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Building the Churchward 45xx Part Four


Coombe Barton

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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.

 

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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.

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I'm not suprised you found attaching the buffer beam difficult if you just tin the mating surfaces and try to sweat them together. For perpendicular joints like these it is much easier, and gives a stronger joint, to just run a fillet of solder along the inside of the joint. Don't worry about visible solder in places where it is not going to be seen. When cleaned up it takes paint well.

 

What I do is to cradle the running plate upside down in my hand and hold the buffer beam against the plate and valances with a small piece of wood with my first finger. Then drop a small piece of 145 degree solder or carry it on the iron (according to preference), add plenty of flux and run the iron along the joint. I also put a small bead between the beam and the valances. If you find your iron is not producing enough head to make a smooth bead, your tip is probably too small. I use an Antex 25W iron with a 3mm chisel bit and find it quite sufficient for the main parts of any 4mm build.

 

I'd also recommend cleaning up the lamp irons before fitting. It is very difficult to get a file to them without scratching anything else. The ones you have that pass through the running plate are fairly strong, but those that are fixed on top, especially those with a half-etch fold, will almost certainly break if try to do anything to them.

 

Nick

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The steps also have a half etched line in them. I would recommend reinforcing them at the rear before fixing them to the footplate - they are very vulnerable to handling damage otherwise!

 

Martin

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Guest PD&SWJR

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I have reinforced the rear of buffer beams on some of my locos with right angle brass section.  Slots / holes need to be cut into them to clear the buffers and rear shaft of the couplings. Possible interference with the ends of the chassis needs to be considered as well. Possibly a 7mm scale thing, as stock is heavier and 1kg of loco hitting a dead end is quite brutal.  Have done the same with steps to strengthen half etch joints, as steps are vulnerable to handling damage.  I do adopt a belt and braces approach with my models, including buildings.

 

Is the Modelex 45xx the same etchings as the kits sold under Malcolm Mitchell's  own name?

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...Possibly a 7mm scale thing...

Yes, I really doubt the need in 4mm unless there's no support from valances.

 

I definitely agree about steps, though, as they are often delicate in 4mm.

 

I also wonder about whether there's any difference between versions of the Mitchell kit. The etches shown in the first entry do appear to be quite simple compared with, say, the Mitchell 517 although the latter copes with more variation (cabs, bunkers, firebox, smokebox, etc.).

 

Nick

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....Is the Modelex 45xx the same etchings as the kits sold under Malcolm Mitchell's  own name?

 

Not quite. As far as I understood it, the Malcolm Mitchell 45xx via David Geen was a slightly updated design, and there was also a 4575 variant (sloping tanks) made available.

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Buffalo - I thought I had cleaned the lamp irons up but have finished the job post installation with a grinding wheel in a Dremel. Light touch and it worked. Made sure it only touched the lamp iron with a little inventiveness with a vice or two and a flexible drive.

 

Martin - good idea - thanks - will reinforce with angle before I go much further.

 

PD&SWJR  - I'll take your advice and put in some brass angle.

 

And there is a difference - as Horestan says they're a different generation. the 44xx Mitchell kit I have from David Geen is a different beastie. although the instruction copying still leaves a bit to be desired. It's certainly not the booklet that Guy Williams described in MRJ 32.

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Guest PD&SWJR

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Slightly O/T, is the 44xx kit from David Geen a 'reduced' version of the Mitchell 7mm that I built about 15 years ago?  I probably still have the instructions somewhere and that was definitely a booklet.

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Don't know. The booklet that was provided back in the 80s contains the same information as the various copied pages in the kit it is't a booklet any more. Guy Williams praised the substantial box, and that's still there, as are the etching wrapped in tissue paper.

 

It certainly seems a better put together offering than the Churchward, having a nickel silver chassis rather than brass. I suppose I'll find out when I build it.

 

However I have discovered that the Churchward instructions are inkjet printed rather than photocopied - a drip of water proved that.

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