N Scale Business Car Build (NS/PGE/BCR/BCPM)

[AlbertSpor]

I would be in for several pairs as well to help the project, and they would useful for several cars I want to eventually do.
Albert Spor

[Lemosteam]

Revised prints are perfect, axles snap in with no cleaning and roll as good as the original MT trucks and look much improved over the Shapeways version. I will be offering for sale them this weekend.

[BCR 570]

Hi John:

That is good news and yes, happy to pay for new prints and shipping.  I have a new address in Point Roberts so domestic USPS shipping option.  I would probably take 2-3 pairs for any future Pullman-derived projects.


Cheers

Tim

[BCR 570]

Preparation of Roof (cont.)
After sanding the roof I could not really see the results of my work as the part is semi-translucent.  I decided that a coat of light grey primer would help me to see where additional sanding might be required:




More sanding with 220 grit sandpaper:




and then some work with 400 grit paper:




Front drip rail (.010" x .020" styrene) installed:




Rear drip rails installed (.010" x .020" styrene):




I made louvred vents from strips of styrene glued together, and a screen from etched metal:




Left side roof vent and front end roof grab irons installed:




Right side roof screen and vent installed:




Now for another coat of grey primer and gloss coat for rivet decals.


Tim

[BCR 570]

Underbody Details
With carbody details now installed, I am moving on to underbody appliances and details.  There is a fair number of items installed underneath and the arrangement has undergone significant changes during BCR ownership.  I began by surveying the underside of the car, measuring the various items and mapping their location underneath the car.

Once that was done I went back to period photographs from the time I am modelling to see where changes were made.  I then drew up a plan for the underside and began sourcing components.

Many of the components required are provided in the Keystone Details Underbody kit, and that comes with instructions for preparation and installation.  Here is my installation plan and the Keystone instructions:




The Keystone parts were de-sprued and prepared for installation.  The grey parts are the ones I had drawn and printed:




I began with the parts to be installed along the centreline e.g. centre sills.  The four rectangular plates contain the ends of the brake levers which protrude through slots in the centre sills.

The three piece assembly at left is the Pullman mechanical drive.  In its present form the car has a diesel power plant and fuel tank underneath which I suspect replaced the mechanical drive in later years.  This power plant is not evident in photographs from the 1970s so I have included the mechanical drive.  The three parts are connected with .015" brass wire.

There are two tanks suspended beneath the centre sills which I had printed.  The item at far right is the generator. 

Here are the centreline parts:




And here they are after assembly onto the centre sills:




Left side components are next.

Tim

[Lemosteam]

Hi John:

That is good news and yes, happy to pay for new prints and shipping.  I have a new address in Point Roberts so domestic USPS shipping option.  I would probably take 2-3 pairs for any future Pullman-derived projects.


Cheers

Tim

@BCR 570 , @AlbertSpor , @nickelplate759 , as promised, the Pullman 242 trucks are now available for purchase, see this announcement:https://www.therailwire.net/forum/index.php?topic=59564.msg842922#msg842922

[BCR 570]

the Pullman 242 trucks are now available for purchase

Excellent!  Will order some directly.

Tim

[BCR 570]

Underbody Details (cont.)
On with the left side underbody details.  I used a Precision Scale Co. AB brake reservoir and triple valve.  The brake cylinder is replaced by the Pullman brake actuator from the Keystone Details underbody kit.

The AB reservoir requires a mounting bracket which I fashioned from strip styrene:




Left side details ready for installation (from L to R):  electrical cable locker, air tank, battery boxes, brake actuator, brake reservoir and triple valve, equipment box, air tanks




Top view of left side underbody details installed:




Left side view with underbody details installed:




Tim

[BCR 570]

Underbody Details (cont.)
Over to the right hand side underbody details.  Ready for installation (from L to R):  battery charging plant, equipment box, battery boxes, water tank, air tank, equipment boxes




Overhead view of right side underbody detail parts after installation:




View of right side with underody details installed:




Tim

[BCR 570]

Preparation of Roof (cont.)
After priming and sanding the roof, it has received another coat of primer and a gloss coat in preparation for rivet decals:




The roof is rally smooth to the touch now.  The rivet strips will add some detail, and I can then install hte remaining detail parts:




Tim

[BCR 570]

Preparation of Roof (cont.)
After priming and gloss coating the roof, I applied Archer rivet decals using field measurements and photographs to locate them.  The precise location was sometimes difficult to determine due to the poor materiel condition of the roof but I think I got close:






Front end roof details are next.

Tim

[BCR 570]

Preparation of Roof (cont.)
With the application of rivet decals now behind me, I was able to move on to the front end roof details.  I had previously installed the drip rails and two front left grab irons.

I installed the longitudinal grab iron front left, formed from .008" brass wire to match the BLMA drop grab irons.  The three vent pipes were also formed from brass wire:




The two roof panels were rendered in 3D and printed.  The smoke jack is a Period Miniatures cast metal part  (SKU #2048 Cone Type Smoke Jack):




The trainphone antenna is next.


Tim

[BCR 570]

Preparation of Roof (cont.)
For the trainphone antenna I elected to use .008" brass wire with stanchions from the Gold Medal Models detail set for Kato smoothside passenger cars.  These are a little taller than what I measured on the prototype, but their use would make installation and achieving an even height much easier.  Two sets were required to provide sufficient stanchions:




The antenna cable goes down into the roof at the rear end of the car, so I started there by anchoring the wire into the roof and then installing the first stanchion:




I then worked my way forward one stanchion at a time, threading them onto the wire, installing them in their holes and then applying thin CA from below:




After installation I was able to tweak the alignment of the stanchions where needed to ensure they were upright and in line with each other:




The completed antenna is a little higher than on the prototype but the alignment is good so I can live with it.  This completes preparation of the roof:




I have a few tasks left such as the interior of the observation lounge, cut levers, curtain above the rear platform, and the replacement trucks which I am picking up tomorrow.


Tim

[BCR 570]

Trucks and Couplers (cont.)
Last week I received the new printed Pullman trucks from Keystone Details (thank you John!).  Hopefully these will enable me to have the correct trucks underneath this car:




As with the original trucks printed via Shapeways, the wheels did not roll freely upon installation.  Following John's advice, I used a spherical engraving bit from a Dremel tool kit to enlarge the axle housings, turning the bit by hand:




I also checked the FVM 3601 wheelsets to make sure they were in gauge:




After a bit of work I was able to achieve two free rolling trucks to go under the car:




A test run around the layout confirmed that the car will roll and track well:




Tim

[BCR 570]

Interior
The last major component for this build is the interior.  As we know, all business car conversions are unique in their layout, so the Micro-Trains interior will not be correct, but it serves as a useful reference for fabricating a new one:




My first point of reference was the original Norfolk Southern drawing for the car's interior layout:




From this I created my own drawing in N scale and adjusted measurements as needed to fit the model:




With the assistance of my friend Geoff, we drew the new interior in Blender:




The layout included rear observation lounge, bedrooms, dining room, staff bedrooms and galley:




Here is the resulting first print, next to the car.  Like the Micro-Trains interior, it is recessed underneath to accommodate the original Micro-Trains steel weight:




Here is the first interior print inside the car for a test fit.  Only a few minor tweaks are needed:






So I am now waiting on a final print for the interior and for the rear ditch lights, and that will complete assembly.


Tim