Author Topic: Coach 9 - Official Work Thread  (Read 7431 times)

Jeff Schumaker

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Re: Coach 9 - Official Work Thread
« Reply #45 on: December 01, 2017, 02:40:18 PM »
Excellent work, Harold. What's next on your list?

Jeff S.
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Dave Crow

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Re: Coach 9 - Official Work Thread
« Reply #46 on: December 01, 2017, 03:36:41 PM »
Harold, the "cups" in the ends of the carbody in which the ends of the truss rods and tensioning nut go - are those castings?

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Harold Downey

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Re: Coach 9 - Official Work Thread
« Reply #47 on: December 01, 2017, 10:40:47 PM »
The truss rods on Coach 3 terminate with washers and nuts.  So - no castings.

Dave Crow

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Re: Coach 9 - Official Work Thread
« Reply #48 on: December 03, 2017, 10:06:25 PM »
Harold, thanks for the clarification.

Harold Downey

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Re: Coach 9 - Official Work Thread
« Reply #49 on: January 31, 2018, 12:09:38 AM »
I am starting work on the patterns for the Hale & Kilburn seats.  This is the window side casting that supports that side of the seat, and where the flip-over mechanism attaches as well.   

It is very challenging, even though it doesn't look too complicated.  I also need to make a complex core box to form the back side cavity.  This is just a warmup for the aisle side casting -- that one is giving me nightmares.   

The first picture is the pattern in process. I am gluing on the first level of core prints in this step.  You can see the actual part just above it.

The second picture is showing something I am trying out.  The original casting has a part number on  it - 71M-3.  The letters are very similar in size and detail to the Hale and Kilburn lettering that definitely needs to be reproduced on the aisle side casting.  I got some mold making silicone rubber.  I poured this over the letters.  Once that hardens, I can peel it off and use it as a mold to make letters out of epoxy.  Then I can glue the epoxy letters to the pattern.  I hope this works!

I'll update as I get further along. 

Harold Downey

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Re: Coach 9 - Official Work Thread
« Reply #50 on: January 31, 2018, 12:10:08 AM »
Silicone mold making

Wayne Laepple

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Re: Coach 9 - Official Work Thread
« Reply #51 on: January 31, 2018, 12:35:05 AM »
Hi Harold --

We have had very good luck making silicon casting patterns at the Railroad Museum of Pennsylvania. We've made builder's plates, number plates and quite a few small bits of hardware. Good luck!

Cheers -- Wayne

James Patten

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Re: Coach 9 - Official Work Thread
« Reply #52 on: January 31, 2018, 12:39:59 AM »
It looks like Hale & Kilburn's successor is the Kustom Seating Company.  Did you talk to them to see if casting pattern 71M-3 (or any other pattern) still exists?  Doubtful, I know.

Stephen Hussar

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Re: Coach 9 - Official Work Thread
« Reply #53 on: February 04, 2018, 01:16:30 AM »
Wow.

Harold Downey

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Re: Coach 9 - Official Work Thread
« Reply #54 on: February 04, 2018, 02:31:21 AM »
A couple more pictures: 

The silicone mold peeled off the letters.  It seems to have worked really well.

Harold Downey

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Re: Coach 9 - Official Work Thread
« Reply #55 on: February 04, 2018, 02:32:42 AM »
And with the epoxy letters placed on the pattern.  The pattern is a little further along.   The core box for this is taking a lot of time.  I will have a picture of that to post in a day or two.

Jeff Schumaker

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Re: Coach 9 - Official Work Thread
« Reply #56 on: February 04, 2018, 02:45:36 PM »
Fantstic work, Harold.

Jeff S.
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Harold Downey

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Re: Coach 9 - Official Work Thread
« Reply #57 on: February 09, 2018, 12:43:20 AM »
This pattern is a one-sided pattern with a cover core.  It will be molded completely in the drag (bottom half of the sand mold flask).  The cover core forms the back side indent and takes care of the offsets in the parting plane. 

On top is the pattern -- the darker wood backing is the core print.  Below is the core box. 

Still have lots of finish work to do -- filling holes, fillets, etc.