Some pictures of the building process of my current (main) project, UP's M-10005 'City of Denver'
It started with the frame mainly made of 2"x1" steel tubes . Body-Bolsters are made of U-tube of app. 3/16" thickness.
Roller bearings were fitted into the body-bolster to get friction-less turning of the trucks.
Each truck has two 36V, 750W PM-Motors connected via chain and an idler to the axle. Two countersunk 'trays' in the middle of the unit holding six car-batteries in total lowering the center of gravity.
As already mentioned in another thread the shell was built up with fiber-boards for the side-panels, extruded metal panels (supported by cross members) for the roof and a foam-core for the unit's nose.
Then several layers of glass-fiber were epoxied inside and outside.
The interior of the nose with the foam core removed
Most of the cut-out for windows, grills ,doors etc. applied
And finally the shell (with grills, some window-frames, basic anti-climber, the final headlight-tube etc.) attached to the chassis - meanwhile I have raised the shell about 3/4" to avoid the overlap of the wheels and the shell.
The exhaust manifold is countersunk into the (white) detachable roof panel. The compressed air coolers, which were also mounted on this panel, have been finished last month (pix later).
The B-unit has been done up to the same status - currently I'm working on the lower skirts of the unit (thin steel tube-section as a basic layer covered with heavy glass-fiber layers).
Regards
Norman
