Re: Phase "Zero" / St Charles Coal Cars (Part 1)

Posted by Jim Courtney on May 29, 2016; 10:14pm
URL: http://c-sng-discussion-forum.254.s1.nabble.com/Phase-I-1902-C-S-Coals-tp5260p5284.html

OK, here is actual proof that Jim Courtney does indeed build C&S models in Sn3!

I'm working on a St Charles coal car c1909, using the same PVC kit, Mike's Shapeways stakes and other parts that Keith is using to build his 1930s version of a Phase 1 coal car.

So, I thought I would add my progress to Keith's thread, so we can build two similar (but different) C&S coal cars in parallel, and share our progress.

This photo from an April, 1915 thread (http://c-sng-discussion-forum.41377.n7.nabble.com/Ph1-Coal-Car-lookalike-on-the-F-amp-CC-td3080.html#a3085) began this project:


Courtesy of Doug Heitkamp


As Keith, Mike and I discussed how to build these cars, Mike tended to want to scratch build out of wood, while Keith and I opted to use the BLW/PVC phase 2 coal car kit, with its injected molded frame, floor and hidden weight as well as cast in coupler pockets.

Keith's post and a recent email finally got me off my butt and back to the work bench--this is my progress so far:



Not ready to haul coal yet, but getting there.

To modify the PVC kit, given the 9" side sills of the phase 2 cars and overly thick deck in the kit, I found that adding Evergreen HO 4x6 strip styrene (0.044"x0.066") to the bottom of the side sills came up with a new notched side sill of just shy of 12 scale inches.  Since the St Charles cars had individual corner irons, I couldn't use the PVC kit ends, so I sliced off the upper end planks from the end beam, carved off the phase two coupler striker casting and truss rod end bolts and made new wood buffer blocks:




For the St Charles cars, I'm using Mike's Shapeways stakes for the 1898 car: http://www.shapeways.com/product/3S69WJAEV/c-s-1898-partial-tapered-coal-car-stake-set-sn3?optionId=57782528. The holes for the mounting pins were laid out and drilled, 0.030" below the underside of the deck overhang, so the bottom of the short outer stakes would be flush with the new side sill.

I built my first pair of sides from S scale Evergreen 2x10s (0.032"x 0.1563") but found that when mounted to the floor against the stakes, Mike's stakes appeared a bit short (Mike's stakes are right on, the over thick PVC kit floor is again responsible).  

So I built new sides of Evergreen 0.030 x 0.156 strip styrene which made the 4-board sides just a wee bit shorter. The scale 2" thick side boards are a bit delicate, and one might use Evergreen 0.040 x 0.156 strip for strength (0.040" yields S scale 2.5" thick side boards).  I was surprised that the printed plastic stakes seem to weld to the Evergreen styrene with MEK pretty well, but will probably run ACC along the joints for strength.






For this car I will be using the 4'-0" wheelbase St Charles arch bar trucks, first produced by Cimarron Works, now sold by Paul Vaughn at PVC.  Keith will be using PVC's ASF 4'-0" arch bar trucks for his car. The St Charles trucks, from delivery until USSA refitting in the mid-teens, had outside hung wooden brake beams (see builders photo above).  I will be modifying Leadville Shops brass castings of wood brake beams/shoes to fit the trucks.

To modify the underframe, I removed the phase 2 brake cylinder mounts and added Evergreen S scale 1x8 over the bolsters to represent the plate bolsters of the earlier car.  I also added inboard brake beam hanger blocks and tie rods.  The main train line is Plastistruct 0.020 rod with PBL "tee" and Grandt On3 scale elbow castings for the cross over pipe. Many NBWs are in the future.




Next up will be the ends to give the box body strength, so's the side stakes don't pop off.