ATSF semi-lightweight smoothside baggage car builds

[Lemosteam]

@arbomambo,

Bruce, methinks you might have some 0.553" or 0.563" axles mixed in with your 0.540"

Here is a cross section (orange lines) of the truck assembly with the sketch used to create the axle 3D turned on (green lines and dimensions):



The 6.858mm dimension X 2 / 25.4 = 0.540".

Are you having a hard time spreading the frames enough to get the axles in?

Were you able to clean the axle pockets with the Dremel 107 bit?  Sometimes wax and print artifacts can partially fill the axle pockets.

That is what this groove is to help with.  Insert on axle end, align the other point with the groove, spread the frame gently and push the axle down the groove:

[Cajonpassfan]

John, wow, what a pretty drawing
Sez a guy who still draws by hand...
Otto

[arbomambo]

I thought so as well...
However, a new package of .540 axles was opened and they are correct.
The design is beautiful; I did note the small designed gaps to allow axle placement without overflexing the trucks.
The .526 axles will arrive tomorrow.

[arbomambo]

The measurement, from inside flat face to inside flat face, (not dimple to dimple)
Is 15/32”.
The items may have printed smaller than actually designed.
I do think the .526 axles will work. We’ll see...

[Lemosteam]

The measurement, from inside flat face to inside flat face, (not dimple to dimple)
Is 15/32”.
The items may have printed smaller than actually designed.
I do think the .526 axles will work. We’ll see...

Do you have calipers for that measurement? As you can see, I am designing to three metric decimal places (0.0000 in inches).

[arbomambo]

I don’t have precision calipers for that measurement, but I can assure you that, as printed and delivered to me, the .540 axles are too long, and won’t fit. It’s apparent if one turns the trucks over and simply lays a .540 axle across the width of the truck.
Regardless,
SUCCESS!
The .526 36” wheelsets arrived in the post today and they fit PERFECTLY!

[Frank Amato]

That looks awesome @arbomambo !!!

  Frank

[arbomambo]

I can’t say enough good things about these printed express trucks.
They are incredibly well detailed and proportioned and really look the part under these unique baggage cars.
Finally, after a few years, we are able to have the correct trucks for these cars.
I’m thankful these were developed and made available!

[Mark5]

Cool that you found axle lengths that work! 

Makes me wonder if other 3d printed trucks have similar issues.

Mark

[thomasjmdavis]

Cool that you found axle lengths that work! 

Makes me wonder if other 3d printed trucks have similar issues.

Mark

I have three pairs of the Keystone Details Stillwell trucks- which were designed for .553 axles.  With a little light clean up, they were perfect fits for the recommended wheelsets.  So I don't think the 3-D printing process is the issue per se. 

Were you able to clean the axle pockets with the Dremel 107 bit?  Sometimes wax and print artifacts can partially fill the axle pockets.

John, is the Dremel 107 correct?  I've been using a Dremel 105 (which is smaller), which is what I am almost positive you recommended to me for the Stillwells.

[arbomambo]

The .526 axle lengths are a perfect fit...and allow free rolling performance.
The .540 axles are not; no matter how clean the dimples/pockets are. They are just too long.
I’m very pleased with the result, and, as the .526 axles are available, it’s a non-issue for me.
The trucks have been painted Floquil bright silver, and the wheelsets have been painted my dirty brown/gray.
After they cure, I’ll assemble everything and take photos.

[arbomambo]

[wazzou]

Wow!  Those are nice.  Congratulations @Lemosteam and @arbomambo

[Dirk Jan Blikkendaal]

My trucks (2 pair, printed by Shapeways Netherlands) were also a little bit tight for 0.540 wheelsets.
A little cleaning and reaming of the axlepoint cones solved that problem easily.
Used a cone shaped mill/drill bit in my motor tool at slow speed.
Trucks are extremely free rolling now......!

Splendid trucks all the way!
Thanks John....

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[Lemosteam]

All, to be clear, @TechnicalATSF commissioned these from me.  Regardless I appreciate the comments, as I know he will too.  Hoping to see the brake parts on one some time.

Looking at the images, I am wondering if @TechnicalATSF reduced their overall width before loading them to Shapeways.  They look like they are on the brink of being a little to wide for the car (which I do not have a casting of, so no good way for me too look at that aspect.  Sometimes its a toss-up between overall width, strength and axle length.  sometimes one of them has to give.

On the bright side, I was not aware that there were 36"x0.526" axle lengths.

@arbomambo , what brand are they?