Casting AC&Y 3900 Series 50' SS Box Car

[peteski]

Yes, very nice.

How's the shrinkage? 


Jason

Isn't that what she said? 

[SAH]

I don't notice any shrinkage Jason.  The underframes I made about a month ago still fit perfectly so by that measure there is none. 

Overall I'm happy with the results.  There are some tiny air bubbles on the side of the SS box car but they don't detract from the appearance.  Both models have bubble holes in the ends.  Not a big deal since I'm making these castings for my personal use.  A different matter if I planned to offer them for sale of course.  I'd still lake them to be bubble free and am hoping the pressure pot will work its magic.

Steve

[SAH]

The prelims are over.  Time to see what I've learned.  Here's the master shell under construction.  Pretty straightforward.  I salvaged an MDC door that was pretty close to the proto rebuild.


The master ready for for mold making.  I shot the next few photos with a low light angle to try to capture some of the additions.  It looks like I caught some of the flaws too.  Should have done this prior to making the mold.   


The mold was cured in a pressure pot for 3 hours at 50 lbs.  Then the interior insert mold was poured and cured overnight without pressure.  There were NO air bubbles in the shell surface mold.  Lots of holes in the insert but since it won't be seen, no problem.

Here's the first casting.  Cured in a pressure pot for 60 mins prior to removal from the mold.  I was stunned at how well the mold filled and the quality of the casting.  No voids at all.  You can see the little nubs where the ladder and the bottom door track will go.  Fashioned from 0.019" and 0.022" brass rod.  They'll hold the ladder and track away from the body.  I was pleased they came out so well.  I also used Archer rivet decals to replace and add some missing on the casting.  I over sprayed them with a clear gloss to seal them in place prior to the mold making.  You can see them at the bottom sill in the last photo.  Worked pretty well.


A view of the side.  There are plenty of whoops and a few dang its in the casting but overall I think it will be OK when decorated.  Stay tuned for a finished model one of these days.  Oh, and I have to say I'm now a pressure pot believer.


Thanks for looking.

Steve

[peteski]

Very nice Steve.  One of these days I'll have to jump into pressure casting and multi-piece molds.  So far I have only been casting simple items in single-piece open molds.

I also smell a question coming:  how much shrinkage have you observe between the master pattern and the final casting?

[wazzou]

I also smell a question coming:  how much shrinkage have you observe between the master pattern and the final casting?

Funny..that's not what I smell.   

[skytop35]

Nice job Steve !  There's no looking back now.

[SAH]

I'm afraid you are right Bill.  I've done three already.  Time to invoke the "Rule of Three" (if you're gonna detail and paint one you might as well do three of them) and see how they finish up before pressing on.  The paint scheme is super simple but nothing like it at present in the decal market.  I guess the next domino to fall will be relearning the decal artwork game.

[SAH]

Detailed and painted.  Lots of flaws but not bad for a first attempt.  The flaws are less noticeable at layout viewing distance.  One thing I'll do next time is to take photos periodically during the master making process.  The camera doesn't lie. 

Thanks for looking and for all the advice TRW community has provided.  I doubt I'd have made it this far without your encouragement.

[SAH]

A final photo to close the loop on this thread.  I learned A LOT.  Casting certainly opens up a whole new range of project possibilities.  Thanks to TRW gang for your help and encouragement.

Steve

[Dave Schneider]

Now that is a great looking car!  It will feel good when people ask where you "got" such a unique model and you can tell them that you built it. Good job.

Best wishes, Dave