Feldbahnmodule with ship

[Ray Dunakin]

Awesome!

[fspg2]

@Bill, @Russ, @Bernhard, @Stuart, @Barney
Gentlemen - thank you very much for your words of praise

Now it's time for a bit of hard work again.

The western and eastern side bridges are mounted on support beams, each consisting of 137 individual parts.

Träger-Montage 103 (fspg2)



Träger-Montage 102 (fspg2)



The two sets of four inner cross members are mounted and soldered using a small Pertinax jig.

Träger-Montage 100 (fspg2)



Träger-Montage 106 (fspg2)



The six 1.0 mm rivets on the sides fit into the corresponding holes from the long beams.

Träger-Montage 107 (fspg2)



Träger-Montage 108 (fspg2)



As a test, the first loosely assembled support beam was inserted into the left portal beam - everything fits so far

Träger-Montage 109 (fspg2)



A number of wire pins in the upper area of the gantry beam still need to be wound into rivet heads.


Träger-Montage 110 (fspg2)

[finescalerr]

Wow. -- Russ

[Bernhard]

Step by step, the project is becoming more and more impressive.

Bernhard

[fspg2]

The next steps will follow, so there are a few small parts again today.

In some places, I won't be able to use the finishing cutter to round off the second side of the rivet head when it is installed.
In contrast to the wire pins normally used as rivet replacements, I have fitted some angles and U-profiles with 1.0mm rivets (head diameter 1.3mm - shank 1.0mm). I accepted the different diameters of the head and the opposite side. On the one hand, the corners are hardly visible later and on the other hand, the slightly larger head diameter provides a little more security against falling out when soldering the neighboring parts when assembling the many individual pieces.

Small Pertinax gauges were again used for the vertical and parallel alignment.

Träger-Montage 112 (fspg2)



Four of these rivets were soldered into the 6.5mm x 6.5mm nickel silver sheet. My existing rivets were a little too long at 6.0mm, so I had to shorten them first.

I used a 2.0mm thick aluminum angle from the leftover box. The excessively long rivets were inserted into eight 1.0mm holes drilled and shortened on the underside with a side cutter. I then sanded the whole unit smooth on a 400 grit sandpaper, holding the small rivet heads in place with a piece of wood (in the following picture, the piece of wood is pushed to one side to show the rivet heads).

Träger-Montage 117 (fspg2)



I then wound the small nickel silver plate with the four shortened rivets...

Twincut Gebr. Ott (fspg2)

(Excerpt from the catalog: https://www.gebr-ott-gmbh.com/werkzeuge-maschinen/)


...a 0.5mm brass sheet with corresponding holes served as a spacer when working with the finishing burr.

Träger-Montage 111 (fspg2)



The first of two parts is ready to fit.

Träger-Montage 113 (fspg2)



The two support beams are connected to the two lateral portal beam tower sides with the aid of eight straight and eight beveled small L-profiles.

Träger-Montage 118 (fspg2)



These were also fitted with the 1.0 mm rivets and soldered in two corresponding Pertinax gauges.

Träger-Montage 114 (fspg2)


Träger-Montage 115 (fspg2)



The rivets of the L-profile still need to be shortened and rounded off.

Träger-Montage 116 (fspg2)

[finescalerr]

Compared to this, my models are crude toys. -- Russ

[Lawrence@NZFinescale]

We should form a support group...

[Bernhard]

Perfect details. Are the long parts also sandblasted? If so, how do you do that?

Bernhard

[Ray Dunakin]

I think you could probably teach the builders of the real bridge a thing or two!

[fspg2]

Gentlemen,
please do not exaggerate!

@Bernhard

Are the long parts also sandblasted? If so, how do you do that?

Yes, I can process parts up to 50 cm long in my two sandblasting booths.
However, as many parts will be significantly larger when assembled, I usually sandblast many individual parts shortly before I take photos.


Träger-Montage 124 (fspg2)



True to the saying (Advertising for ZDF - Second German Television) "you see better with the second one", I discovered another error on a second look.

I had already provided small rivets for the connection of the two middle U-profiles with the longitudinal beams in this picture:
 
Träger-Montage 112 (fspg2)


A second look revealed something else - the original had hexagon head screws!

Träger-Montage 121 (fspg2)



Träger-Montage 126 (fspg2)



The existing M0.8mm hexagon head screws had to be shortened from 6.0mm to approx. 2.8mm in length for installation.

The required screws were screwed together with three 0.25mm thick washers into a 2.0mm thick brass sheet with existing M0.8mm threaded holes - the protruding ends were cut off and sanded smooth on a sandpaper board. The now smooth threaded ends will certainly be "sharpened" 

Träger-Montage 130 (fspg2)




Even though assembling and soldering the crossbeam blocks was quite time-consuming and laborious, I was not able to save any time compared to 3D printing with subsequent centrifugal casting...

Träger-Montage 119 (fspg2)




Träger-Montage 125 (fspg2)


...but it was then around €200.00 + postage cheaper.

You certainly can't get rich building models, but the many small partial successes do make you a little happy 


Träger-Montage 122 (fspg2)



All the 1.0mm rivets already soldered into the sides of the cross-member blocks and the L-profiles from picture beam assembly 115 were shortened to 2.0mm and then wound with the finishing cutter. A 2.0mm brass sheet with 1.1mm holes helped as a spacer when pinching off (see picture 119 above).


Träger-Montage 123 (fspg2)



Once prepared, I soldered the L-profiles to the longitudinal beams. Small Pertinax blocks with corresponding holes ensured that the side rivets remained in position.


Träger-Montage 128 (fspg2)




Träger-Montage 127 (fspg2)



I positioned the parts in a Pertinax jig for precise alignment.

Träger-Montage 129 (fspg2)




Instead of soldering the cross member blocks to the long members, I glued the unit together with Loctite 648.
The indentation in the Pertinax gauge was protected with Sellotape to make it easier to wipe off any excess adhesive.  As all parts must be precisely positioned within a maximum of three minutes when gluing with Loctite 648, one side was attached first and fixed in the jig with spacer blocks and small clamps. The second side was then done in the same way.

Träger-Montage 131 (fspg2)


The four threaded rods for the leveling blocks must now be fitted.

In addition, the headband magnifier, a small pair of pointed tweezers and certainly some patience will now help to fit the middle float support with the shortened M0.8mm bolts, the washers and the nuts.

Träger-Montage 132 (fspg2)

[finescalerr]

That turned out acceptably. -- Russ

[Stuart]

Awesome!

Stuart

[fspg2]

The four side bridges also need handrails.

Träger-Montage 141 (fspg2)



Träger_Montage_142 (fspg2)


An assembly jig is again used to assemble the individual railing sections at right angles.

Träger-Montage 133 (fspg2)


The small 0.8 mm rivets aligned all parts precisely in the corresponding 0.9 mm holes in the Pertinax template when soldering the pre-tinned L-profiles.

Träger-Montage 140 (fspg2)




The lower 2.5 mm x 2.5 mm L-profile shown in light green in Figure (Träger-Montage 133 ) was given 3.0 mm wide cut-outs in another Pertinax template.

Träger-Montage 134 (fspg2)




In the original bridge, slotted holes were provided between the railings of the secondary bridges and the first vertical supports on the bridgeheads to compensate for temperature-related length differences.

Brueckenkopf_12 (fspg2)


Although they are shown in the model, they have no function - the temperature expansions will certainly be limited here  

Small brackets (2.0mm x 0.4mm - side length 6.5mm) will connect the side bridge to the fixed railing on the bridge heads (as in the prototype). The small brackets are only soldered to the vertical supports.   
In my model replica, the handrails (drawn in red and green) are placed on the two protruding rivet heads of the small brackets and thus serve to align the handrails.
This will make it easy to remove the side bridges.


Träger-Montage 135 (fspg2)



Träger-Montage 136 (fspg2)


Träger-Montage 137 (fspg2)



Träger-Montage 139 (fspg2)




The end pieces of the handrails are bent. In the model, I would have had to bend the 2.5mm x 2.5mm L-profile with an outer radius of 12.0mm.
An attempt to bend an annealed offcut ended up in the scrap.

I then obtained two left and two right parts from a 3.0mm thick MS58 flat profile.

Träger-Montage 138 (fspg2)




As I currently have to wait for the next 2.5mm x 2.5mmL profiles to be delivered, the 8.0mm x 5.8mm wooden beams that were sawn from a 20mm x 10mm beechwood strip back in 2014 were...

westl_Nebenbruecke_Montage_014 (fspg2)


 
westl_Nebenbruecke_Montage_012 (fspg2)


westl_Nebenbruecke_Montage_013 (fspg2)



westl_Nebenbruecke_Montage_015 (fspg2)


...with a rotating wire brush on the pillar drill. This left me with some signs of ageing in the rather hard beech planks.

After an initial bluing with gray-brown wood stain, the parts have already been loaded for testing and are waiting to be transported to the bridge....

Träger-Montage 143 (fspg2)

[finescalerr]

Good golly Miss Molly ... and this is just the beginning! -- Russ

[Stuart]

Frithjof -

Just a question.  I am unfamiliar with the Pertinax product you commonly use for holding brass pieces in position for either milling or soldering operations.  Is this material unaffected by the heat of a soldering iron?  I use MDF to hold things in position when I do my soldering but it burns and is only good for a single usage.

Stuart