The CWR (Continuous Welded Rail) Train Thread

[fcnrwy23]

The CWR (Continuous Welded Rail) Train Thread


September 16, 2017

This train will be the longest of the MOW projects that I have done.  I started to research this one right after; I had finished the BCT.   

What this Train does...
The CWR or Continuous Welded Rail train, is used to transport on average, usually about 9 miles of welded rail, carried in ¼ mile lengths.   The Rail is 'pulled off" the train, by first pulling a single stick of rail down to the edge of the roadbed.  The end is then secured in place, to the existing track with a set of chains. The rail remains stationary as the train moves away from it.  When the end of the current stick is reached, a "Fish Plate" is mounted to it and the next rail to go.  The Train then continues down the line, repeating the process.   At Grade (Road) Crossing, either one of two things will happen.  At a Major crossing, the rail is cut (torched) to keep the road clear.  At a minor crossing (residential, example) the rail is buried with fill to allow usage of the road, until the Rail replacement process begins.
The CWR train would proceed the arrival of the TRT train...

A CWR in action.

The Model.

In designing the CWR, the first project was creating the "Rail Handling Cars."
I first had planned on using for the Handling cars, Atlas 50-foot flatcars (10 will be used). Since, most of the trains that I have seen on video use flatcars.
   But, the main concern that I had was what the "torque" (I will call it "Clothesline force") that would be placed on these cars. I figured that a dozen or so, pieces of rail would be a good load to carry.
But, the "weight" or lack of, on the Atlas 50 footers was stumbling block.  After more research, I found that CSX had / has used old gondolas for this task.  To find out, if the gondolas were a better option, I decided to do a weight comparison.  The Atlas flats came in at, 0.4 of an ounce  each.  The Roundhouse gons came in at 0.8 ounces.  The gons would also offer me more structural support for the Rail "racking" system that I would have to also create.


The initial three types of cars used on the CWR.  Gondolas (Handling Cars), Flatcars (Guide and Pinch Roller Cars).


The Rail

I intended to use .030 x .060 styrene dim stock to simulate the Ribbon Rail.  It is the closest in size to Atlas code 80.   The ribbon will consist of three (3) piece of stock (comes in 14 inch lengths, yes it also comes in 24 inches) cemented together.  This will make a 42" rail ribbon.   I plan on, "attaching" one end of each ribbon to the head car and allowing the rest of the rail, to "float" inside the racks.


The first test of the Rail Racking system.

The Racks

My first attempt on the racks, was to purchase some "knitting" squares.  Upon, getting a sample, it was clear the openings in the grid work are too big.  At least, "width-wise"  I will have to make some visits to the local "craft" stores to see whatelse is available.
The support for the girds will simply be, styrene "C" channel, glued to the insides of the gondolas.



Next Up...

The Guide and Pinch Roll Cars...


Jerry G.

[sd45elect2000]

http://www.nscalekits.com/

Might save some time using these. The rail is very flexable and good looking.

Randy

[fcnrwy23]

http://www.nscalekits.com/

Might save some time using these. The rail is very flexable and good looking.

Randy



Randy,

I am impressed by the product, Styrene rail.   One of the guys here at my house, helping clean the FCN layout. (I have an open house for the local NMRA meet, tomorrow).
Asked why he has never heard of this stuff before, you have it posted as 2009?.
Offering cast metal, "bunks" is a great idea in adding weight to each car.  But, the 18" minimum radius is a problem with my requirements.  All of my MOW trains have some requirements for minimal running.  The ability to maneuver a 9 3/4" track radius, is the Main One!.  Because, if it will do that, It will work anywhere! 
With the prototypical Rail profile, I am concerned about it's ability to flex enough for that requirement..

Jerry G.

[prbharris]

Might save some time using these. The rail is very flexable and good looking.

Thanks Randy. The 'flexible rail' is still available at www.nscalekits.com  - and comes in a 50ft length you can cut to fit. It seems as if this would work on your model really well. I like the idea of using the 'net' to retain the rail within the gondola. This will look great!

Peter Harris
N Scale Kits
www.nscalekits.com

[fcnrwy23]

Thanks Randy. The 'flexible rail' is still available at www.nscalekits.com  - and comes in a 50ft length you can cut to fit. It seems as if this would work on your model really well. I like the idea of using the 'net' to retain the rail within the gondola. This will look great!

Peter Harris
N Scale Kits
www.nscalekits.com

Mr. Harris,

On the website's video, how many "ribbons" were onboard, when it was running?
Has the train been "Tested" to run on 9 3/4" radius?    Has not?   Why Not?
Test it on 9 3/4" radius, and with as many rails as possible.  Let us know, good or bad! ..

I "torture-test" everything to make sure I get all the "bugs" out!!   
In my experimenting, I would normally assemble the train, than run it. And than, add "Rails" until it fails.  Go back and see what and why it failed and then make the changes or go back to the drawing board.  Whichever is required..

At present, I was hoping for 12 rails for the load.  That may NOT be a realistic result, with the flexibility that seems to be required.
It was suggested to me, Of possibility making the Rail out of packing foam (it is dark grey in color and very flexible, but, I would not know where to start in forming this stuff.  I can't work miracle's, People!  ).

I have been pretty fortunate, with things working out so far!    Who knows..

Jerry G.

[fcnrwy23]

October 7, 2017

Well for the time being, this project is on HOLD.
Until I can find flexible rail... 


Jerry G.

[prbharris]

On the website's video, how many "ribbons" were onboard, when it was running?

The cars on the video were running with nine 'welded rails' running through the bunks fixed onto metal cars. The video was shot when the rail was released three years ago on a modular layout - but the consist was used again at the UK International N Guage Show last month.

Has the train been "Tested" to run on 9 3/4" radius?

I have tested the consist on a 9 3/4 radius with the nine 'welded rails' in place. There is some buckling in the rail due to the differential in length between inside and outside rails [the rails are fixed onto the bunks in two locations along the consist] but there was no whiplash and the cars remained stable on the track.  Without the fixing there would be movement of the rails beyond the ends of the consist, something that I wanted to avoid.

I hope that this helps.

Peter

Peter Harris
N Scale Kits
www.nscalekits.com

[fcnrwy23]

Mr. Harris,

Thank you for the reply.

Since, my last post, It has been mentioned to me, that "Fixing" the rails at their "Center point". Would possible give the rail, the freedom of movement it requires.
Also, adding additional weight to the Handling Cars themselves, would also help.  I have a surplus of "Atlas" car weights on hand.   They are very thin, about .030" thick.

Right now, I have some Non-model railroad issues to take care of.  So, this project will be on hold for some time..


Jerry G.

 

[prbharris]

"Fixing" the rails at their "Center point" would possibly give the rail, the freedom of movement it requires.

Yes

Also, adding additional weight to the Handling Cars themselves, would also help.  I have a surplus of "Atlas" car weights on hand.   They are very thin, about .030" thick.

That would work too.

The plastic 'welded rail' is in stock whenever you want supply for the project, when you get going.

Peter

Peter Harris
N Scale Kits
ww.nscalekits.com

[fcnrwy23]

The plastic 'welded rail' is in stock whenever you want supply for the project, when you get going.

Peter Harris


Thank You,

Jerry G.

[fcnrwy23]

The CWR (Continuous Welded Rail) Train Thread

February 24th, 2018

I now again have time to revisit this project...

The CW Handling Cars....

Last weekend,  I added the additional car weights that I had in mind.  The weights are, thin sheets of metal made by the Atlas Model Co. for their 50 foot Flatcars.  I used two (2) shortened, (1 ¾" ) sections of the car weights.  The addition of these pieces plus the cast metal sills that come with the Roundhouse cars, brings the car's total weight to 1.2 ounces each.

Cars with weights added...



The gondola's weight according to the NMRA should be 1.1 ounces.  But I am assuming because of the body material removed (ends), that even with the addition of the metal weights.  I have only gained, (+) .1 ounces more.
    I am still trying to find a suitable, "Grid" (Bunks) framework for securing the rail in place. Something, "styrene" or "styrene-like" would be ideal.

I have also, just ordered the "N-Scale Kits"  CW rail and will see what I can make of it....

Next Up...

CW Handling Car Update ...
OR  The Guide and Pinch Roll Cars...


Jerry G.

[nkalanaga]

Two suggestions:

Replace the Atlas weights with sheet lead.  It can be cut to fit with scissors, leaving the car floor smooth; it weighs a lot more than the Atlas weights; and once glued in and painted, won't be health hazard.

For others wanting a similar train, if you can find a bunch of the old DI(?)/GHQ cast metal flatcars, they should solve the weight problem.  Those things are heavy.

[fcnrwy23]

The CWR Train

February 25th, 2018


Work has progressed on the Power/Pinch Roller Car.  This afternoon, I was able to fabricate the main sub-assemblies...

(2) Pinch Roller assemblies.  Made from styrene rod, tube, sheet and flat stock.
(2) Small, Diesel Engines.  Also made from styrene rod and flat stock.
And the filled-out the Safety Railings on the upper level...

The Sub-Assemblies..


The near-complete car...



I will put this project on hold, until the "Rails" arrive.  Than, I will have more information and know which way this project will go...


Next Up....

The Rails...


Jerry G.

[fcnrwy23]

March 3, 2018

Unfortunately, the Rails did not come in the mail today.
So, I turned my attentions to the other cars in the train...

Pinch Roller Car.. aka "RAPU" Continued....
This car (which I guess I should be calling the: RAPU = RAil Pick Up) is most detailed (modeling-wise) of all the cars on this train.  The "pinch rollers" "Grip" the rail allowing for it to be easily handled in the "Recovery" or "Pulling Up of Rail" process.  It is not usually used than when Rail is being "Laid Down".  It carries the same mechanical assembly, in the same order on both sides of the car. One for each rail, of course. 
The assembly consists of the following:  a Pinch Roller "Gripper" assembly, a Genset (power for the assembly), a Diesel Fuel tank for the Genset, the related Rail Guides and an Operator's Shack or Cab for keeping an eye on things.

Near Completed RAPU car...


Next Up....

The Rail Guide Cars OR the Rail...  Whichever comes in first..


Jerry G.

[fcnrwy23]

March 8, 2018

Hoorah!!  The Rails finally came, in Tuesday's mail. 

This is what 50 feet of rail looks like...


Close-Up of the Rail.


The rail does appear to be very pliable, which is encouraging.   I was hoping to carry at least, an dozen sticks on the train.  But, because of the packing it has gained a "Curled memory".  The accompanying paperwork, suggests to straighten it by using "Warm water" and some "physically manipulating" of the material.  I have tried that, but that has been proving to be difficult and incomplete process.
I decided to go, to a more "straight-forward" measure..

Well, I just got done stringing up the rail, out to "half" it's total length from my workbench vise,.  I've clamped the "loose ends" and used string to attach it to the conduit box, under the layout..   I am hoping that this will "straighten" it's mind.

The stretched, rail with a paper marker.  (so, I don't accidently walk into it)..


I will check-in on it, tonight and again tomorrow morning..

Jerry G.