A small update as the W1 etches are back and need progressing.
The bolts arrived this week and like all others I've looked at, the heads are too deep, I presume this is so you can actually use them as bolts and the over deep head is for small tools to grip.
Out of the packet the heads are 1.0 mm deep, which is about twice as deep as they should be, so the question was, how to reduce the size of the head.
A mini lathe would be handy but the chuck on mine does not go this small, I can barely hold them with my fingers. So a cunning plan was devised, basically a hand made jig from some scrap brass that was 0.50 mm thick.
Place the bolts in the vice loosely and then with a bit of wriggling line them up with the jig, it's a simple jig with five 2.0mm holes in. Once the bolts are all square and in place then simply tighten the vice, file the heads and there you have it, consistent bolts with 0.50mm deep heads.
The visual impact is worth the effort, two of the super heater bracket bolts have the correct head depth, one is from the packet.
Finally an overall view when the W1 stopped play, not much to show other than the smoke box door flange is in place, ready for the brackets and door locking bars across the front. The two outer access doors on the baffle back plate are fitted and all that's required now are two handles on the outer doors and the four fixings on the middle door.
The door clips were a pain to make consistently and accurately but by the end they were turning out more like the real thing, having said that from the few images I've seen the real things are just tack welded on and level and straight are not two words you'd readily use to describe their fitment. Fortunately there's a front plate with mesh cinder guard to go on so all of this just needs to be representational, unless of course I'm make the cinder guards removable.
Mick D