Westrail WQL flat wagon 

Adding to my collection of S scale flat wagons is this model of a WQL flat wagon.

Westrail had a fleet of 62 WQN class wagons capable of carrying 2 x 20’ containers, the builder Goninan also proposed a lengthened version to fit 3 x 20’ boxes.

This S scale model is based on that proposal and the WQL designation is made up.

Construction is mostly from styrene strip and shapes with American Models Barber roller bearing bogies and MTH wheels. The couplers are Kadee HO #118’s with the glad hand removed and set at the correct height for S scale. Archer 3D decals were used for the weld lines and floor plate patterns.  The combined air reservoir and valve were 3D printed while the air hoses, brake wheel and gearbox came from DPH. The brake pipe unions are from Precision Scale Company.

The model was finished with Vallejo Chrome Yellow and decals printed at home, apart from the Westrail logos which were kindly printed for me by John Miller.

AQNY (formerly WQN) flats with the WQL

Westrail WQN with Sulfur Containers

Following on from my post back in March 2016 regarding the WQN flat wagon, have almost completed the first pair of sulfur containers, they are now just waiting on tarpaulins.

They were 3D printed from a CAD model I created based on photos of the prototype and knowing the.length and width of a standard 20’ container.

As shown in the last photo, free standing details were added using styrene strip and brass wire, before painting, decaling and weathering.

Westrail/ARG WQN/AQNY

Westrail introduced the 61 strong class WQN standard gauge flat wagons in 1998 and they were manufactured by United Goninan at Bassendean.
Each wagon carries 2 - 6.1m containers for use on the Sulphur train between Kwinana and Malcolm siding.

Loaded AQNY 32208Y at Kwinana.

Empty AQNY 32209A at Kwinana.

The model is depicted post 2012 after reclassification to class AQNY under ARG ownership. 

It is primally constructed of sheet styrene; 0.5mm for the side webs which then narrow down to form the centre sill over the bogies. The top & bottom flanges are 0.4mm & 0.25mm thick styrene respectively. Sections of sheet brass were added in the end platforms for strength and after the styrene angle braces were added the body felt much stronger.

American models roller bearing bogies, NWSL wheels and Kadee HO No. 118 couplers were used.  The air brake reservoir was 3D Printed by i.Materialise and the brake piping was added with 0.04 & 0.05 phosphor bronze wire from Tichy. The brake wheel & gearbox were from Detail Associates (now discontinued) and attached to a stand made from styrene angle.

A construction photo

primer coat - in the spray booth 

Prior to weathering

second attempt at weathering the deck - this time with rust coloured pigments

The model was airbrushed using Vallejo Desert Sand acrylic primer as a base and Polly Scale Railbox yellow, followed by a light coat of Polly Scale CN Yellow No. 12 on the sides, all thinned with their respective thinners. The CN Yellow is quite a good match for the Golden Yellow used by WAGR and later Westrail. As the Polly Scale line of paints have now been discontinued the CN Yellow was rationed and the final weathering will cover most of the Railbox Yellow colour.

I created by own artwork for the decals and had them printed through Westland Models, using  Microscale Decal Set to settle them down to the paint. Details were pickd out with Lifecolor paint, using black, white orange & rust dark shadow.

Finally a coat of Model Master clear flat was applied to seal & protect the decals and hide the decal 

film, weathering was done with a selection of Lifecolor acrylic brown paint and pigment powders.

Next project are the containers...

GS

3D-Printed Sn3½ Flexible Track

As an experiment, I recently tried 3D printing some sleepers for correct-scale Sn3½ track, using a similar principle to commercial flexible track.  I used the Makerbot Replicator printer which we currently have at home on loan, using a chocolate brown filament so the basic colour is about right.

It seems to work fairly well, although it would be a bit time-consuming printing sleepers for a basement-size layout.  For a modest layout, though, it appears to be a feasible proposition.  

The photos show the track with Code 70 rail (weathered, from MicroEngineering) but code 83 would fit too as the dimensions of the base of the rail are the same.  The tops of the sleepers have a textured finished from the printing process rather than the fake woodgrain on commercial track.

3D printed track with handlaid track in the background.
Note: I don't recommend use of unsupported MDF as trackbed
as it will inevitably sag - this is just a temporary arrangement.

The longest length which will fit in the printer is 18 sleepers @ 12 mm spacing which equates to 216 mm of track, so about 4 lengths would be required for a yard of track.  Printing each length takes just under one hour.  It may well be possible to print several lengths at one time side-by-side which wouldn't save much time but would save on trips back and forth to the printer.

Computer rendering of the sleepers.

As for cost, the cost of the plastic material works out to about $6 per yard, plus the cost of the rail of course (not including any costs for the 3D printer itself).  As a comparison, the NorthEastern scale lumber which I have used in the past for handlaid track costs about the same.

I also 3D-printed a jig to make it easier to insert the rail by keeping the sleepers parallel to each other so the rail slides in relatively easily.  So far, I have made about 1.5 metres of track.  

The 3D design could be changed to print straight track or fixed curves of any desired radius rather than having "flexible" track.  For example, if laying parallel tracks in a yard it could be easier to lay lengths of straight track to avoid the inevitable "wobbles" with flexible track.

D/DA Diesel Loco - 3D Printed

The first test prints have arrived for both the D and DA class diesels.  Both models have now been assembled and are running, including DCC and sound (Tsunami EMD645 non-turbo).

The model is designed to use a Hollywood Foundry mechanism, which can be supplied with the correct axle spacing.  Hollywood Foundry don't offer the correct size (15.7 mm) wheels in their normal range, so the wheels are from Northyard but Hollywood Foundry can fit them to their bogies during the normal assembly process at no extra cost, other than the cost of buying the wheels.  

The cosmetic bogie sideframes will be 3D printed as well.  

There is more info on the Marbelup Models blog.

Test print of D class fuel tank, with 7 layers of lead sheet added.
Weight: 166 grams.  Top 2 layers have central gap to clear motor.

Butlers Swamp Models for 3D printed fine detailed scale model train kits

Hi Everyone,

Its about time I let people know I have started a little kit manufacturing empire of my own, Butlers Swamp Models.

The former name of Lake Claremont near where I currently live, and the name to the original siding nearby before Claremont Railway Station was built on the Eastern Railway (Western Australia).

First model to be released under this brand is my 3D printed A Class bogie for the Railwest kit, which I am absolutely sure will be a cracker.

Why release an extra piece for this already awesome kit, well the resin side frames while they look acceptable I think will look a little out of place. And since I had been working on my own scratch built A Class for some time and have been converted to 3D printing along the way, I was not happy with the appearance nor having to chop up the resin side frames for mine, I was going to create these anyway so I am excited to offer them to you as well.

Please see my new page here to get more details and to order.

http://butlersswampmodels.blogspot.com.au/

Peter

RA Class Diesel - 3D Printed

This week, I received the first test prints for an RA class diesel from i.Materialise.  Converting the 3D drawings from the R class turned out to be easier than I thought, taking about 1.5 weeks of "spare" time, compared to several months to draw the R class originally.

Although the bulk of the long hood is the same as the R, the RA is about 16 mm longer overall, with the extra length being noticeable in the "front porch", short hood, the louvre panels behind the cab and the fuel tank.  The RA doesn't have dynamic brakes, so the vents at the rear of the long hood on the R had to be "blanked" over.  The headlights are different too, with two lights side-by-side rather than one above the other.

Note that the RA is presently sitting on temporary dummy inner bogies (3D-printed in blue) fitted with 12 mm diameter wheels rather than the intended 14 mm diameter, while awaiting delivery of drive bogies from Hollywood Foundry.

Two new 3D-printed models at the Exhibition

Marbelup Models unveiled two brand new 3D-printed models at the 2014 Model Railway Exhibition, neither of which have been modelled before, as far as I know.

The QMC car wagons were converted in 1963 from the earlier QMB wagons.  The WMB's were used to carry car bodies only, which were fully assembled in local (WA) factories, whereas the QMC's and later QMD's carried complete cars.  Photos indicate that the wagons were mainly used between Kalgoorlie and Perth and were often included on the Westland passenger train as well as freight trains.  These narrow gauge car wagons were made redundant after the standard gauge trains started running right through to Perth, and some were converted to QMG long, bulkhead flat wagons between 1970 and 1973.

The steel-sided RB open wagons were built between 1930 and 1937, with a total of 177 being built.  Some RB's lasted until 1971 in their original form.  Others were converted, quite early on, to class RBW by the addition of wooden hungry boards to increase the capacity for carrying wheat.  The RBW version survived until 1990.  Marbelup Models intends to produce the RBW version in the future.

VDR Refrigerator Van

 Here are some photos of the VDR refrigerator van produced by 3D printing by Marbelup Models.

The 3D drawing was modified from that for the VD van, although the modifications were quite extensive as the roof of the VDR was raised to provide extra height inside the refrigerated compartment, presumably to allow for the thickness of the insulation material.  

The bodywork for the refrigerator compartment was based on the somewhat derelict WVD van at the ARHS museum at Bassendean, although the WVD is slightly different in that the refrigeration equipment was mounted underneath the van rather than in the centre compartment of the VD.  Little information was available on the appearance of the refrigeration equipment on the WVD, hence the choice of VDR for the model, as well as the lack of evidence that the WVD's carried the attractive advertising livery.

Some of the VDRs had a single door each side to the refrigerated compartment and Marbelup Models would consider producing the single door version if there is sufficient demand.

The main decals were done by Westland Models and are available from them should you wish to have a VDR for yourself.  Some of the tiny decals for load, tare, etc. were done at home on a laser printer using laser decal paper from local hobby shop.  The laser printed decals sprayed with a Testors Decal Bonder which made them easier to apply as the laser decal film is extremely thin and fragile.  I understand Westland Models will be including the smaller decals in their VDR sheet for future orders.

Prior to decalling, the model was airbrushed with Revell gloss white enamel, and Revell matt varnish used as a clear protective coat over the decals.  The underframe is Revel No. 9 "Anthracite".  The bogies are American Models Bettendorf style, with 3D-printed bolsters to convert them to narrow gauge.

The 3D-printed body of the VDR is printed in one piece, and printed upside down to obtain the optimum definition for the louvred sections.  Some cleanup is required to roof as there is visible stepping and also remnant of the support structure from the 3D printing process.  The lack of other detail on the roof makes the cleanup pretty easy.  The exhaust pipe from the refigeration unit is vulnerable to damage while cleaning up the roof, so there is a spare printed on the underframe in case if gets broken (which it did on the test model).  All the the details visible are included in the 3D printed body, apart from handrails and the brake pulls rods and their supports, which must be fabricated from brass wire and strip.

Recent 3D Printed Models

For those not at recent S scale nights at AMRA, here are some photos of my latest 3D-printed models.

VD Bogie Louvred Van (painting not finished yet)

Interestingly, the original VD vans were built in Enghiem in Belgium, which is only about 60 km from the i.Materialise factory in Leuven where the 3D printed version was made.

SXT Bogie Sheep Wagon

WAGR Water Column (assembled and painted by Doug Firth)

3D Printers Available from Officeworks

Exciting News is that Officeworks are now selling 3D Printers, yes the revolution is coming, and first order of business is getting down to the East Vic Park or Joondalup stores which apparently are the only ones stocking them.

So $1500 bucks later I am the proud owner of his very first 3D printer I have wasted no time printing things off, some good results and some iffy results but very happy.

I first tried my GC wagon unmodified from what I sent to Shapeways and i.Materialise which while it printed very well it was full of very tough support material which I am struggling to get out of the center, I'm sure it will make a good gravel wagon.

Next to try was my drawing of the AI coach I have been working on a while.

Both in the Lime Green PLA and white ABS materials that this printer uses:

Quality is great for this little coach, which while it wont match the Prime gray from iMaterialise, the look and feel is superior to the WSF (SLS) from Shapeways.

Cost for this coach I estimate to print is about $3, which is pretty good seen as 3DSystems whom sell the printer use a razor blade system to sell these printers (like ink jet printers the cartridges are over priced and you have to use their printer cartridges) but I am working on a work around to maybe print with cheaper generic ABS plastic.

Overall looks like printing the coach sides and glueing the sides together works best for this method, the great thing is that "Plastruct Plastic Weld" is able to glue ABS and styrene together so works great with these parts making seemless welds.

This is probably a great option for making masters for coach sides for casting, but at this price for a small coach which when I finish with the drawing will be complete minus couplers W irons wheels and grab handles and a roof (printed roof doesnt look great, though going to try printing on its side) it could do it just about as cheap as a cast urethane kit... just kidding!

American Models Bettendorf Bogies

Bettendorf bogie on a VG van

Another source of bogies for relatively modern WAGR wagons is from American Models.  This company, based in Michigan, USA, make a wide range of S scale standard gauge locos, rolling stock and track.

In the parts section of their web site, they list a number of styles of bogies (or trucks as they call them).  The most useful for WAGR modellers are the Bettendorf freight car trucks and, for some modern Westrail era wagons, the 50-ton roller bearing trucks.

Bettendorf with "scale" wheels

50-ton roller bearing, with "scale" wheels

I first came across the Bettendoorf style when I visited Caboose Hobbies in Denver, during a holiday in the US in 1984.  I bought one pair just to try them.  That was a long time ago and, since then, I have bought two batches of 10 pairs, and asked for the bogies without wheelsets, which cuts the price almost in half.

Of course, the bogies are standard gauge so they have to be narrowed to suit Sn3½.  The Bettendorf bogies are sprung so they can be easily be dismantled - but don't lose the springs.  Kadee make an inexpensive manual uncoupling tool (#241), one end of which doubles as a "spring pic", which I have found useful for removing and inserting the springs.

The basic principle to narrow the bogies is to cut the centre from the original plastic bolster, and rejoin the two halves of the bolster.  For a while, I was using K&S 6.35 mm brass channel to splice the two halves of the bolster back together.  Recently, I went to the local hobby shop to get some more channel and they didn't have any, so I bought some K&S 6.35 mm x 3.2 mm rectangular brass tube instead and that actually worked better.

Original bolster (bottom) and shortened bolster.

The bolster is deeper towards the centre with a slope on both the top and bottom surfaces.  I found that by grinding away the sloping parts with a Dremel motor tool and "plastic" cutting disk, the end pieces of the bolster are a snug fit in the rectangular brass tube.  I found it easier to do the grinding with the original bolster in one piece, before cutting it into three pieces.  Take care not to damage the "bumps" which locate the springs.

A length of between 18 and 18.5 mm seems to work well for the brass tube.  This is based on fitting replacement wheelsets with 26 mm axles.  The bearing holes in the sideframes are quite deep and I don't think 25 mm axles would work as the wheels would rub against the inside of the sideframes.

Cut sections of original bolster with rectangular brass tube.

I drill the centre pivot hole 2.2 mm as this will take a 2-56 screw with minimal slop.  I drill the matching hole in the bottom of the brass tube a bit larger, say 2.5 mm, so that the bogie can rock a little bit from side to side or end to end.  Obviously, it is important to get the pivot holes in the exact centre of the brass tube.

I have also drilled 2 small holes in the underside of the brass tube so that I can use small screws to secure the two halves of the bolster in place although, if they are a tight fit, this may not be necessary.

The bogies I have bought have been "rust brown" in colour so I have have airbrushed them (Revell 9 "Anthracite") before reassembling them.  The current production are available in black, judging by the website photo, which would be better.

The 50-ton roller bearing bogies are not sprung, and are cast in one piece.  I haven't actually used this type, but I have seen some that have been converted to Sn3½ (and there are no springs to lose).

Update - 23 January 2014

To simplify regauging of the Bettendorf bogies, I have designed a new bolster for 3D printing.  The first test prints arrived today and they seem to have worked very well.

Bettendorf bogies with 3D-printed bolsters (grey)