While I was up in Maine and Pennsylvania, I finally got the chance to sit down with Jason and Bernie. Between the two of them, I got a slew of pattern projects to chew on, and some great insights to improve my pattern making as things go forward. I had to take some time after I got back from Maine to work on a few personal projects, but I'm able to devote the bulk of my free time for the last month of my summer to pattern projects.
I spent half a day making a pair of sleds to cut the draft for my patterns by machine planer in minutes, instead of hours with hand planes as I did with my first round of patterns. This obviously sped things up quite a bit, so within the first week and a half of work, I've been able to complete the fabrication of the pilot truck oil cellar, get pretty far along with the lead truck frame, and prepare most of the parts for the driving box oil cellar.
The sled on the right gets used first, and cuts a 2 degree taper along the length of (formerly) square stock until the taper extends the full width of the board. If the pattern requires, I flip the piece and place it on the 4 degree sled to cut the draft on the opposing face. I know Bernie and I use different construction methodologies, but if anybody ever can find this useful now or in the future, I hope it can save you some time.
Here's the pilot oil cellar. I'll actually assemble it over the coming academic year, since I can do the smoothing/finishing in an apartment.
The lead truck frame arches don't sit flush with the plane of the casting. The big upright sections are frame arches, while the shallower and wider pieces are the core prints which will be used to create the air space in the casting underneath the arches. The piece in the background is the core box shaping up. I still need to make some small pieces to add to the sides of the arches for the swing link bosses, and attach everything together. But this pattern is *nearing* completion- at least fabrication wise. Thats a 24" rule on the side, and a 12" up front for reference.
For all my patterns following the lead truck frame, I've switched to a marine grade plywood hoping it would be a lot easier to work with hand tools for the finer work than the cabinet grade stuff I used first. It has turned out to be a lot more consistent, but it sure is ugly!
In addition to wrapping up fabrication on the lead truck frame, I'm hoping to start work on the pilot truck journal box proper, finish the driver oil cellar, and perhaps start on the drive box. It is unlikely at best that I will make it to the drive boxes in the next couple weeks, but it gives me a nice goal.
