3D printed Jordan spreader with lighting

[peteski]

Hey, you can give it a try and see how it works out. The positive photoresist spray I use doesn't require such a high temperature for drying it.  The material thickness is worrisome though.

[craigolio1]

It's been months since I worked on a model train.... so I decided to jump into a project that had caused maximum frustration, and it didn't disappoint.

First, I chickened out with trying to etch my own cab windows and decided to just scratch build the windows.  When I was looking for a kit to bring in for my 14 hour night shift, I hastily grabbed the spreader box with out much time to pre-plan what I would need to bring to work on it.  I had drawn some artwork for etching which would have been a great help as a template, but I didn't think of printing it until after I was at work and had gone through the project, taking an inventory of what I'd need.  So I decided to free style it. 

I used a drill to try to make rounded corners but I had no luck getting four holes perfectly aligned in styrene so I abandoned that.  I finally ended up cutting some 010"x020" strips and assembling window frames, with the intent of using filler to create the round corner.



This was satisfactory at 0200 after hours of frustration, but not so the next day.  So for the next night shift I printed the artwork for use as templates and got to work making the parts out of thin brass sheet.



I aligned the square with the corner of each window and used it to locate the drill bit. 



Prior to removing the template I scored lines between the holes, leaving room to file a bit away, and also scored lines for folding and trimming later. The result was still not perfect but definitely something I can live with.



For removing the centers out of the frames, I found that scoring each edge 5 times, then drilling a hole in the centre, and giving it a little twist with the bit popped it out.  I slipped with the knife on one frame which resulted in the centre frame being ripped out, but that's ok as those ones get all-weather window and styrene filler anyway.  Then i took a file to the frames and squared it all up.



I decided to leave some taps on the top so that I would have a surface to glue the roof to.  Here it is folded up.



Of course I scored one fold line to deep and it broke while folding, but that's an easy fix during assembly.

A test fit looks like it's going to work.



I still need to file down the cab to get the windows to sit down well.  I also need to figure out how to attach it to the cab.  I'm thinking of gluing the roof to the windows and then installing them as a removable part.  This will give me a large flat surface to align the parts on, instead of the cab edge.  This will also give me better access to the lighting circuit for soldering the wires from the platform and cab rooves.  Also I can then paint the roof assembly, and install the windows prior too installing it.  To align it with the cab I'm thinking  brass wire soldered in the corners.  The nice thing about the brass wire is I can bend it out a little to put friction on the walls to hold the roof assembly in place with out glue.

[Dwight in Toronto]

Oh man, Craigolio - I have to say that it’s a relief to see that you’re back!  I’ve often wondered if/how the spreader project was progressing, and the bridge piers etc.  Watching (again) with interest. 

[craigolio1]

Oh man, Craigolio - I have to say that it’s a relief to see that you’re back!  I’ve often wondered if/how the spreader project was progressing, and the bridge piers etc.  Watching (again) with interest.

Thanks Dwight.  I've spent the spring and summer working on an old VW I bought. Good to be back and I'm hoping to keep moving the spreader forward.

Craig

[craigolio1]

I got the cab roof assembled, including soldering on some all-weather windows.  Hopefully a coat of black will hide some of the blemishes.  The cab will stay like this until painted so that I can access wiring inside it.





With the cab complete, the main body is ready for paint prep so it's time to get back to the hydraulics for the wings.  The wings themselves are done but i still need four telescopic rams on hinges for each wing. 

For the rams I used brass tube and music wire, using the printed rams as templates for the length.  I'm not quite sure how I'm going to fix the music wire to the body.  I'm thinking a right angle bend then just hook it through a piece of styrene.



For the end that attaches to the wings, I need hinges that allow vertical and horizontal movement.



 I started by flattening one end of the tube and drilling a hole in it.  Then I took some left-over brass fret, made a c shape, and drilled holes in that.



To hold them together I threaded a piece of phosphor bronze wire through and bent a hook on each end.





Now I have my 8 rams.



Next up I need to build some more robust hinges for attaching the wings to the body.  One of them has broken off and i imagine the other ine will too eventually.  These parts will have stresses applied to them as I pose the wings, so they need to be tougher.

Finally, when the wings are out, the small wing panels on the front will need to open to accommodate,



 ...so I started on some hinges for those.



I'm getting very close final assembly!