Passenger Brake Van C1860

Discussion in 'G3' started by Jon Nazareth, 26 August 2021.

  1. Jon Nazareth

    Jon Nazareth Western Thunderer

    Thank you, Overseer, all clear as crystal.


    Not much to show today, just the brake shaft hangers, a pair of stepped collars for the brake shaft hangers and a pair of collars to stop the shaft sliding about.

    Jon

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  2. geoff_nicholls

    geoff_nicholls Western Thunderer

    My method of forming G3 springs is similar in principle to Jon's, but cruder, and probably meant more burnt fingers. The former is plywood, the brass rod pushed in a hole in the centre becomes a part of the spring with soldering. It's held in a vice during assembly of each spring. I try and pre-form each spring leaf to make the job easier.
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  3. Jon Nazareth

    Jon Nazareth Western Thunderer

    First picture showing the build so far. Brake blocks with their hangers suspended from even more hangers (?). Not sure what they would be called
    I wasn't sure how to fix the springs in place. Normally there would be pins fitted into the backs of the springs which would be fitted and glued into holes in the W irons. I have done this on whitemetal springs but, I thought that I may break too many twist drills drilling into the laminates of the springs. I was thinking about this problem while in the shower and the idea came to me to solder the springs to the W irons. Each spring/W iron was placed and clamped into position and then soldered. With the first attempt, the heat travelled up the screws melting them very slightly into the styrene which meant that on disassembly, I had to unscrew the screws. I'm sure that you know what I mean. With the others, I clamped tissue, soaked with water, to the W irons which acted as a heat sink. After the soldering, the screws easily pushed out this time.
    In the picture, the spring/W iron units are held in place with 14BA machine screws and nuts with the spring hangers simply butting up to the solebars. I'm thinking that on final assembly, I may place a drop of Araldite on the hangers gluing them to the solebars but, they seem to sit okay at the moment without any glue. I'll have to give that one some more thought.
    The next job will be to machine up some small tubes which will be silver soldered to the backs of the brake hangers and will eventually take the brake rods.
    Second picture showing those whatdoyoucallthems.
    Third picture showing a goods brake van in the background. This build will be very similar except it will be painted green instead of grey.

    Jon

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    Last edited: 10 September 2021
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  4. Jon Nazareth

    Jon Nazareth Western Thunderer

    Overseer
    Pondering the braking system and the position of the push/pull rods and their connections to the brake blocks. There will have to be some very long spacers not only in order to make those connections but also to be able to clear all of the other gubbins like axle boxes et al. I can understand your statement when you said that this system wasn't very popular!

    Jon
     
  5. Overseer

    Overseer Western Thunderer

    While the drawing seems to show a pull rod outside the W iron it is more likely that they were actually close to the wheel face and behind the W iron.
     
  6. Jon Nazareth

    Jon Nazareth Western Thunderer

    Thanks, Overseer, as you can see, this is what I've done with this mock up.

    The fixing points for the brake rods have been silver soldered onto the brake hangers and the first connecting rods have been made and tried in situ, they fit! There's another on the other side. The rubber bands are to hold the blocks in the closed position while everything is tested and fitted in place. The rods as per drawing are shown as 2" wide and that's how these scale although they look a little over scale, ah well.

    Jon

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  7. Jon Nazareth

    Jon Nazareth Western Thunderer

    The rods are in place and, I must have done something right as they are all the same length. I started to fix in place the cross shaft with it's collars but, I noticed something didn't look quite right. I hastily removed the collars and shaft and wiped off the loctite. I'm not sure what it's called, the lever that can be seen in the third picture, is, according to the drawing, supposed to be connected to the rod that connects to the right angled lever that sits below the wheel and shaft. From what I can see, it can't do that as it would foul the wheel on the right hand side. I'll need to make another, (ah, just thought of it's name, 'actuating arm') actuating arm that connects just to the brake blocks and the one shown in the photo can be slid along in order to make the whole thing work. If you page up to the drawing, hopefully it will be seen what I'm babbling about. :D
    Because of the way that the brake rods are set up and in order to clear the wheels, I had to make up two lots of spacers, some 1/16" and some 3/16"

    Jon

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  8. Jon Nazareth

    Jon Nazareth Western Thunderer

    P.S. There is a bracket that holds the elbow crank, which connects to the brake standard, that needs to be made. The drawing doesn't show the said bracket so, I've got to work something out for that.

    Jon
     
  9. Jon Nazareth

    Jon Nazareth Western Thunderer

    All of the cranks and rods have been fitted. The brass collars were originally held with loctite but, on assembly, they one by one fell off, these have now all been soft soldered into position. The next job is to make and fit the shaft and housing in order to have the brakes working. The making and fitting of the brakes et al have proved a bit of a trial, fitting and applying the nuts and bolts especially so. I'm hoping that I can get it all back together again after all has been removed for painting.

    Jon

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  10. michael mott

    michael mott Western Thunderer

    Lovely work on the chassis so far. It is so nice working at a scale where one can use real nuts and bolts, it gets tricky when one needs to make the square ones though.

    Michael
     
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  11. John Gledhill

    John Gledhill Member

    That looks absolutely stunning Jon, well done!

    John.
     
  12. Jon Nazareth

    Jon Nazareth Western Thunderer

    This is as far as I'm going with the underframe at the moment and will move on to the body. The brake shaft is fixed to this box/cupboard and I think that I'll be able to place it more easily once the body has been made up.

    Jon

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  13. Jon Nazareth

    Jon Nazareth Western Thunderer

    This is my method for bringing all of the various pieces to length.

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    Here is the first side frame all assembled. The framing jig is the same one that I used to make up the underframe. Also in the picture is a small square that I made up so that I could fix the uprights vertically.

    Jon