Today, I retrieved the Proxxon MF 70 from the shed workshop, and set it up on my bench in the warm. The aim was to begin milling out the spaces required to fit the Kadee coupling gear boxes in each of the floor mouldings.
Before I get into that, I am reliably informed the coaches I'm building weren't dual braked. Sorry, Graham.
They were dual heated, though.
Anyway, on with the milling...
It's only a tiny mill, and getting a lengthy resin moulding clamped to the bed is an exercise in itself. Using a combo of proper bed clamps and some modelling clamps and an offcut of timber, I managed to get the floor moulding held firmly so it won't fly about if the cutter snatched.
First, I have to mark out the area to be cut.
This new generation of Kadees uses a plastic moulded gear box, instead of the older cast metal ones. I made a rough and ready plastic sheet template, and worked out the original moulded slot is just a tad narrow. It needs to be about half a millimetre wider each side. The depth to cut is down to the moulded step level in the vee slot. Using a set square and black marker, I marked out the area to be removed. Filling in the area with the marker meant I could see where the cutter had been, at least at first, so I could gauge the correct cut.
As you can see, a slice needs to be taken out of the crossmember. I also had to allow for an overcut into each corner to allow for the shape the cutter leaves.
Here's the rig with the floor moulding firmly clamped in place. I used a 3mm diameter cutter, and the rotation speed was about 11k RPM. It's soft material, so it doesn't need to be spinning much faster.
Ready to go. I didn't start in the middle. I actually started on the far edge, and cut about a millimetre away at a time. I think, since the material is quite soft, I could almost get away with a full depth cut. That might speed up the process, anyway. Essentially, I made a cut, stopped everything to clean up and check things, then repeated the process until the full depth required had been removed.
Yes. It gets a bit messy. The "swarf" tends to stick to everything by static, and I was continually stopping the machine to blow and brush the stuff away so I could see where the cutter had got to! After this first "proving" cut, I rigged up the vacuum cleaner to try to keep the mess under control.
I ended up with a nice interference fit for the coupling gear box on the first attempt. Okay, a couple of passes with a fine file and a little surgery to remove some blockages, but it was nice and snug. I guarantee that'll be the last time in this build that'll happen! A little slop won't hurt, though, as the gear box will be held by a bolt through the hole meant for the JLTRT buckeye. A smear of epoxy will help if required.
When I batch build like this, I tend to build one vehicle virtually through to completion. Like a prototype build for a real full-sized vehicle, this lets me find problems and work out any mods - like fitting the Kadees - before I get stuck into the remainder.