Feldbahnmodule with ship

[finescalerr]

So the wall is at the very front. Now I understand the reason you want absolute perfection. -- Russ

[Hauk]

,,Das Höchste, wozu der Mensch gelangen kann, ist das Erstaunen."
– Johann Wolfgang von Goethe

(I think I finally ran out of superlatives...)

[Bernhard]

I am really impressed with the result. Do you already know how you make the cover plates?

Bernhard

[fspg2]

The sheet pile wall will not mark the lateral end of the segments – after all, the main protagonist of the thread title still needs to find its place. It will be docked together with a "water" basin on the long side of the three harbor segments, whereby it should remain easily removable in order to also access the parts further inside (bunker operation, road paving, etc.).


Modul-Übersicht_1 (fspg2)




I continued working on the sheet pile wall cover a little.

@Bernhard

Do you already know how you make the cover plates?

Yes, I do

Spundwand_Abdeckung_drücken_01 (fspg2)



A gauge will help to shape the pieces, which are around 10.0 cm long.

Spundwand_Abdeckung_drücken_03 (fspg2)



Spundwand_Abdeckung_drücken_06 (fspg2)



The 3.4 mm thick round rods and the HPL parts for the gauge were glued together with superglue.

Spundwand_Abdeckung_drücken_04 (fspg2)


Spundwand_Abdeckung_drücken_05 (fspg2)



This was followed by the first bending tests with various copper and brass sheets (MS58 and MS63) that had been annealed beforehand. A vice pressed the plates together, then the vertical outer side was bent.

Spundwand_Abdeckung_drücken_07 (fspg2)



The 0.1 mm thick copper foil was the easiest to shape. Unlike the double-angled, vertical sheet piles, I found these parts too unstable.


Among the other candidates with thicknesses of 0.15 mm and 0.2 mm, there was a clear winner:

Spundwand_Abdeckung_drücken_08 (fspg2)

[Bernhard]

Well done!

Bernhard

[fspg2]

Some jobs are simply no fun when they are repetitive!

So, I sandblasted the first fifty Z-shaped, vertical sheet pile elements before burnishing them.
However, during assembly, I noticed that the 8.0 mm long legs were slightly wider and I couldn't fit the 0.5 mm groove with the T-profiles without reworking them.
This problem did not occur during the test fit before sandblasting. So the sandblasting treatment had made the 0.1 mm thin sheets correspondingly wider.

The next steps were divided into two parts:

a)
The already "finished" sheets were recut on the sheet metal cutting machine, similar to the following picture. The vertical wooden strip ensured the correct distance, while I pressed the sheet against the cutting edge with the horizontal strip. When the cut was correct, the vertical strip covered the entire length of the sheet!


Spundwand-Lauenburg_27 (fspg2)



b)
The new copper sheet, which had arrived in the meantime, was again cut into 116.0 mm x 40.0 mm pieces on a paper cutting machine.
Since I didn't feel like repeating the same procedure as before, I tried folding the sheet at right angles without annealing it first.

A machine vice should help.

Spundwand-Lauenburg_24 (fspg2)



Clamped between two Pertinax strips approx. 14.0 mm high, the first side was bent at a right angle with the aid of another Pertinax strip and smoothed again with moderate pressure.
 
Spundwand-Lauenburg_25 (fspg2)



For the second fold, I pushed the sheet metal, with the first leg facing down, into a slotted 8.0 mm thick Pertinax plate and filled the gap with a wooden strip cut to size. This ensured that the counter angle was also at a right angle.

Spundwand-Lauenburg_26 (fspg2)



I will not be sandblasting and blueing the 130 sheet metal parts obtained in this way. They will be glued to the base boards, painted, and later aged accordingly. The burnishing should prevent the metal from showing through if the paint chips off.
 
In the following picture, you can see only two of the five sheet pile parts prepared in this way. Most of the sheet metal parts are only loosely placed here so far. The sheet metal angles only needed to be 24.0 mm wide, so around two hundred and sixty cut copper foil strips are currently waiting for a new task. I deliberately left the raw material wider in order to have a better contact surface when cutting off the legs.

Spundwand-Lauenburg_28 (fspg2)

[Ray Dunakin]

Fascinating work!

[fspg2]

When I came up with the idea in 2007 to recreate the old Lauenburg lift bridge (inaugurated in 1900 and replaced by a new structure in the 1950s) on a scale of 1:22.5, the remains had unfortunately been lost to history due to the construction of the new lock (2006).

During my visit there, I was only able to take a few pictures at the spot where my father had his picture taken in front of the new bridge in 1962.


Hubbrücke_Ziegeleibahn_Lauenburg_1 (fspg2)



In 2007, it looked like this:

Delvenau_Wehr_21 (fspg2)



Delvenau_Wehr_15 (fspg2)



Delvenau_Wehr_16 (fspg2)



Delvenau_Wehr_17 (fspg2)



Delvenau_Wehr_18 (fspg2)

Photo by J. Dannenberg


Delvenau_Wehr_19 (fspg2)

Photo by J. Dannenberg
On the right is the railway line to Lübeck.


Delvenau_Wehr_20 (fspg2)



At the time, I didn't take any more pictures of this "bridge" because I was more interested in the possible remains of the old lift bridge. In the prototype, there were no rails on this small bridge.


However, that has now changed. The new harbor area is to be connected to the lift bridge segments so that the light railway can run on both areas.


Grundriss_Module_005 (fspg2)



Grundriss_Module_008 (fspg2)



What was under the bridge...

An excerpt from an overview drawing of the lift bridge showed only the left side....

Delvenau_Wehr_05 (fspg2)




It was the old weir at Delvenau, which was demolished as part of the new lock construction and gave way to a new building.


I received the following picture from a former bridge keeper:

Delvenau-Wehr_01 (fspg2)

Hellmich Collection

So first, the dimensions from the drawing were converted to a scale of 1:22.5 and the photo was scaled accordingly in Photoshop.

Then, a full-size model was created from Styrodur to visually check the proportions with my available space of 1.2 meters in width.

Delvenau-Wehr_04 (fspg2)



Upon closer inspection of my pictures (19 + 20), I noticed that the right side of the Delvenau weir had a sloping platform. So I adjusted the CAD file accordingly.

Then I started drawing the first wall sections in CAD in order to create the corresponding milling files.

First, the placeholders—created according to the dimensions on the first drawing:

Delvenau_Wehr_02 (fspg2)



Delvenau_Wehr_03 (fspg2)



Delvenau_Wehr_03b (fspg2)



The next adjustment arose when comparing my brick dimensions to the respective dimensions in the drawing. The widths of the individual pillars and the areas between them were adjusted to the nearest millimeter.

Delvenau_Wehr_06 (fspg2)


In the above illustration, the height of the middle section was not yet correct.


The joints for the individual bricks were first milled into 5.0 mm HDF boards with a 0.5 mm double-edged cutter at a depth of 0.3 mm. Before starting the second pass at a depth of 0.5 mm, all protruding wood fibers were sanded smooth with 400-grit sandpaper.
 
Delvenau_Wehr_07 (fspg2)



A 1.5 mm cutter milling cutter cut around the serrated outer edges—I only had to cut through four small retaining bars with a cutter at the end.

Delvenau_Wehr_08 (fspg2)



Unlike the original, the bridge will be slightly wider so that the light railway can run smoothly over it.

Delvenau_Wehr_09 (fspg2)



Delvenau_Wehr_10 (fspg2)



Delvenau_Wehr_11 (fspg2)



After gluing the individual elements together at right angles, I carefully cut the joints with a fine 0.5 mm saw blade.

Delvenau_Wehr_12 (fspg2)



Delvenau_Wehr_14 (fspg2)



The CAD archway compared with the first glued-together part.

Delvenau_Wehr_13 (fspg2)

[finescalerr]

Inspirational. -- Russ

[Bernhard]

Interesting research and once again perfect work.
Is there still commercial shipping traffic on the canal today?

Bernhard

[fspg2]

@Bernhard

Is there still commercial shipping traffic on the canal today?

Commercial shipping continues to operate on the Elbe-Lübeck Canal (formerly the Elbe-Trave Canal). In order to enable larger ships to travel from Lauenburg to Lübeck, the old Lauenburg lock was replaced by a larger new structure in 2006.
Before 1900, travel from Lauenburg to Lübeck was much slower (in 1398, it took up to five weeks to transport salt from Lüneburg to Lübeck – a distance of approx. 71 km as the crow flies; by 1840, it took only nine days in some cases):
Wiki-German: https://de.wikipedia.org/wiki/Stecknitzkanal
Wiki-English: https://en.wikipedia.org/wiki/Stecknitz_Canal


Unfortunately, I don't have any precisely dimensioned documents from the old Delvenau weir, so I have only been able to calculate the proportions from the pictures that were kindly provided to me.

The basis for this was the drawing Delvenau_Wehr_05.
Here I was able to read off the initial dimensions and gradients of the embankments.
The pictures were then scaled in width in Photoshop and the heights were approximately determined.

The side facing the lock entrance is quite clearly visible in a few photos.

I think that, on the whole, it looks quite consistent so far.


Delvenau_Wehr_22 (fspg2)



Delvenau_Wehr_26 (fspg2)




Unfortunately, I am missing some important information from the back.

Delvenau_Wehr_25 (fspg2)




The drawing shows a swing gate...?

Delvenau_Wehr_05-Klapptor? (fspg2)



However, I found no references to this type of barrier on the internet.


The two racks in the following picture...

Delvenau_Wehr_29 (fspg2)

Colored image from the Hellmich collection

...suggest a similar height-adjustable barrier, as shown in the following two examples: A - B   

Was the weir submerged in the Delvenau from above (which I assume from the length of the poles visible) and the water flow regulated by the depth of submersion, or was the weir always under water and the water more or less dammed up by the lift height?

Two different barriers side by side are shown here: C.

I hope to obtain more detailed information through my request to two archives that are said to have documents on the Delvenau weir. I am particularly interested in the exact functioning of the lock and the side guides.


I did a little more drawing today.

Delvenau_Wehr_30 (fspg2)



In an almost forgotten archive folder, I found another view that I received from the former lock keeper in 2007. I colored it a little and removed a few distracting elements
Here, I can now determine the positions of the individual railing supports a little more precisely than was possible in the pictures in the last post.

Delvenau_Wehr_27 (fspg2)

Animation of image from collection: Hellmich


The blue guide lines show the individual supports.

Delvenau_Wehr_28 (fspg2)

Colored image from the Hellmich Collection

[fspg2]

There were a few things to deal with in recent weeks:

Firstly, while milling three pieces of wall for the Delvenau weir, a very loud and ominous rattling noise suddenly could be heard coming from the milling room.
The height sensor on the milling spindle had been machined very poorly.

Höhentaster_01 (fspg2)


Fortunately, I was in the next room and was able to press the emergency stop button.
In the middle of the final pass while milling the outer contour of three wall panels with a 1-tooth milling cutter, it moved to the height sensor for no reason and got stuck in it.


Höhentaster-02 (fspg2)



The attempt to turn off the damaged surface failed completely. The milling cutter tip had apparently "welded" itself to the probe. The closer the turning tool got to the center, the more uneven the surface became—even after an attempt at grinding, it still looked unusable.

There were now two options:

a) Apply a disc to the damaged surface using a two-component adhesive and then finish it on the lathe (the built-in induction switch would have meant that bonding would not have been a problem),

or b) as was done, turn a new insert (left in the following image).

Höhentaster-03 (fspg2)



Secondly, I was in rehab with my new knee    


And finally, the chimney in my room bothered me (visible on the left in the following picture). Demolishing it would have been very costly, especially since I would have had to laboriously carry the demolished stones down the stairs in a bucket. In addition to the dust pollution, all the parts would have had to be disposed of as hazardous waste.

Between the standard gauge track next to the light railway ramp, I previously only had about 30 cm of space on the right-hand side to move around.

auf-die-Beine_1 (fspg2)



So I simply edited a segment (which was built in 2007) a little.


Segment-Anpassung_01 (fspg2)


Segment-Anpassung_02 (fspg2)


Segment-Anpassung_03 (fspg2)


Segment-Anpassung_04 (fspg2)


Segment-Anpassung_05 (fspg2)


This gives me 15 cm more space to move between the main line unloading track and the wall 


Here is a picture from the beginning—with little distance to the wall:

Feldbahn-Regelspur-Rampe_4 (fspg2)

[finescalerr]

You have turned chicken s**t into chicken salad. The results are improved machinery and a better layout. All that while recovering from knee surgery. Most satisfactory. -- Russ