As I hinted in one of my previous blog postings I wasn't entirely happy with the windows in the station building. Some were ok (usually the ones I'd shot in photographs) but others were a bit iffy. I'd been slowly developing the process and the cut files for the laser cutter. This picture shows versions 1, 2 and 3 from left to right.

Version 1 was a single 1mm cut with the detail engraved on the top. The single thickness made for a lack of relief that I didn't think gave adequate depth for the sash. Version 2 used two layers of 1mm MDF, engraved some detail on the front but also used the second layer to give space for the rear sash pane. This looked a lot better but I didn't get the design in the correct space to fit the glazing material. This made glazing really difficult and my choice of glazing material didn't help as it was quite thick. It didn't stick very well and I tried to resort to super glue which then caused white crazing in the glass.

Version 3 now has a much better recess for the glazing, I also found that I could laser cut the acetate sheet which I purchased from the Model Shop in London. I managed to get the setting such that I could just gently pop the glazing sections out of the sheet. The biggest problem was that I would pop the windows out and then immediately lose them.

I also chose to start making the windows in some supplemental frames and leave these frame on the main sheet. This meant I didn't have to wrestle finding all the individual bits in the bottom of the cutter and I could more easily spray the windows.

So now I managed to make up lots of replacement windows, the glazing held in with PVA which dries clear and doesn't spoil the glazing material. The windows were painted white with the very edge of the frame painted in the same light green as the down pipes.

One of the key things I wanted to achieve was consistency, I wanted all the windows to be equally good  so that they will all match.

I've also been doing so work on the good shed artwork. This is a difficult exercise in laser cut brickwork, particularly around the buttresses at each corner. I tried just cutting out the parts for one corner to see how it might come out. The base wall is 3mm MDF, the bulk of the buttress is 1.5mm and the plinth is 1mm. All  need different allowances for the interlocking bricks, I cut these over-length so I can then sand them back to match. I still need to allow a little more for the thinnest section of the buttress.

I gave it a quick coat of brick red followed by my usual treatment of Wilco fine filler and Vallejo grey wash. The result shows I'm on the right track (I hope).

Some good progress.

David