Building The Canyon Diablo Bridge

[TrainCat2]

Quick shots of the remaining Overlays: P4-P5 and P5-P6 installed


P6-P7 and P7-P8 installed


P8-P9 and P9-P10 installed


The builder needs to complete the Top Chord Bottom Overlays for the other half of the Truss Frame.

[TrainCat2]

We still have a lot of Overlays to go. The next series is the Top Overlays for Bottom Chord. The first Overlay is between P1 and P2. It also will require small notches whose sizes will depend on the building skills of the builder. For that reason, these were not etched out.


The Overlay was measured and small notched removed with an X-Acto knife. On all of the Overlays on the Bottom Chord, the builder will need to align the Overlay being applied to align with the rivet patterns of the Side Overlays. Bottom Chord Top Overlay P1-P2


Bottom Chord Top Overlay P2-P3


Bottom Chord Top Overlay P3-P4

[TrainCat2]

Bottom Chord Top Overlay P4-P5


Bottom Chord Top Overlay P5-P6


Bottom Chord Top Overlay P6-P7


Bottom Chord Top Overlay P7-P8

[TrainCat2]

Bottom Chord Top Overlay P8-P9


Bottom Chord Top Overlay P9-P10


The builder needs to complete the Bottom Chord Top Overlays for the other half of the Truss Frame. Next up will be the Top Overlays of the Diagonals.

[unittrain]

That is one awesome bridge I love these kinda projects .

[TrainCat2]

The next series is the Upper Overlays of the Diagonals. The first Overlay is D1 (D1U). It also will require small notches whose sizes will depend on the building skills of the builder. For that reason, these were not etched out.


The Overlay was measured and small notched removed with an X-Acto knife. Test fit to be sure the Overlay will be orientated the correct way so the oval lightning holes will align. Some slight trimming may be needed on one end of the overlay to get things aligned. Installed Upper Diagonal Overlay D1U:


The installation of the Upper Diagonal Overlays begins to bring the structure to life since most of the detail is covering the raw soldered structure. Here is the installed Upper Diagonal Overlay D2U:


Installed Upper Diagonal Overlay D3U:

[TrainCat2]

Installed Upper Diagonal Overlay D4U:


Installed Upper Diagonal Overlay D5U:


Installed Upper Diagonal Overlay D6U:


Installed Upper Diagonal Overlay D7U. There will be slight variations in the structure because of the build process. The result can be minute overhangs of the Overlays. You can see one here before I use a few strokes of a file to correct.

[TrainCat2]

Installed Upper Diagonal Overlay D8U:


Installed Upper Diagonal Overlay D9U:


The builder needs to complete the Upper Diagonal Overlays for the other half of the Truss Frame.

[TrainCat2]

Down to the last series of major overlays. This group will be the undersides of the Diagonals and the Bottom Chord.
Installed Lower Diagonal Overlay D1L and BCL1:


Installed Lower Diagonal Overlay D2L, D3L and Bottom Chord Overlay BCL2 between P2 and P4:


Installed Lower Diagonal Overlay D4L and BCL3 between P4 and P5:

[TrainCat2]

Installed Lower Diagonal Overlay D5L:


Installed Lower Diagonal Overlay D6L:


Installed Bottom Chord Overlay BCL4 between P5 and P7:

[TrainCat2]

Installed Lower Diagonal Overlay D7L:


Installed Lower Diagonal Overlay D8L:


Installed Bottom Chord Overlay BCL5 between P7 and P9:

[TrainCat2]

Installed Lower Diagonal Overlay D9L:


Installed Bottom Chord Overlay BCL6 between P9 on the left to P9 on the right:


The builder needs to complete adding the Lower Diagonal and Bottom Chord Overlays for the other half of the Truss Frame.

[TrainCat2]

Applying Gusset and Batten Post Overlays On The Side Truss Frame

With the basic structure of the Truss Frame complete and all of the major Detail Overlays affixed to the structure, we begin adding the major details to the Truss Frame. First we will add several of the large inner Gusset plates to the interior of the frame where there is an I-Beam Post. We will not add the Batten Post Gussets until all of the small Batten Plates have been secured to the posts.

On the Interior Gussets, there are slots for Floorbeams up at the Top Chord and small slots for the Lower Sway Braces to the Bottom Chord. The Exterior Gussets do not have any slots in them and can have multiple layers of Gussets like the prototype does. Interior Gussets have only one layer to make the design, assembly and alignment of the interior components easier.

Normally the attachments for the X-Bracing on the bridge interior goes from the bottom of the Floorbeam down to the top of the Lower Sway Brace. Except for the Gusset at P2, the other Gussets at the knee of the Bottom Chord (where the Chord changes angles), will have the X-Bracing attachments soldered to the Gusset. P2’s Gusset is exempt since it does not have any X-Bracing. When walking on the Lower Walkway, you would have to duck down to pass under the Floorbeam at P2.

Before adding all of the Batten Plates, install the Interior Gussets for P1, P2 and P3


Afterwards add the Interior Gussets for P8, P9 and P10.


Notice that the bottom Gusset for P9 is not included in the drawing. This is because we will need to solder the X-Bracing attachments to the Gusset before installation and I will defer that for last as I do not want the attachments to get damaged during the Batten Plate installation.

[TrainCat2]

Interior Gussets for P1, P2 and P3


Interior Gussets for P8, P9 and P10


Test fit Floorboards FB1 at P1, FB2 at P2 and P3. Also test fir the Lower Sway Brace for P2 and P3. The same Lower sway Brace used at P3 can be used for P8 and P10.

[TrainCat2]

We are at the point that the Batten Plates need to be applied to the Batten Posts (P4, P5, P6 and P7) before we can add anymore Gussets to the Truss Frame. Here is an image of Batten Plates being applied to half of P4. Although time consuming, these plates are not hard to apply and the effects is 1000 times worth the effort.


It will take me awhile to get the rest of the Batten Plates on. Hope you are enjoying seeing the bridge come together.