Tag Archives: Jig

Five Shunter Challenge Pt5: Gearboxes

Today we look at the gearboxes that will be fit to the five shunter kits.

My previous models have used Branchlines gear boxes, but I was really keen to try some of the gearboxes produced by High Level Kits for the x5 shunter challenge. In fact, one of the main reasons I purchased the Sentinel and 88DS kits was because the High Level Kits gear boxes were included in both kits. This would allow me to use these gear boxes test with the remaining three locos (as they require gear boxes to be purchased separately).

The instructions for the High Level Kit gear boxes are clear and well illustrated. It is important to work through the instructions and consider the placement of the various reduction gears. Don’t rush this.

I quickly put together the little 0-4-0 gear box provided with the RT Models Sentinel kit, ensuring the folding of the nickel silver pieces were at 90 degree angles using a hold n’ fold tool.

I test fitted the gear box to the compensated chassis and gave it a running in. Everything is running well. On to the next one…

2014-10-12 20.36.44-1LR

2014-10-18 20.01.26-1LR

x5 Shunter Challenge Progress

BR Class 02 Diesel ShunterDJH

Chassis block folded. Compensation fitted. Axles Fitted.

Sentinel post war 100HP 0-4-0VBT – RT Models

Chassis block folded. Compensation fitted. Axles Fitted. Gear Box Fitted.

Ruston & Hornsby 88DSJudith Edge

Chassis block folded. Compensation fitted. Axles Fitted.

11001Judith Edge

Chassis block folded. Compensation fitted. Axles Fitted.

English Electric/Hawthorn Leslie 0-6-0DEJudith Edge

No progress

P.S. If there are any aspects of x5 shunter challenge that you want me to cover (be it soldering, equipment… anything at all) please do leave a comment or contact me by email. I will reply. You can also follow me on twitter for instant updates.

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Five Shunter Challenge Pt4: Fitting and removing wheels

Today is a brief look at how I fit wheels to axles.

The five kits being built in the x5 shunter challenge either have Alan Gibson wheels or Markits wheels. The BR 02 is the only model with Markits wheels which are very easy to fit using the special Markits screwdriver. The axles have a square shaft that only allows each wheel to be fitted in one of four positions.

Alan Gibson wheels are friction fit, meaning that wheels are pushed onto a typical rounded axle. The brute force required to push or pull wheels off axles can be a bit scary, especially when you are fitting them onto your lovingly constructed chassis with brake rigging etc. For this reason I purchased some wheel fitting jigs. I bought a selection of cog and wheel ‘pullers’ and ‘pushers’ from fohrmann-WERKZEUGE. These tools have been very useful and limit the chance of damage to any of the models.

x5 Shunter Challenge Progress

BR Class 02 Diesel ShunterDJH

Chassis block folded. Compensation fitted. Axles Fitted.

Sentinel post war 100HP 0-4-0VBT – RT Models

Chassis block folded. Compensation fitted. Axles Fitted.

Ruston & Hornsby 88DSJudith Edge

Chassis block folded. Compensation fitted. Axles Fitted.

11001Judith Edge

Chassis block folded. Compensation fitted. Axles Fitted.

English Electric/Hawthorn Leslie 0-6-0DEJudith Edge

No progress

P.S. If there are any aspects of x5 shunter challenge that you want me to cover (be it soldering, equipment… anything at all) please do leave a comment or contact me by email. I will reply. You can also follow me on twitter for instant updates.

Five Shunter Challenge Pt3.4: Comprehending Compensation

This time we continue the discussion about my plans to build these five kits with compensation. As with all things in life, there are a number of different ways to fit a compensation system and the five shunters being built require quite different approaches. Today we will look at the horn block compensation system.

What are Horn Blocks?

This DJH kit of the BR Class 02 Shunter is built as a rigid chassis, but after attempting to build the chassis a few years ago, I decided that I would prefer to include compensation. The rigid chassis is constructed on horn blocks (bearings that look like brass cubes), so I decided to purchase a separate horn block compensation kit.

The driving axle shouldn’t be compensated on a 0-4-0, so I started to prepare the non-driving axle for compensation. The compensation kit instructions include helpful illustrations, but I was a bit scared to discover that I would need to cut a wider hole in the chassis for the compensated horn blocks to fit into.

I built up the outer horn block plates and used these to marked out the chassis with a permanent marker.

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I then cut out the square gap using a fine hack saw with a thread-like blade.

The advantage of this horn block system is that you can manually adjust the height of the driving axle and the amount of compensation either side using screws. This means that even if my cutouts are not identical I can urh… compensate.. for that with the screws. I must admit that I am really pleased with the result and the chassis runs really well.

2014-11-10 21.45.24LR

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x5 Shunter Challenge Progress

2014-11-11 20.41.42LR

BR Class 02 Diesel ShunterDJH

Chassis block constructed, compensation fitted.

Sentinel post war 100HP 0-4-0VBT – RT Models

Chassis block constructed, compensation fitted.

Ruston & Hornsby 88DSJudith Edge

Chassis block constructed, compensation fitted.

11001Judith Edge

Chassis block constructed., compensation fitted.

English Electric/Hawthorn Leslie 0-6-0DEJudith Edge

No progress

P.S. If there are any aspects of x5 shunter challenge that you want me to cover (be it soldering, equipment… anything at all) please do leave a comment or contact me by email. I will reply. You can also follow me on twitter for instant updates.

Five Shunter Challenge Pt3.3: Comprehending Compensation

This time we continue the discussion about my plans to build these five kits with compensation. As with all things in life, there are a number of different ways to fit a compensation system and the five shunters being built require quite different approaches. Today we will look at the compensation system for the three Judith Edge kits.

Judith Edge kits can be built rigid or they can take two different types of compensation. They include etch lines for horn blocks (see the DJH BR 02 in the next blog entry) and they include their own ‘balance beam’ compensation system.

How do I build the balance beams?
I must admit that it has been the balance beam compensation that deterred me from building my Judith Edge kits for so long, as I just couldn’t comprehend how to put the beams together. I didn’t find the instructions that helpful in this regard (I’m a ‘copy the picture’, kind of guy). I couldn’t understand where to solder the axle bearings or how to create a pivot for the beams.

While researching some other peoples Judith Edge builds on RMweb and looking again at the very helpful emails that Judith Edge sent me when I first purchased 11001 (that I still didn’t really understand), it suddenly happened… Eureka!!! Everything written in the instructions and emails made sense. What I was failing to understand was the axle bearings are actually soldered on the insides of the balance beams (See the picture below).

You can see the balance beams on the inside of the chassis with the axle bearing soldered onto them.

You can see the balance beams on the inside of the chassis with the axle bearing soldered onto them.

You then use some spare metal rod or a track pin to create a pivot for each of the beams (the Peco track pins are quite useful in this regard).

Peco track pin acting as a pivot

Peco track pin acting as a pivot

A good tip is to put some paper between the balance beam and the side frames while soldering the pivot pin in place (to stop them soldering together).

 

This realisation of how to complete the balance beams was a fantastic moment for me, as it now means I can build any of the Judith Edge kits.

x5 Shunter Challenge Progress

2014-10-09 22.09.22LR

BR Class 02 Diesel ShunterDJH

Chassis block constructed.

Sentinel post war 100HP 0-4-0VBT – RT Models

Chassis block constructed, compensation fitted.

Ruston & Hornsby 88DSJudith Edge

Chassis block constructed, compensation fitted.

11001Judith Edge

Chassis block constructed. compensation fitted.

English Electric/Hawthorn Leslie 0-6-0DEJudith Edge

No progress

P.S. If there are any aspects of x5 shunter challenge that you want me to cover (be it soldering, equipment… anything at all) please do leave a comment or contact me by email. I will reply. You can also follow me on twitter for instant updates.

Five Shunter Challenge Pt3.2: Comprehending Compensation

Last time I discussed the difference between compensated and rigid chassis’ and my plans to build these five kits with compensation. As with all things in life, there are a number of different ways to fit a compensation system and the five shunters being built require quite different approaches. Today we will look at the compensation system fitted to the RT Models Sentinel.

The RT Models kit and instruction sheet are intuitive and explain the compensation system very well. The side frames include an elongated hole for the non-driving axle bearings to pop into, which allows the non-driving axle to rock up and down.

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A pivot for the non-driving axle is created using a v-shaped etch that makes light contact with the centre of the axle. The pivot allows the non-driving axle to deal with cambers and uneven track.

2014-10-08 17.57.42PSLR

 

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x5 Shunter Challenge Progress

BR Class 02 Diesel ShunterDJH

Chassis block constructed.

Sentinel post war 100HP 0-4-0VBT – RT Models

Chassis block constructed, compensation fitted.

Ruston & Hornsby 88DSJudith Edge

Chassis block constructed.

11001Judith Edge

Chassis block constructed.

English Electric/Hawthorn Leslie 0-6-0DEJudith Edge

No progress

P.S. If there are any aspects of x5 shunter challenge that you want me to cover (be it soldering, equipment… anything at all) please do leave a comment or contact me by email. I will reply. You can also follow me on twitter for instant updates.

Five Shunter Challenge Pt3.1: Comprehending Compensation

Last time I discussed setting up a loco chassis with a chassis jig, but these five kits will differ from any of my previous kit builds by being constructed with compensated chassis’. All of my previous loco kits have been built on a rigid chassis.

What is a rigid chassis?
Rigid chassis kits have very minimal up/down/left/right play on each axle in the chassis, but all of the wheels maintain contact with the track. It is essential that the chassis is set up as square as possible using this technique.

What is a compensated chassis?
If a chassis is compensated, then it essentially has a bit of sprung suspension on some of the axles, allowing the loco to cope with uneven track joints. A compensated chassis can also cope with some quirkiness in your building abilities, such as slightly wonky wheels and axles.

It is apparently beneficial to include compensation on one axle of an 0-4-0 locomotive kit to help ensure the loco runs well. As three of my loco kits are 0-4-0 I thought it was time to take the plunge.

I first read about compensation in Iain Rice’s book titled ‘Locomotive kit chassis construction in 4mm‘. Although I understood the principles, I really struggled to comprehend how to build a loco with compensation. As with all things in life, there are a number of different ways, and the five shunters being built require quite different approaches. I will discuss each locos compensation in more detail next time.

x5 Shunter Challenge Progress

BR Class 02 Diesel ShunterDJH

No progress

Sentinel post war 100HP 0-4-0VBT – RT Models

The chassis is folded up and the axles are fitted. The instructions are nice and simple to follow.

2014-10-08 17.58.44-1LR

Ruston & Hornsby 88DSJudith Edge

Side frames cleaned up

11001Judith Edge

Spacers fitted

2014-10-09 20.10.27LR

English Electric/Hawthorn Leslie 0-6-0DEJudith Edge

No progress

P.S. If there are any aspects of x5 shunter challenge that you want me to cover (be it soldering, equipment… anything at all) please do leave a comment or contact me by email. I will reply. You can also follow me on twitter for instant updates.

Five Shunter Challenge Pt2: How do you build a straight chassis?

One of the objectives of attempting to build these x5 shunter kits simultaneously is to become better at each step of the building process.

Chassis difficulties

I find that the most challenging stage of constructing loco kits is chassis building. There is nothing more frustrating to me than when the finished product runs poorly. There are a few reasons why poor running can occur, but the first suspect will be whether the chassis is built straight and whether the axle bearings are free running. The next will be whether coupling rods align with the wheels properly.

Chassis jig

I decided to invest in a chassis jig a while ago. This item isn’t cheap, but it really took a lot of the stress out of the initial set up of the chassis block and axles. There are a small number of these type of jigs available, but the one I have is the Chassis2 by Avonside Works.

While building the various chassis’ as part of the x5 shunter challenge I have also become more comfortable with building these kits by hand (without the jig), which must be a step in the right direction.

Building the chassis block

For each of the kits I cleaned up the side frame etches with wet and dry paper. I then fitted the ‘dummy axles’ to the jig and set the jig up so it aligns to the position of the axles on each model. Setting the axle positions on the jig allow each side frame to be constructed in an identical manner and then the whole chassis to be soldered together straight and firm.

2014-10-09 20.10.27LR

It is also important to note that all five of these chassis will be built with compensation (my previous kits have all been rigid chassis), but more about that next time.

Below is an update on progress with each model. I aim to have all of the chassis completed and prepared before moving onto constructing the bodies for each loco.

x5 Shunter Challenge Progress

BR Class 02 Diesel ShunterDJH

No progress

Sentinel post war 100HP 0-4-0VBT – RT Models

The chassis is folded up and the axles are fitted. The instructions are nice and simple to follow.

Ruston & Hornsby 88DSJudith Edge

Side frames cleaned up

11001Judith Edge

Spacers fitted

English Electric/Hawthorn Leslie 0-6-0DEJudith Edge

No progress

P.S. If there are any aspects of x5 shunter challenge that you want me to cover (be it soldering, equipment… anything at all) please do leave a comment or contact me by email. I will reply. You can also follow me on twitter for instant updates.