difficult to track down and correct ::) .
Yes, repair or replace the mill so you can resume work on the model. I understand your frustration. When the laser broke in the middle of cutting the parts for my last model, I nearly threw everything into the trash. (Hmm. Maybe that wasn't such a bad idea ....) -- Russ
Quote from: fspg2 on January 01, 2024, 08:39:58 AMBack to troubleshooting (NO RETURN): Between the holidays, I had another idea:
I started the milling computer and deactivated the WLAN connection - after all, there is a LAN cable.
Another milling attempt in the air was made without any further problems now ... and after a long wait: no more error messages either.
In the next few days I will hopefully be able to start a proper milling and then get some milling work done that has been a long time coming.
I really hope you have found a permanent solution to your printer troubles!
Best wishes for a productive new year!
I understand your frustration. That is the disadvantage of CNC machines. Unless you are an electrical specialist, you are relatively helpless in the face of the problem. I hope you find the error soon, because we are eagerly awaiting further progress on the project!
Bernhard
Thank you very much for your sympathy!
In 2012-02-26, I had milled the four support brackets (https://www.finescalerr.com/smf/index.php?topic=1424.60) for the roof structure. However, at the time I hadn't thought about how I could mount these four blocks on the roof precisely aligned... :?: :?: :?:
Even though the milling machine is still a bit of a pain at the moment, yesterday I milled out four auxiliary supports for the Münzel-crane from 1.5mm MS58.
These auxiliary supports ensure precise alignment to the side and in height.
Hilfsspanten_Aufbauträger_01 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Hilfsspanten_Aufbautra_ger_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137591)
Hilfsspanten_Aufbauträger_02 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Hilfsspanten_Aufbautra_ger_02.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137592)
Hilfsspanten_Aufbauträger_04 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Hilfsspanten_Aufbautra_ger_04.gif) (https://www.buntbahn.de/fotos/showphoto.php?photo=137594)
Hilfsspanten_Aufbauträger_06 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Hilfsspanten_Aufbautra_ger_06.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137596)
Two frames were soldered together with 1.0 mm brass wires at 5.0 mm intervals. The protruding wire ends were cut off and the surfaces sanded smooth on a sandpaper board. Two 1.5mm wide grooves were milled into the underside of each of the four support brackets at the appropriate distance and hard-soldered to the frame.
Hilfsspanten_Aufbauträger_07 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Hilfsspanten_Aufbautra_ger_07.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137597)
These units are mounted from below, so that the four carrier supports, inserted through the four roof openings, are already correctly positioned.
In the following two pictures, the parts are loosely inserted for testing and still need to be soldered.
Hilfsspanten_Aufbauträger_08 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Hilfsspanten_Aufbautra_ger_08.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137598)
Hilfsspanten_Aufbauträger_09 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Hilfsspanten_Aufbautra_ger_09.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137599)
Impressive!
Nice that you have once again found time to devote yourself to your project - in your usual perfect manner, of course. I always admire your CAD work.
Bernhard
It's good to see you back at work and turning out consistently impressive components. -- Russ
Each update to the project is a shot of inspiration.
Pure perfection.
Hi Frithjof.
It is a pleasure to see your skills in action,I miss them.
cheers Kim
Many thanks for the approving words.
In the meantime, I continued with the auxiliary frames for the superstructure support.
Hilfsspanten_Aufbauträger_10 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Hilfsspanten_Aufbautra_ger_10.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137601)
Hilfsspanten_Aufbauträger_11 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Hilfsspanten_Aufbautra_ger_101.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137707)
For the cross members, 0.4mm thick, 6.0mm x 12.0mm nickel silver sheets (on the edge grooved to half the material thickness with a 92° V-milling cutter) were bent to 90°.
Dachträger_Eck-Knotenblech_01 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Dachtra_ger_Eck_Knotenblech_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137610)
Dachträger_Eck-Knotenblech_02 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Dachtra_ger_Eck_Knotenblech_02.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137611)
The two 480 mm long outer U-profiles (8.0 mm x 4.0 mm) were also grooved at the lower end...
Münzelkran Ausleger 5° biegen_02 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Mu_nzelkran_Ausleger_5_biegen_02.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137699)
..and bent by 5° on the vice - aligned vertically at the groove edge.
Münzelkran Ausleger 5° biegen_01 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Mu_nzelkran_Ausleger_5_biegen_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137698)
First, the two long U-profiles are fitted with the side plates and the soldered wire pins are rounded off with the finishing cutters to form "rivet heads".
Ausleger_Spitze_01 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Ausleger_Spitze_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137704)
A Pertinax gauge was provided with corresponding cut-outs.
Ausleger_Spitze_02 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Ausleger_Spitze_02.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137705)
At the same time, the 0.4mm thick nickel silver gusset plates are inserted into corresponding recesses in another Pertinax jig. Short 1.0mm wire pins are inserted into 3.0mm deep holes and the pre-drilled 2.5mm x 2.5mm L-profiles are mounted. It takes much longer than I thought ;)
Ausleger_Montagehilfe_Innenstreben_01 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Ausleger_Montagehilfe_Innenstreben_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137701)
Ausleger_Montagehilfe_Innenstreben_02 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Ausleger_Montagehilfe_Innenstreben_02.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137702)
Ausleger_Montagehilfe_Innenstreben_03 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Ausleger_Montagehilfe_Innenstreben_03.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137703)
Extremely satisfactory. -- Russ
@Russ
Thank you very much!
In the meantime, I soldered the inner struts to the gusset plates and the rivet wires in the assembly template.
The 1.0 mm wire pins were then shortened to around 2.0 mm using wade-free pliers.
The heads were rounded in two steps. As the shortened wire ends were mostly cut off at an angle (I couldn't get the pliers into most corners parallel to the cut), a finishing cutter with an inner diameter of 1.2mm was initially used to make it easier to center the tip. Then all the heads were brought to the correct height with the 1.0mm finishing cutter. With an angled wire end, I used to have the problem that the finishing cutter with the correct diameter broke off at one of the tips and I had to use another cutter.
Ausleger_Montagehilfe_Innenstreben_04 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Ausleger_Montagehilfe_Innenstreben_04.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137711)
Although I had drilled 1.1mm holes in the Pertinax plate for the 1.0mm wire ends, I had to use several 0.2mm thin strips of sheet metal to lift out the soldered unit.
Ausleger_Montagehilfe_Innenstreben_05 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Ausleger_Montagehilfe_Innenstreben_05.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137712)
ere you can clearly see that even a resistance soldering device with about half the power setting can certainly steam the Pertinax. Despite a mask and the fume extractor, ventilation is required.
Ausleger_Montagehilfe_Innenstreben_06 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Ausleger_Montagehilfe_Innenstreben_06.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137713)
The lower U-shaped cross-section of the cantilever had to have an angle of 5° at both ends.
Ausleger_01 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Ausleger_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137718)
Ausleger_02 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Ausleger_0_2.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137719)
A 3D drawing was first created which, in addition to the U-profile (dark yellow), contained a guide groove with stop/left (cyan), two 1.2 mm chamfers for the guide pins (green) and two end chamfers (magenta). The U-profile to be shortened at both ends was created with oversize (red ends).en.
Ausleger U-Profil unten quer ablängen_01 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Ausleger_U_Profil_unten_quer_abla_ngen_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137714)
A DWG file was created from this...
Ausleger U-Profil unten quer ablängen_02 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Ausleger_U_Profil_unten_quer_abla_ngen_02.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137715)
...and sent a copy as a DXF file to the milling software. The individual milling parameters (milling cutter, drill - type of contour inside, outside, without - rotational speed - speed - plunge depth per pass - holding bars if necessary - ...) were set here. The result was then saved as a job file on the server.
Ausleger U-Profil unten quer ablängen_03 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Ausleger_U_Profil_unten_quer_abla_ngen_03.JPG) (https://www.buntbahn.de/fotos/showphoto.php?photo=137716)
I was lucky today. There was no fault message during this short milling run.
Ausleger U-Profil unten quer ablängen_04 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Ausleger_U_Profil_unten_quer_abla_ngen_04.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137717)
I was able to insert the parts into the assembly jig of the boom loosely... and everything fitted.
Ausleger_Montagebrett (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Ausleger_Montagebrett.gif) (https://www.buntbahn.de/fotos/showphoto.php?photo=137720)
Most impressive. I love to see construction of such high quality. -- Russ
Definitely very high quality work.
Clearly I need more tools. ;)
Such high precision and machining is far beyond me but I sure enjoy watching it, and occasionally even get some ideas from it.
Many thanks to Russ, Bill, Lawrence and Ray!
@ Lawrence
QuoteClearly I need more tools.
I don't really believe that. You show us true masterpieces that can't be typed.
There are many masters of their trade here in the forum who also conjure up the most amazing works of art at the kitchen table!
Today there is just a small update on the Münzel crane.
For the rear diagonal support struts, a left and a right gusset plate had to be milled from 0.3 mm nickel silver. Since such small parts tend to "hide" from time to time, the parts were made twice.
Ausleger hintere Stütze_01 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Ausleger_hintere_Stu_tze_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137749)
Ausleger hintere Stütze_02 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Ausleger_hintere_Stu_tze_02.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137750)
Ausleger hintere Stütze_03 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Ausleger_hintere_Stu_tze_03.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137752)
Here's a little movie about milling these rear support nodal plates from 0.3mm nickel silver: click (https://www.youtube.com/watch?v=Hq1FDGBVr9I)
(unfortunately only 480p after uploading)
Quote from: fspg2 on February 06, 2024, 07:20:59 AMHere's a little movie about milling these rear support nodal plates from 0.3mm nickel silver:
After watching that, I definitely need more tools!!
Lovely stuff.
That mill seems to work much like my laser. I'd never seen one operate before. Thanks! -- Russ
Your fantastic work always inspires me !
Bernhard
Why does it mill the outer edge twice?
Amazing, truly amazing work!
Many thanks for your words of praise!
@Ray
QuoteWhy does it mill the outer edge twice?
Simply put, to save my milling cutters.
I often use nickel silver (hard) in addition to brass MS58, e.g. as a 0.3mm plate it feels as strong as 0.5mm brass (hard - MS58).
It is somewhat more difficult to mill than MS58. For this reason, I only scratch the surface to a shallow depth in the first milling pass (for cutters up to 1.2 mm only 0.15 mm deep - for larger diameters and thicker plates also 0.2 mm).
Then I use a sandpaper file - with 1000 grit sandpaper stuck to it - to break up the edges, some of which are usually only slightly flared, before I then gradually select a maximum of 1/3 to 1/2 of the milling diameter as a further depth infeed for thicker material.
I mill nickel silver up to 0.4 mm completely through with cutters from 0.8 mm after scratching in the second pass. I allow the milling cutter to plunge at least 0.2 mm into the carrier material.
I also approach this carefully... until a milling cutter breaks off.
I glue my plates to be milled - whether brass, nickel silver, Vivak, Pertinax - onto 12mm to 20mm thick MDF with GUDY® 870 (https://www.neschen.de/en/product/gudy-870/).
I generally do not use cutting data calculators, as the speeds are usually given for larger machines with wet cooling.
Sorotec (https://www.sorotec.de/shop/?language=en), for example, has an app on Google play and Apple (https://app.sorotec.de/) as well as a PDF (https://www.sorotec.de/webshop/Datenblaetter/fraeser/schnittwerte.pdf) with tips for download.
The values given there can serve as a guide - I usually made my first attempts with half of these values.
I mill dry, only with aluminum I use spirit as cooling, which I apply with a brush from time to time on the section to be milled (ventilation and no open fire).
If the speed of your spindle cannot reach the specified values, try significantly reduced values in percentage terms.
The Münzel crane has been fitted with a ladder for the boom. After the milling machine stopped working three times in quick succession within about 10 minutes in the middle of its milling job, I was able to solder the ladder together at the end of the day.
Ausleger mit Leiter 03 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Ausleger_03.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137754)
Ausleger mit Leiter 04 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Ausleger_04.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137755)
Ausleger mit Leiter 05 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Ausleger_05.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137756)
it is difficult to find ways to express how impressive your work is and so is your explanation of how you prepare and mill the parts.
Frithjof, your explanations of the cutting values are absolutely the same as my experience. You should never work with the values specified by the tool manufacturer. These are optimized for industrial use.
Bernhard
Another parallel with the laser: Sometimes it must make two passes to cut thick or very hard materials. Now I better understand how a mill works. And the crane boom (or whatever it is) looks terrific! -- Russ
It's not really a model. 'Just' the real thing made smaller!
As the saying goes.
A jaw-dropper.
You are certainly keeping up your incredible standard Frithjof.
All the very best
When I recently riveted the jib of the crane arm to the lower U-profile and used the inserted Pertinax strip to limit the depth, I took the following pictures:
Ausleger_Nieten_einsetzen_01 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Ausleger_Nieten_einsetzen_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137798)
Ausleger_Nieten_einsetzen_02 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Ausleger_Nieten_einsetzen_02.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137800)
After soldering, I saw a big mistake... I had probably worked "just quickly" without looking closely! Grrrrrrrrrrrrrr... :o
Previously, I had soldered the inner L-profiles (2.5mm x 2.5mm) and the 0.3mm nickel-silver gusset plates with 1.0mm wire pins rounded on one side.
However, the L-profiles were mounted facing downwards in the original and not upside down as in my case. :(
Because I count rivets, I could not leave the boom in this condition.
The attempt to solder out the entire inner unit without any losses failed miserably. Neither with the resistance solderer, the soldering iron nor the flame did I reach my goal. The L-profiles detached from the gusset plates first, so that I got ended up the outer boom frame...
Ausleger zweite Runde (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Ausleger_zweite_Runde.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137802)
...and had all kinds of scrap parts.
ab in den Schrott (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/ab_in_den_Schrott.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137801)
Now new parts have to be found "just in a hurry" ;)
I feel your pain
Misery loves company so it's refreshing to realize that even you sometimes make a mistake. I make them much more often! -- Russ
Ouch.
Annoying, but at least you've found a good use for the scrap.
Bernhard
In the meantime, all the unsuccessful parts of the boom have been made and fitted again - but this time the right way round :!:
Rivet pins soldered_01 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Nietstifte_einlo_ten_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137888)
Small sections of 0.5mm fluxless solder wire were soldered with the resistor soldering tool. The black "mud" always occurs when using the S39 flux. It disappears again when it is subsequently washed off with hand washing paste and a toothbrush.
In February 2012 (https://www.buntbahn.de/viewtopic.php?t=6691&start=640), I had already milled out and pre-assembled the first parts for the crane base. After that, they disappeared into the "harbor crane project box".
Yesterday we continued. Once again, a Pertinax jig was milled for precise alignment, into which the individual parts are inserted in exact alignment for soldering.
Drehkranz_Sockel_01 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Drehkranz_Sockel_01.gif)[/ ;) url]
Drehkranz_Sockel_02 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Drehkranz_Sockel_02.gif) (https://www.buntbahn.de/fotos/showphoto.php?photo=137898)
Drehkranz_Sockel_03 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Drehkranz_Sockel_03.jpg)[/url]
In the picture above, all the corner angles between the cross frames and the outer side stringers are still missing... but will come soon. ;)
Satisfactory. -- Russ
It's like good wine, storage makes the pieces better.
Bernhard
@ Bernhard
I probably still have a few wine barrels stored here. :)
Before I can continue with the assembly of the ladder and the upper auxiliary struts, a 2.5mm hole has to be drilled through the two 4.0mm x 8.0mm U-profiles of the conically converging cantilever.
To guide the drill at the correct angle, I milled a small jig from Pertinax.
Bohrschablone_Seilrolle_1 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Bohrschablone_Seilrolle_1.gif) (https://www.buntbahn.de/fotos/showphoto.php?photo=137939)
It consists of two 3.0 mm thick half shells and a base that ensures vertical alignment on the drilling table.
Bohrschablone_Seilrolle_2 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Bohrschablone_Seilrolle_2.gif) (https://www.buntbahn.de/fotos/showphoto.php?photo=137940)
When milling, the 2.0mm holes for the dowel pins were drilled first, followed by a centred groove with a depth of 1.25mm on each of the two half shells using a 2.5mm ball nose cutter. Finally, the outer contour was milled with a 1.5mm single tooth cutter in three passes, each 1.2mm deep (speed 22000 rpm - feed 1000mm/min).
Bohrschablone_Seilrolle_3 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Bohrschablone_Seilrolle_3.gif) (https://www.buntbahn.de/fotos/showphoto.php?photo=137941)
The two halves are aligned with 2.0 mm rivets and glued together with superglue.
Bohrschablone_Seilrolle_4 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Bohrschablone_Seilrolle_4.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137942)
Bohrschablone_Seilrolle_5 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Bohrschablone_Seilrolle_5.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137943)
I love watching your models come together. -- Russ
You always have a simple way to create a fixture that ensures parts will be correctly aligned and holes will be correct. It is satisfying to see.
Hello Russ, hello Bill,
Thank you very much!
The sheave at the tip of the boom was the next part to work on.
Seilscheibe_01 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Seilscheibe_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137949)
A drawing for two half-shells was reknitted for this...
Seilscheibe_02 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Seilscheibe_02.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137950)
...and milled out of 1.5mm brass...
Seilscheibe_03 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Seilscheibe_03.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137951)
... and both parts soldered together.
Seilscheibe_04 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Seilscheibe_04.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137952)
An aluminum remnant was prepared on the lathe so that the pulley could be positioned precisely on it.
Seilscheibe_05 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Seilscheibe_05.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137953)
An 1.5mm ball end mill produced the outer recess for the rope. The edges were slightly rounded with small files and fine sandpaper.
Seilscheibe_06 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Seilscheibe_06.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137954)
The result, however, was scrap metal... What had happened?
Seilscheibe_07 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Seilscheibe_07.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137955)
I had not pre-tinned the two half-shells, but only coated them with a (probably too diluted) soldering paste and pressed the parts onto the soldering pad with an old pair of pliers when soldering with the flame.
After washing off the "mud", the result looked okay.
There was a small "crack" during the last pass with the ball cutter... and I saw the gap. :evil:
So I made a second attempt.
Why I didn't just take a 3.0mm brass sheet and machine it on both sides... I don't know ?
Seilscheibe_08 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Seilscheibe_08.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137956)
A 2.5mm deep pocket was milled in MDF for a 3.0mm scrap piece of MS58. This gave me a plane support surface for the subsequent two-sided machining of the 68mm x 40mm piece.
Once the height had been measured, 2.0mm holes were drilled 6.0mm deep in order to achieve a precise fit for both sides using 2.0mm rivets (or pins).
In addition, 3.0mm holes were drilled to fix the brass plate with small screws for machining.
Seilscheibe_09 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Seilscheibe_09.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137957)
(Front - sandblasted on the left - natural on the right)
After the front side was finished, the panel was turned vertically (right/left) and positioned precisely using the locating pins and screwed down again.
The back was given the same recesses (0.5mm + 0.75mm).
Finally, the outer contour was machined with the 2.0mm two-tooth cutter in three depths (successively 1.2mm - 2.4mm and 3.6mm .... Speed: 22000 rpm - feed rate: 300 mm/min).
Three small holding corners prevented slipping during milling.
Seilscheibe_10 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Seilscheibe_10.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137958)
(backside)
The retaining bars were cut through with the fretsaw.
The same processing steps were then carried out as for the first attempt (turning to the final diameter and milling the recess with the 1.5 mm ball end mill.
Seilscheibe mit Kugelfräser (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Seilscheibe_mit_Kugelfra_ser.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137976)
As the ball cutter was firmly clamped in the top slide (and was not turned by a small drilling machine), the main work was carried out by only one (here left) cutting edge.
For a symmetrical milling result, the pulley was machined from both the right and the left.
Seilscheibe_11 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Seilscheibe_11.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137973)
The left-hand sheave is threatened with the same treatment.
The first sheave has already been burnished and placed on the crane tip as a test.
Seilscheibe_12 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Seilscheibe_12.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137974)
Finally, a picture of the photo composition of the upper picture on the windowsill with sunlight.
Seilscheibe_13 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Seilscheibe_13.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137975)
Always fascinating to see the way you do things.
Useful to now know the German for scrap metal too - a word I feel will be useful in my own modelling.
If at first you don't succeed, try again. The result? Perfection. -- Russ
Fascinating! And I really like the color of the finished sheave.
Hello everyone,
Next up is the substructure of the crane house.
Münzelkran Unterbau 04 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Mu_nzelkran_Unterbau_04.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137982)
Several 6.0mm x 4.0mm U-profiles were provided with corresponding holes and recesses at the ends of the profiles. Four 1.0mm brass plates and eight supports (made of 3.0mm MS58) for the four rollers were also milled.
Münzelkran Unterbau 03 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Mu_nzelkran_Unterbau_03.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137981)
Münzelkran Unterbau 02 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Mu_nzelkran_Unterbau_02.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137980)
Münzelkran Unterbau 05 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Mu_nzelkran_Unterbau_05.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137983)
Münzelkran Unterbau 06 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Mu_nzelkran_Unterbau_06.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137999)
Here, the individual parts have already been loosely inserted into the crane housing from below.
Münzelkran Unterbau 07 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Mu_nzelkran_Unterbau_07.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=138000)
Pertinax gauges were milled as an assembly aid for precise alignment of the individual profiles.
Münzelkran Unterbau 09 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Mu_nzelkran_Unterbau_09.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=138002)
The next step is to drill holes in the eight supports and solder everything together.
Münzelkran Unterbau 10 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Mu_nzelkran_Unterbau_10.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=138003)
Ho-hum, another inspirational and impressive stage nears completion .... -- Russ
Hello Russ,
there are still a few small parts to be made before the crane is finished.
The many small parts always require much more time than you might think.
The eight supports for the rollers (12.0mm x 8.35mm x 3.0mm) were inserted into a pocket milled in Pertinax and fixed tightly with two small pieces of wood. Two 1.0mm holes were then drilled and two corners milled at an angle.
Münzelkran Unterbau_11 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/Mu_nzelkran_Unterbau_11.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=138004)
Münzelkran Unterbau_12 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Mu_nzelkran_Unterbau_12.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=138006)
Münzelkran Unterbau_13 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Mu_nzelkran_Unterbau_13.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=138008)
The substructure is not soldered directly onto the 2.0 mm thick MS58 base plate of the crane housing. Neither the resistance soldering iron nor a 100 watt soldering iron would have produced a clean result. I would have generated enough heat with the flame, but would very likely have removed the already soldered and riveted metal strips.
A 0.5mm MS58 sheet now serves as an auxiliary floor. Grooves 0.25mm deep were milled for the U-profiles and everything was fixed and soldered with the help of the previously made Pertinax gauges and metal clamps.
Münzelkran Unterbau 14 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Mu_nzelkran_Unterbau_14.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=138028)
This also makes it a little easier to fit the small M1.0mm model screws, as the profiles are now freely accessible from all sides.
The four 1.0mm support plates for the wheel supports are first fitted with four 1.0mm screws with washers and nuts at the corners. A small wooden strip clamps the screw inserted from below with the tweezers. A small open-end wrench and a socket wrench then screw everything together.
Münzelkran Unterbau 15 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Mu_nzelkran_Unterbau_15.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=138029)
Without a headband magnifier, I would be at a loss here, especially as there are a few more screws waiting.
Münzelkran Unterbau 16 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Mu_nzelkran_Unterbau_16.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=138030)
Quote from: fspg2 on April 13, 2024, 02:19:01 PMThe many small parts always require much more time than you might think.
That always seems to be the case no matter what material we use!
Perfect work again, Frithjof. I find the turning of the grooves in the pulleys particularly interesting. I need a lot of similar pulleys for my project.
Bernhard
Merci
@BernhardThere are many pulleys available from various suppliers, for example: click (https://www.google.com/search?client=firefox-b-d&sca_esv=1a57d827cf09faae&sca_upv=1&q=modellbau+seilscheibe&uds=AMwkrPv3j3EkEIkbFS2D5_BLUQ3_neMsamu-aL5itcq2_Xuuho0D3TfH5wanewCWkmk2Gj1sNkQt7686fr2T9C0evAjWE8JfgtvVSKWzS3trvdBoIIYLBoufiynFHzM-zu8O96JekysujKnaZFeU0CdoEzZ7nYE0oYpZ7xIiZxh6jy5F8Krt4g5UhEMYzXulD4x7_vFFuLRkfk9BfLL0OjlN_gddKH8zZfZHaHG_ZGayz-2NYRVmvGneujBmihq4mRHL7D800asdE3oBHLMxZU01aX7yAOzsxQ&udm=2&prmd=ivnbz&sa=X&ved=2ahUKEwiLnJPiwceFAxWuhP0HHQi1Di8QtKgLegQIDBAB&biw=1483&bih=1262&dpr=1)
or click (https://knupfer.info/shop/index.php/details-beschlage-1/seilrollen.html)
After I wrote the other day...
QuoteAs the ball cutter was firmly clamped in the top slide (and was not turned by a small drilling machine), the main work was carried out by only one (here left) cutting edge.
..I had already machined the second rope pulley a few days ago with my old Proxon milling machine.
I had clamped it crosswise in the Multifix quick-change system in a special holder with 43mm neck (https://pewetools.de/produkt/spezialhalter-asj43-l-passend-zu-grundkoerper-as/).
Seilscheibe_14 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Seilscheibe_14.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=137978)
The result looked better right from the start.
The last few days went by very quickly - but little was done. As already mentioned, the small parts require an enormous amount of time.
On the prototype, nuts with 20mm [size=85](21mm)[/size] threads have a height of 18.0mm [size=85](19.4mm)[/size].
Various suppliers offer brass model nuts with a high head and or flat head ...... However, both versions of the 1.0mm nut have the same height of 1.0mm.
After the first trial assembly, this height seemed too high to me. So I drilled fifteen 1.0mm holes in a 3.0mm MS58 remnant and inserted an M1.0mm bolt with a (too high) nut in each.
Two 0.8mm brass strips and 240 grit sandpaper were glued to the sides of a dressing board that had been built some time ago.
runter von der hohen Mutter 1 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/runter_von_der_hohen_Mutter_1.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=138038)
The surface grinding was carried out with even pressure until the remaining piece scraped along the two lateral guides.
runter von der hohen Mutter 2 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/runter_von_der_hohen_Mutter_2.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=138039)
ere again the comparison with 1.0mm and 0.8mm nuts:
runter von der hohen Mutter 3 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/runter_von_der_hohen_Mutter_3.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=138040)
runter von der hohen Mutter 4 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/runter_von_der_hohen_Mutter_4.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=138041)
Today I started on the four running wheels. These are guided on both sides by 2mm x 5mm x 2.5mm deep groove ball bearings. The diameter is 12.0mm with a tread width of 3.0mm. The total width with collar is 6.0mm.
Münzelkran Laufrad 01 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Mu_nzelkran_Laufrad_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=138042)
MS58 in the dimensions: 45.0mm x 40.0mm x 6.0mm, which was positioned in a milled pocket in the MDF material, serves as the base material.
Münzelkran Laufrad 02 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/Mu_nzelkran_Laufrad_02.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=138043)
Various 2.0mm rivet pins were once again used for precise alignment on both sides, while small screws prevented wobbling during milling.
In the following photo, most of the fastening screws have already been removed.
Münzelkran Laufrad 03 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/Mu_nzelkran_Laufrad_03.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=138044)
The milled outer diameter here is still 12.3 mm and will be brought to the final dimension of 12.0 mm on the lathe in the next step.
Time required with milling data creation and milling around 2.5 hours - costs significantly cheaper than 3D printing at shapeways (here around € 72.00 for delivery on May 14, 2024).
Satisfactory, of course. -- Russ
I continued with the machining of the four wheels.
After cutting through the retaining bars, I was able to continue machining the wheels on the lathe.
To do this, I turned the end of a 14.0mm brass round rod to 12.0mm, drilled a 1.6mm deep hole with a 5.0mm milling cutter and then milled it to a diameter of 6.0mm. This gave me a centric pocket for the 6.0mm collar of the wheels.
This was followed by a 1.8mm hole for a 2.0mm thread to secure the wheels.
Laufrad abdrehen 01 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Laufrad_abdrehen_01.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=138133)
This allowed me to bring the four wheels to the final dimension in three passes, one after the other. A dial gauge showed the exact depth.
Laufrad abdrehen 02 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Laufrad_abdrehen_02.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=138134)
The outer edges were slightly rounded with a small flat file.
Laufrad abdrehen 03 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Laufrad_abdrehen_03.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=138135)
After the second side of the wheel had also been rounded, the surface was treated with 1000 grit sandpaper and sanding fleece.
Laufrad abdrehen 04 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Laufrad_abdrehen_04.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=138136)
(a longer screw was used for this photo to show the assembly more clearly)
Then the wheels were changed.
Laufrad abdrehen 05 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Laufrad_abdrehen_05.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=138137)
Now the wheels just had to be sandblasted and burnished.
Laufrad abdrehen 06 (fspg2)
(https://www.buntbahn.de/fotos/data/8181/medium/Laufrad_abdrehen_06.jpg) (https://www.buntbahn.de/fotos/showphoto.php?photo=138138)
That looks so easy I'm sure anyone can do it with no practice! -- ssuR