Building the Churchward 45xx Part Four
Buffer Beams
I’m glad I’m keeping this blog – saves me having to remember which bit comes next. However finding the right place in the instructions and the correct bits is another matter ...
So buffer beams. This model is of one of those built with full length frames, so there’s no fiddling with the appearance of modifications. However the instructions tell you how to bend things for the shorter frames, but does not tell you what do for the longer frames. Studying a pic of 4564 suggests that you cut the wings off the buffer beam backing (number 3 on the fret). So a trim was done and hope that’s right.
Laminating the buffer beams – tried tinning one of the two halves – very thin layer of solder with the iron – then clamping together and using the blowtorch to make the solder flash through the join. Two things here – the clamps take longer to cool then you might think (ask me how I know) and the application of the small amount of solder needed for the tinning. This was shown me at ExpoEM North, the first Manchester one, by a guy who was making track. This involved cutting very small bits of solder from the reel using a craft knife and putting the solid solder up against the joint, then applying the iron. Here I put the small amount of solder on the fluxed up work (9% phosphoric acid) and using the iron to spread the solder over the surface, then mate, then clamp, then torch, success.
Attachment to the footplate is a little bit of a challenge. You have to clamp it vertical with very little to support it. An iron needs to be held there for a long time (tried it!), so we’ll try with the blowtorch again. Clamping and getting the thing at right angles worked at the fourth fifth sixth attempt. And that’s only for the rear buffer beam – still the front one to go. Tinning the edge of the beam sandwich and the edge of the under-footplate with the iron was necessary then making sure there were no lumps and bumps in the solder. Flux, minimal solder then it worked. Phew!
However the swear box got topped up. Frequently.
The front buffer beam only took three four attempts.
Next it’s the front lamp irons which pass through holes in the footplate. Cleaning them up from the etch is a little bit of a challenge to the ham handed such as me, dropping them several times in the process. Praise be for the apron. Soldering them in place is not as difficult as I thought it might be – drop them in from underneath the footplate and a quick dab with the iron and there they are. The photo shows them in their non cleaned state – the centre iron especially needs a little more attention from a file. It may or may not be easier than smoothing them off before soldering, we’ll see. The photo is before cleaning. The footplate now resides in a mildly alkaline cleaning fluid and wil be attacked with a toothbrush when I’ve finished posting this blog entry.
The uncleaned up front footplate and buffer beam, with the lamp irons in place. The rear buffer beam is similar.
During the rest of the build we’ll have to be careful of the lamp irons so as not to snag them.
The next bits are the 8BA nuts to secure the body to the chassis. Must remember to open out the holes to take the bolts BEFORE soldering on the nuts.
On a thread, Paul from north Devon asked why the problem detail was not yet on the blog – my reply "The next blog entry is being written now - the trials are ongoing. Suffice to say it's been four working hours to get to bufferbeams laminated and set onto the footplate. And I've not yet finished for the night - lamp irons, if I can see the ***** things."
So this is not a short job.
- 5
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