George G Posted September 16, 2012 Share Posted September 16, 2012 All, I'm scratch building a BR class 307 out of sheet metal but I've hit a problem. What would be the easiest way to cut out the holes for the windows? I'm using 0.5mm thick steel. I though about cutting them out with a saw which would be very time consuming. I'm now looking at punching them out with a metal hole punch, but this seems to be an expensive option as the equipment isn't cheap. Can anyone tell me the best method to use and what tools are required? George Link to post Share on other sites More sharing options...
The Nth Degree Posted September 16, 2012 Share Posted September 16, 2012 Half mil steel is quite thick and would require expensive dies to cut through that effectively, and you'll have to make 4 of them. Unless you plan to produce and sell them it could prove quite costly, or you would have to REALLY want one. Cutting them by hand would be incredibly laborious and would only cost a pack of blades. What would be much easier (I think) would be to modify a BR Suburban coach, but I'm not absolutely sure of the window size and positions matching exactly. Good luck though. Link to post Share on other sites More sharing options...
R A Watson Posted September 16, 2012 Share Posted September 16, 2012 Drill a hole in the middle of the window appature then use a jig saw with a very fine tooth blade to open out to almost the finished shape and then file to finish. It will be a long job! Link to post Share on other sites More sharing options...
RMweb Gold Donw Posted September 17, 2012 RMweb Gold Share Posted September 17, 2012 The late Peter Korisson made himself a small steel jig which consisted of four holes for the corners of a coach window which meant only placing the jig once for each window. The straigh bits were then fretted out. This only works if the windows are all the same size. Don Link to post Share on other sites More sharing options...
Giles Posted September 17, 2012 Share Posted September 17, 2012 I should consider getting them laser cut, or better, water-jet cut - if you were able to draw them out in any CAD package capable of exporting a DXF file. You'd then get a really nice, uniform, and repeatable job. A company called Sciss does cutting, and is used to dealing with small stuff for model engineers, as well as commercial stuff. Hope it's useful Link to post Share on other sites More sharing options...
George G Posted September 17, 2012 Author Share Posted September 17, 2012 What is the cheapest material to build the coach from? I would like the same type of material that Ace Trains use to build their coaches. I want to punch out the windows using a square hole punch, then i'm going to file the rounded edges of the windows. I don't have room for a jig, and I don't want to use a cnc machine. Link to post Share on other sites More sharing options...
'CHARD Posted February 17, 2013 Share Posted February 17, 2013 What is the cheapest material to build the coach from? I would like the same type of material that Ace Trains use to build their coaches. I want to punch out the windows using a square hole punch, then i'm going to file the rounded edges of the windows. I don't have room for a jig, and I don't want to use a cnc machine. Judging from what Ace says on its website, here: http://www.acetrainslondon.com/archivecoaches.html they appear to use painted tin. " What is the cheapest material to build from? " is a rather different question. It's probably laminated cardboard, plywood or MDF, assuming you want something workable that stands a chance of doing the job. But why not go the plasticard and extruded plastic section route? Link to post Share on other sites More sharing options...
N15class Posted February 18, 2013 Share Posted February 18, 2013 What is the cheapest material to build the coach from? I would like the same type of material that Ace Trains use to build their coaches. I want to punch out the windows using a square hole punch, then i'm going to file the rounded edges of the windows. I don't have room for a jig, and I don't want to use a cnc machine. If you use a square punch how are you going to round the corner there will be no metal to file. Link to post Share on other sites More sharing options...
PatB Posted February 18, 2013 Share Posted February 18, 2013 Definitely investigate laser cutting. Effortless, accurate and cheaper than you might think. If you insist on cutting the windows yourself, consider going to sheet aluminium for easier working. Link to post Share on other sites More sharing options...
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