For my model of Whatley, I need a variety of aggregate wagons and following on from a joint DEMU project to build an Axle-Motion bogie, I have been working on a kit of parts for the Redpath Dormand Long PTA Steel Tipplers.
I made the masters and then the moulds back in January. Since then, I have been busy casting parts for a rake of these wagons. To avoid excessive undercuts when casting these, I cast them in pieces:
- Main wagon box
- End panel with horizontal ribs
- Underframe Ribs (3 types)
- Buffered Headstock
- Non-Buffered Headstock
I'm able to put together inner wagons (two non-buffered headstocks) or outer wagons (one of each type of headstock). The outer wagons have 51L sprung Oleo buffers fitted (18 inch heads IIRC). The inner coupling will be a kadee fitted at prototype height via a hole cut in the headstock. My preferred coupling is the long shanked centre-set whisper coupler and there is just the right amount of room (5.5mm) between the frames to accept one so that the "whiskers" function without the need for a draft box.
If I ever get around to doing a Steel layout with a working tippler, I'm hoping that I'll be able to fit a rotary Sergeant coupling in place of the kadee (fingers crossed that there is enough room).
In addition, there are a couple of bits that I am awaiting etches for: the roughly diamond-shaped lattice-like surround to the auto-coupler, lamp brackets and ladder. I've drawn these up as a custom etch (just need to send it off to PPD).
The example below is of one of the better castings. Note the air bubbles along the top edge of the box (easily filled and sanded but a pain non the less). Also, I haven't got round to cutting out the holes in the left hand bogie side frame yet (just a push-fit at the moment).
An inner wagon awaiting the addition of under-frame components:
The masters for the headstocks, under-frame ribs and end panels
Mould of the main box. This is as per Jon Hall's design (using a sacrificial thin layer of 10 thou styrene sheet to reduce the number of bubbles) but modified to include lego registration holes to ensure a nice "true" fit.
A casting "straight from the mould" with the scrap layer visible.
Lots of pieces! There's got to be a couple more wagons worth in this lot but still a way to go before I can do a full rake.