Best Of Scratchbuild Project - Van Iron Woodchip Cars

[nkalanaga]

Interesting that Precision Scale is now (apparently) owned by PF&S Railway Supply.  It's been nine years since I could get out to Pasco, but they had, and probably still have, quite a retail store.  Back then they weren't a manufacturer, though.

[cv_acr]

Wow these chip cars are coming out nicely. I really need to get my HO scale scratchbuilds back off the back-burner.

[BCR 570]

Internal Bracing
Following painting, it is now time to install the internal bracing.  This was left off prior to painting in order to be able to apply a good coat of paint inside the cars.  The inside of the cars was painted with a colour straight out of the bottle (Vallejo RUST) so as to be able to easily match it when painting the bracing.

On the prototype, the internal bracing serves to keep the sides from bowing out due to the weight of the wood chips.  They were a constant annoyance for mills as they often fell out of the cars into the screw conveyors during unloading.  it was not uncommon to see cars with one or more braces missing.

On the model, the braces actually serve to keep the sides from bowing in.  I use .020" x .020" strip styrene for the braces and I cut the triangular gusset plates from .010" x .060" strip styrene.  I referred to drawings and photographs for location of the braces, which differs from the cars built by Hawker Siddeley, National Steel Car or Railwest.  There is also some difference between the Series 1 and Series 2 Vancouver Iron-built cars.

The process begins with marking the location of the braces on top of the car.  This is done with a Sharpie marker.  The dots of ink will largely be hidden by the gusset plates, and will eradicated entirely when the braces and gusset plates are painted:




Next, for each car six lengths of .020" x .020" are cut roughly to length and gently sanded square at each end.  Due to minor variations in car width along the length of the car, each brace must be custom-fitted.  it is necessary to achieve a gentle pressure fit for each one.  If the brace is too long it will cause the sides to bulge out; if too short it will not remain in place when the glue is applied.  Here is a Series 1 car with six braces cut and ready for trimming:




After trimming, the brace is maneuvered into place with tweezers and sighted for correct alignment:




Liquid cement is then applied carefully at each end of the brace with a small artist's brush:




This process requires frequent minor adjustments to the length of the brace, which is accomplished with a fine cut file:




Here is a Series 1 car with all six internal braces installed:




At each end of the braces, a triangular gusset plate rests on top to help join the brace to the side of the car.  The gussets rest partially on the car side and partially on top of the brace.  I make these from .010" x .060" strip styrene.  After cutting .060" x .060" squares, I then chop them in half diagonally to get the triangles:




Prior to positioning each gusset plate, a small dab of glue is placed in the desired location:




The gusset plate is then installed on the model with tweezers.  These tiny parts love to fly out of the tweezers!




The tweezers are used to move the gusset plate into its correct position and alignment:




A little more glue is then applied in order to lock the part down in place:




This photograph shows a Series 1 car with all six internal braces and all of the gusset plates installed:




The Series 2 cars differed from the first order in having additional diagonal braces at each end.  These extended from the centre point at each end out to the joints with the nearest transverse brace.  A rectangular gusset plate covered the joint between the diagonal braces and the ends of the cars.  At their outer ends they tied into the gussets for the nearest transverse brace:




Here is a Series 2 car with all internal bracing and gusset plates installed, including the additional diagonal braces at each end:




This photograph shows all six cars after completion of the internal bracing and gusset plates, illustrating another spotting difference between the Series 1 and Series 2 cars:




This is a significant milestone as it is the last structural work on the cars!  The bracing and gusset plates will be painted to match the interior of the cars, and it will then be on to application of decals and weathering.  That is all the remains now to complete these cars.


Tim

[MK]

You must not be a coffee drinker!   

[BCR 570]

Decals (Part 1)
These models had to be packed up and put away for the recent move to a new apartment.  During the last few months work was undertaken to research the decal requirements, create the artwork and order the decals.  The decals have arrived and the time has now come to get these cars to the finish line.

For these cars I did not have any stencil diagrams or field measurements, so all of the decal requirements had to be estimated from photographs.  I have learned a lot about freight car stenciling in recent years so was able to make some educated guesses as to sizing.  The following image is an initial layout guide for the three Series 1 cars to be decorated in the original scheme with large P.G.E. initials:




I then forwarded my layout guide to Philippe Whyte who created the artwork on the computer for me.  Some elements of the layout were able to be adapted or borrowed from previous sets we have done.  Here is an image of the artwork for the three Series 1 cars in this scheme:




During the process of reviewing and proofing the artwork, I print it out on paper for the purpose of checking the fit on the model.  This photograph shows a printout of the reporting marks, data, and P.G.E. initials on the model for a test fit, which is compared to photographs:





The process was repeated for the two Series 2 cars I am modelling, which were delivered in the map logogram scheme.  Here is an image of my initial layout based on the few photographs of these cars available to me:




This image shows the computer artwork with two versions of the map logogram.  This logogram wraps around one of the side posts and appears to have been modified for these cars.  I will try out both versions of the map on a test section I built for this purpose:




Here is one of the two Series 2 cars during the process of test fitting the paper printouts of the reporting marks, data and map logogram:




I am also completing one of the Series 1 cars as repainted for the British Columbia Railway in light green with the dogwood logogram.  Here is my initial layout for the decal requirements:




The decals include reporting marks, data, CAUTION NO ROOF blocks, consolidated stencils and dogwood logograms.  Here is the finished computer artwork:




This photograph shows the light green car with paper printouts of the main decal components placed for the test fit:




Once everything has been checked, proofed and test-fitted, the individual sets are then assembled into a sheet for sending to the printer:




One important thing to consider during this process is to leave enough room for cutting between the individual decal components.  If they are too close to each other the task of cutting them out will be more challenging.  it is also helpful to leave space at the sides for holding the decal sheet with your fingers while cutting.


The completed decal artwork is then sent to Precision Design in Altona, Manitoba who does an excellent job of printing them.  The turnaround time is usually quite quick but for some reason (possibly our recent flood situation) this particular set got held up in the mail and has only just arrived.  Here are the finished decals:




So that is the process for getting custom decals created.  I will get these cars decaled during the Christmas break, and will be back with another update as that work progresses.


Tim

[BCR 570]

A Higher Level
I am taking a short break from layout re-installation to clear some lingering model projects.  I am hoping to qualify for the NMRA's AP Car Builder's Certificate and would like to use one of these cars for the models to be judged.  I elected to apply decals to BCOL 9590 first as I have some other BCR Light Green touch-up work waiting.  Before applying the decals, I wanted to try and super-detail the underframe in hopes of potentially increasing my score.  The additions included floor stringers and additional brake rigging.

Here is a view of the underside of a prototype car (with some of the brake rigging dislocated):




And here is the model with my additions, which will require painting to match:




Tim

[BCR 570]

Decals (Part 2)
On to decals!  I always begin with the end decals, and to support the car on its end I use a now very old roll of toilet paper.  I place a tissue down inside the centre to protect the opposite end of the car:




A close-up of the 'B' end with reporting marks and STEEL WHEELS/SPRG D3:




For the sides, I lay the car down on a sheet cut from a plastic shopping bag, which provides a nice slippery surface that won't harm the other side:




A close-up of the right side:




And a 'B' end right side oblique view:




Curiously this car received a relatively simple stencil scheme with no CAUTION NO ROOF or reflectors.  On to the next cars!


Tim

[SirTainly]

That's looking amazing! I do hope it helps get you the NMRA certificate.

[mmagliaro]

Tim, if this doesn't qualify as one of the 4 scratchbuilt cars for your NMRA Car Builder's certificate, the reviewers would have to be blind.   You've got all the documentation: prototype photos and measurements, and step-by-step photos of your construction, plus the model itself oozes accurate, excellent craftsmanship. 
As long as you show the proto photos and some step-by-step photos to prove you scratch built it, it can't miss!

[BCR 570]

Decals (Part 3)
The next cars to be decaled are the three in their original paint and stencil scheme with the large P.G. E. initials.  Cars still in this scheme could be seen into the early 1980s.  They will provide some diversity within my chip car fleet.  As before, I start with the end reporting marks and other stencils:




I then move on to the side stencilling:






Fully decaled cars:






Tim

[BCR 570]

Decals (Part 4)
On to the last pair of cars which represent the second series of woodchip cars built by Vancouver Iron & Engineering.  They came in the map herald scheme, and unlike the Hawker Siddeley cars they featured a map herald which appears to have been altered to go over the side rib.  My friend Philippe provided two different map heralds for me to try out on a test section of side which I built in styrene:




On the left is a standard PGE map herald, which is altered in appearance when it goes over the side rib.  On the right is a modified map herald which has been widened to compensate for the side rib.  The widened herald looks like a better match for what I am seeing in prototype photographs, but my placement was not quite far enough to the left.  Oh well that is what the test section was for.  On the cars I was able to position the map herald a little further to the left and the result was highly satisfactory:




Here are the two cars upon completion of decal application:




So all six cars are now decaled, and all that remains is to administer some paint touch-ups, apply the weathering and final seal coat, and install air hoses and trucks:




Tim

[BCR 570]

The Home Stretch (Part 1)
The six models have received paint touch-ups, and some weathering and final seal coat applied by Jeff Briggs.  For this next phase which is the home stretch, the cars are joined by two cars from the subsequent PGE 9766-9825 series which have been in service on my layout for several years.  The opportunity is being taken to upgrade them with the correct Atlas National C-1 trucks and brass air hoses:




The Atlas National C-1 trucks came from a Railwire colleague and were original equipment on their Hart ballast cars.  They are the correct trucks for both series of Vancouver Iron cars and the subsequent first series of Hawker Siddeley cars.  I equipped them with Fox Valley #3302 wheels which are the correct axle length for the Atlas trucks:




Prior to installing the trucks, I cleaned out the bolster pin holes with a #47 drill bit to remove paint.  It is necessary to use Atlas bolster pins as the Micro-Trains ones do not fit into the Atlas trucks.  The styrene pad underneath the car prevents damage to the internal bracing and gusset plates on top:




One has to be careful when installing the trucks at this stage.  I prefer to use a tool from Aztec for pushing the bolster pins home as it exerts the force only where needed.  The trick is to have the hole hold the pins firmly without requiring a lot of force to drive them in:




Again, the styrene pad is used to prevent damage on top.  After installation the trucks are checked for rotation:




Air hoses are next.

Tim

[nkalanaga]

I had never noticed that these were only 70-ton cars.  Interesting.  Similar cars in the Northwest US were 100-ton.

[BCR 570]

Yes, all of the chip cars up to and including the Railwest cars were 70-Ton and are referred to in Mechanical Dept records and drawings as such.  I would have to check on the later NSC cars delivered in the 1990s.

Tim

[nkalanaga]

By the 1990s I suspect they were 100-ton.  By then there weren't many 70-ton cars being built.

Any idea why PGE/BCOL preferred 70-ton chip cars?  Light rail? 

I'm not sure the 1960s/70s northwest cars, starting with the Gunderson plywood-side cars, would actually hold 100 tons of dry chips, but leave them out in the rain, and the weight would go way up!