Ron Heggs Posted August 2, 2011 Author Share Posted August 2, 2011 Still building the first 27 deck beams, the original way Have now finished cutting and grinding the two steel templates to enable all the remaining +100 deck beam blanks to be made identically ... and I have a cunning way to enable the beams to be lengthened to meet the required different lengths - to be shown later in the thread Photos of completed template assembly - Maximum capacity is 23 - 40thou blanks, each blank is 174mm x 14.5mm, which will be drilled and clamped, then all filed to conform to the template The six slots will enable cuts to be made to accept 20thou x 6mm strip for the longitudinal beams ... to be continued >>>>> 1 Link to post Share on other sites More sharing options...
Mucky Duck Posted August 2, 2011 Share Posted August 2, 2011 Just a photo of the prototype deck beam details - Copyright Richard_T NO rivets being modelled Note - the tie beam between the two piers - more cross bracing Ron I take it you don't plan to squeeze a camera down there then Ron? Rivets or no rivets, I'm sure this layout is going to have so many fascinating 'hidden' nooks and crannies that will be well worth snapping. It's got to be the most ambitious single-handed project on RMweb, alongside Jim's Birmingham New Street. … and I know how you feel about the Spanish summer heat, it's a modelling time-killer! Link to post Share on other sites More sharing options...
Guest jim s-w Posted August 2, 2011 Share Posted August 2, 2011 Hi, Jim Presume you are referring to the turntable deck handrails The supports maybe plastic, but the handrails will be brass wire. Neither of which would stand up to a derailed loco, as you point out They should be easily repaired if the worst happens, although there shouldn't be any slow speed mishaps Cheers Ron Hi Ron If it was all brass it would easily stand up to a derailed loco on the turntable. I suppose we all fear the worst happening now and then and given the amount of effort in your stuff I would hate to see a derailed train demolishing one of your beautiful bridges. Keep up the good work Cheers Jim Link to post Share on other sites More sharing options...
Ron Heggs Posted August 3, 2011 Author Share Posted August 3, 2011 I take it you don't plan to squeeze a camera down there then Ron? Rivets or no rivets, I'm sure this layout is going to have so many fascinating 'hidden' nooks and crannies that will be well worth snapping. It's got to be the most ambitious single-handed project on RMweb, alongside Jim's Birmingham New Street. … and I know how you feel about the Spanish summer heat, it's a modelling time-killer! Hi, There will be room for a camera, hand-held or webcam, to take a complete photo shoot of all the layout's nooks & crannies I wouldn't like to feel I'm modelling all this detail just for it not to be seen, however difficult it may turn out to be - I think Jim has the upper hand on his experience of layout construction, and it shows in the atmospheric trackwork photos The summer heat , and my work on the villa to accommodate immediate family moves, all cuts down on the time for modelling Cheers Ron Link to post Share on other sites More sharing options...
Ron Heggs Posted August 3, 2011 Author Share Posted August 3, 2011 Hi Ron If it was all brass it would easily stand up to a derailed loco on the turntable. I suppose we all fear the worst happening now and then and given the amount of effort in your stuff I would hate to see a derailed train demolishing one of your beautiful bridges. Keep up the good work Cheers Jim Hi, Jim Don't have any problems with the bridges, having dropped one onto the ceramic tiled floor, and survived completely intact The turntable is another matter. Examining the structure, if the handrails were to be made out of brass, the fixing points would still be vulnerable, unless - ... If the fixing points were designed as a push fit arrangement, then the handrail would probably remain intact so could be refixed without any other damage Will have another look at the handrail arrangements, and come up with a viable re-design Cheers Ron Link to post Share on other sites More sharing options...
Ron Heggs Posted August 3, 2011 Author Share Posted August 3, 2011 If it was all brass it would easily stand up to a derailed loco on the turntable Hi, Jim Have re-designed the handrails/supports in brass and enabled them to pivot outwards if accidentally hit by loco or hand A bit of trial & error test build required to check if that will work OK Cheers Ron Link to post Share on other sites More sharing options...
Ron Heggs Posted August 3, 2011 Author Share Posted August 3, 2011 As indiicated in post 602 above, the deck beams vary in length for each span section, the longest being 188.5mm, 13.5mm longer than the first beams So a test build to check the lengthening method was required - it is not efficient to make a set of templates for each beam length The resulting test build of the longest deck beam 188.5mm - 13.5mm longer than the first deck beams - This is how I lengthened the standard 175mm deck beam - Cut 10mm off each end Insert a 40 thou piece 6.75mm long x 6mm high Fix in position - leaving this as the 'fix' would not be strong enough to carry the expected deck loading Cover the end 18.75mm with 5 thou sheet - this is the strengthening 'fix' and finally fix 20 thou x 4mm wide deck beam flanges and vertical strengtheners Can you see the 'fix'? ... to be continued >>>>> 1 Link to post Share on other sites More sharing options...
ozzyo Posted August 4, 2011 Share Posted August 4, 2011 Can you see the 'fix'? ... to be continued >>>>> not me sir. OzzyO. Link to post Share on other sites More sharing options...
MarstonVale Posted August 4, 2011 Share Posted August 4, 2011 magician! Link to post Share on other sites More sharing options...
Nile_Griffith Posted August 4, 2011 Share Posted August 4, 2011 And I get all worked up trying to stick a bit of plastic rod to a chassis !!!!!!!!!!!!!!!!!!!!!!!!!! Link to post Share on other sites More sharing options...
Jon Fitness Posted August 4, 2011 Share Posted August 4, 2011 PlasticFantastic!!!!! Link to post Share on other sites More sharing options...
Ron Heggs Posted August 5, 2011 Author Share Posted August 5, 2011 - Finally got round to unpacking the pillar drill and setting it up in the workshop The result - A 23 pack of deck blanks drilled and clamped ready for the file and saw (maybe even try the linisher) - there's going to be a lot of plastic dust/swarf around this weekend - in the workshop of course, not the modelling workstation Oh well, back to building the deck sub-structure - 150+ 27mm long x 6mm deep beams, etc. - I'll be glad when it's time to load test ... to be continued >>>>> 1 Link to post Share on other sites More sharing options...
Ron Heggs Posted August 6, 2011 Author Share Posted August 6, 2011 - after linishing (definitely the best way) - there was a lot of melted swarf and dust - the discolouration is steel dust White plastic - Filthy job - Cleaned up and separated - 21 blanks (not 23 - must have mis-counted ) All ready for the next deck structure - after the completion of the present one ... to be continued >>>>> 1 Link to post Share on other sites More sharing options...
Ron Heggs Posted August 9, 2011 Author Share Posted August 9, 2011 The deck build is finally coming together - the first deck section is 890mm long and includes the skew over the MSJ&AR railway - and lies between spans N1, S1 & S2A Changed the build procedure - fixing the deck beams under the deck plating first and will then fit the 27mm long longitudinal beams next - this will ensure the deck beams are precisely fitted at 28mm centres A few pictures showing the latest progress (which is very slow at present due to excessive heat) Underside uppermost - the slight kink visible on the left about 2/3rds towards the far end, is due to the slight angular change of the deck beams where spans S1 & S2A will abut Deck plating (40 thou) with side upstands (20 thou) Now the slow fitting of the longitudinal beams - 6 between each pair of deck beams ... to be continued >>>>> 5 Link to post Share on other sites More sharing options...
multivac Posted August 9, 2011 Share Posted August 9, 2011 Changed the build procedure - fixing the deck beams under the deck plating first and will then fit the 27mm long longitudinal beams next - this will ensure the deck beams are precisely fitted at 28mm centres Underside uppermost - the slight kink visible on the left about 2/3rds towards the far end, is due to the slight angular change of the deck beams where spans S1 & S2A will abut Deck plating (40 thou) with side upstands (20 thou) Now the slow fitting of the longitudinal beams - 6 between each pair of deck beams ... to be continued >>>>> Fantastic work, I still don't understand how you prevent such a long plastic structure from warping. I built a little hut in plastic card and it warped in 3-D. Link to post Share on other sites More sharing options...
Ron Heggs Posted August 10, 2011 Author Share Posted August 10, 2011 Fantastic work, I still don't understand how you prevent such a long plastic structure from warping. I built a little hut in plastic card and it warped in 3-D. Hi, It's the choice of plasticard thicknesses and solvent/adhesives, and the build method Always start with the thickest pieces and allow to dry completely, ensure there are sufficient strengthening pieces included to reduce any subsequent warping Speed of build is always going to be a problem, as each joint should be given chance to harden before fixing the next piece to the assembly One way to speed up a build, is to build it in small modules first, then join the modules together Ron Link to post Share on other sites More sharing options...
Ron Heggs Posted August 15, 2011 Author Share Posted August 15, 2011 Finally managed to get a bit of a run at the deck again - - still have the bottom flanges of the longitudinal beams to fit Whilst cutting the flanges and webs for the longitudinal beams, I have come up with another time saving idea on future deck constructions Revised process - The top flanges of the longitudinal beams will be fitted first in long strips directly on the deck plating, then the top flanges of the deck beams, also in long strips - cutting away the underlying strips to enable both sets of flanges to seat flat against the deck plating - then the longitudinal beams, fixed in place in long strips, followed by the deck beams - and finally the bottom flanges to the longitudinal beams (these will be the only bits to require individual cutting and fixing) The next deck section is a lot shorter - between N3 (275mm) & S3 (179mm) span beams So the revised process will be tested here ... to be continued >>>>> 1 Link to post Share on other sites More sharing options...
Ron Heggs Posted August 15, 2011 Author Share Posted August 15, 2011 Testing the new process on the next deck build - Longitudinal beam top flange strips fixed and a few cut out ready for the deck beam top flanges Deck beam top flanges in place Longitudinal beam webs fixed - next step is to fix the deck beams (in this case each one is a different length) ... to be continued >>>>> 1 Link to post Share on other sites More sharing options...
RMweb Gold bcnPete Posted August 16, 2011 RMweb Gold Share Posted August 16, 2011 Lookin´very good Ron Forgot to ask if you have any shares in Plastikard...if not, you should ask for sponsorship... 1 Link to post Share on other sites More sharing options...
ColinW Posted August 16, 2011 Share Posted August 16, 2011 I like the way that the deck has turned out Ron, will be interesting to see it altogether when you have finished it. Colin Link to post Share on other sites More sharing options...
iak Posted August 16, 2011 Share Posted August 16, 2011 You are sir, producing a work of genius! As ever the results are stunning Ron - bravo B) Link to post Share on other sites More sharing options...
Ron Heggs Posted August 16, 2011 Author Share Posted August 16, 2011 Continuing with the small deck section between N3 & S3 span beams - Cut the deck beam web for the longest (176mm) of the seven beams - The remainder are incremental reductions down to 172mm in length Beam in place - The left-hand part of the beam will be removed when offered up to the support pier at this point Longitudinal beam flanges pieces fixed and the top flange strip wrapped around the curved deck beam end Bottom flange fixed to deck beam This procedure will be repeated for the remaining seven deck beams ... to be continued >>>>> 3 Link to post Share on other sites More sharing options...
Ron Heggs Posted August 16, 2011 Author Share Posted August 16, 2011 bcnPete, on 16 August 2011 - 08:02 , said: Lookin´very good Ron Forgot to ask if you have any shares in Plastikard...if not, you should ask for sponsorship... Hi, Pete No shares, but I could have the largest Plastikard stock in Spain Cheers Ron Link to post Share on other sites More sharing options...
Ron Heggs Posted August 16, 2011 Author Share Posted August 16, 2011 I like the way that the deck has turned out Ron, will be interesting to see it altogether when you have finished it. Colin Hi, Colin Thanks for your comments - It's going to be a 'bit at a time' assembly, to show the viaduct build grow Cheers Ron Link to post Share on other sites More sharing options...
Ron Heggs Posted August 16, 2011 Author Share Posted August 16, 2011 You are sir, producing a work of genius! As ever the results are stunning Ron - bravo B) Hi, Ian 'Genius & Insanity are opposite sides of the same coin' Thanks for your continuing viewing of this thread Ron Link to post Share on other sites More sharing options...
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