Disney American

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JBodenmann
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Re: Disney American

Post by JBodenmann » Fri Jul 16, 2010 8:09 pm

Drilling for the #00-90 screws.
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JBodenmann
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Re: Disney American

Post by JBodenmann » Fri Jul 16, 2010 8:20 pm

The headlamp body has been disassembled, the front and back clear drilled and the sides tapped for the #00-90 screws and re assembled. Here the top portion has been pulled together with masking tape. The masking tape will hold things together when the top holes are tap drilled. Then disassembled again and clear drilled and tapped. Remember...put it together, take it apart, put it together take it apart. Fiddle and fit, fiddle and fit. That's model building. The brass was well annealed and massaged to fit. The flanging operation of the sides required them to be annealed three times, the front and back only once.
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JBodenmann
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Re: Disney American

Post by JBodenmann » Fri Jul 16, 2010 8:23 pm

Here is the headlamp body so far. It is sitting next to the forming die. When the body parts were drilled they were on the forming die.
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JBodenmann
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Re: Disney American

Post by JBodenmann » Fri Jul 16, 2010 8:30 pm

This headlamp requires some panels with bevels on the edge. One panel .093" thick for the bottom, and three panels .062" thick for the back and sides. Here is the set up for beveling the panels. A stop on the right to align the panels and the head of the mill tilted to 30 degrees. Tilting the head of the mill is something I absolutely hate to do as getting it squared up again is a real fiddle.
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JBodenmann
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Re: Disney American

Post by JBodenmann » Fri Jul 16, 2010 8:45 pm

This is as far as I got before running out of gas tonight. Headlamp box fitted together, bevelled panels, and headlamp mount pieces cut out. Next up the bezel to hold the round glass. The door and latch for the fireman's side of the headlamp, the chimney bits, and the reflector and burner. Not a real oil lamp burner but it will look like one, it will have a mag light bulb. There will be a couple AA batteries in the headlamp. You will have to open the door to flip the switch. A little piano hinge about three inches long will also have to be made. Little baloney like this headlamp is just too much fun to make, several little puzzles to be solved, definitely not a project for a flatliner!
See you in the funny pages..
Jack
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JBodenmann
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Re: Disney American

Post by JBodenmann » Fri Jul 16, 2010 8:48 pm

Here are a few more while I am at it. Here is a stack base that I cobbled together. The boxes of goodies that George brought me had no stack base.
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Last edited by JBodenmann on Sat Dec 26, 2015 9:43 pm, edited 1 time in total.

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JBodenmann
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Re: Disney American

Post by JBodenmann » Fri Jul 16, 2010 8:50 pm

Here is the inner stack tube and the cinder deflector.
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JBodenmann
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Re: Disney American

Post by JBodenmann » Fri Jul 16, 2010 8:55 pm

And here is the stack on the smoke box. Dr Thee, who started this engine in the late seventies did a great job on the sheet metal parts of the stack. The stack is made just like the prototype with curved segments joined with nice neat rows of tiny rivets, beautiful! Not an easy part to make.
Happy model building
Jack
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Dick_Morris
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Re: Disney American

Post by Dick_Morris » Fri Jul 16, 2010 11:52 pm

Jack - the headlight is beautiful, as usual. I have an RRSC cast aluminum kit which has some really nice castings, but your sheet metal work looks much better.

For anyone wanting to build a stack, the Disney drawings show it fabricated from individual sheets. The RRSC drawings just show two pieces of spun brass.

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JBodenmann
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Re: Disney American

Post by JBodenmann » Tue Jul 27, 2010 8:52 pm

Here are a few shots of the headlamp. First, spinning the reflector, .062" copper on a wooden die held in place with the live center pushing against a brass cup. Aluminum would be better for the die but I didn't have any 3" diameter aluminum. Get R' done. You can also see in the photo a ball bearing with a round aluminum tire mounted to the end of a length of 1/2" x 1/2" HRS. This is the roller that will form the reflector.
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AReflector1.jpg

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JBodenmann
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Re: Disney American

Post by JBodenmann » Tue Jul 27, 2010 8:59 pm

Here the reflector has been zoomed once with the roller. After being well annealed it was spun at 500 RPM and the roller was pressed against it using the carriage and cross slide. The first thing that always happens when spinning something like this is pie crust around the edges. Wigglepalooza!
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JBodenmann
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Re: Disney American

Post by JBodenmann » Tue Jul 27, 2010 9:02 pm

Here is how to deal with the wiggly edge. Rawhide mallet on the steel table. Gently flatten out the pie crust edge. Then re anneal and back on the die for more spinning.
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AReflector3.jpg

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