Almost two years ago, I prepared a series of OpenSCAD files to 3D print the ends/sides/detailing for a series of Gresley teak stock.
The original intention had been to use the prints as patterns for resin casting.
At the time, this was the thread where my efforts were described
http://g3forum.org.uk/index.php?topic=2709.15
For a variety of reasons I was distracted and the patterns and moulds were boxed and stored.
Now I have made further progress with 3D printing of GWR and GCR stock, I have resurrected the Gresley stock with the intention of 3D printing most parts, rather than casting.
There are "bulky" components (e.g. the coach ends and domed roof end components) which I may still cast, since the print time is long.
I have made minor revisions to the original SCAD files to reflect the change of production method.
I shall (over the next few weeks) be uploading (as "zipped" STL files) bundles which produce individual diagrams, including those mentioned in the original thread.
I have been prompted to do this following expressions of interest by more than one party.
LNER Gresley Stock
The first downloadable package is now ready.
As a "starter" test piece (before moving on to the bogie coaches) here is the 32ft 4-wheel PBV to diagram 120.
https://gauge3.info/downloads/LNER/D120.zip
Pack consists of 3 side files, the ducket and the non-gangwayed end.
Each side is made from 2 sections (max module length <260mm) but the section which includes the guard's compartment is different for each side (only one side is fitted with a guard's lookout/ducket and that side has a plain panel to accommodate).
Note that all Gresley 4-wheel PBVs are not the same: Dia 120 (built 1928/1930 Stratford and York) were total new-builds on steel underframes, whereas diagrams 170/176/177 (built Darlington 1933 and 1935) were on secondhand Howlden GNR timber underframes of varying, slightly shorter, lengths but with 6 inch longer wheelbase. D120 also differed from the others in having opening/swivelling toplights to the outer panels, with rain deflectors above.
LH side module.jpg LH side module 2.jpg RHmodule.jpg
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The 52ft 6in Gangwayed Brake Third Open to dia. 217 is currently test printing and will be available in a few days also
in preparation are the 52ft 6in Gangwayed Third Open to dia. 216, to be followed by 61ft 6in stock.
Excellent, these will easily fit my Solvol bed John. Thank You!
I think one of these will have to go to the top of the print list. I ordered some "Burly Wood" PLA but on arrival it's a rather pale beige colour. It will get painted, so I guess it doesn't really matter but telling the actual filament colour from a web page clearly isn't that straightforward.
Regards,
IanT
A Trio of Gresley Coaches.
Link to screenshots of the STL modules https://gauge3.info/LNER_modules/index.html
The 61ft 6in D5 SFO (Semi-Open First)
This coach incorporated an open saloon of three first class seating bays together with four compartments served by a side corridor.
They were useful coaches to supplement the first class seating of a restaurant car.
They were built between 1928 and 1931 and ran on turnbuckle underframes.
The files to print the sides are at
https://gauge3.info/downloads/LNER/D5_SFO.zip
The maximum module length is 337mm (a package containing shorter modules will be provided later).
The large saloon windows were fitted with the shallow Stone's pattern glass vane/louvre vents: The file is in the accessory packs and will need either:
a) to be printed in clear material ... or
b) a pattern printed from which to make a mould to cast in clear polyester resin (my preferred option)
Either way, the frame will need to be painted.
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The 52ft 6in D140 FK (Side Corridor Gangwayed First)
The first two were built 1929 for the Cromer Express service and ran on riveted turnbuckle underframes. Later builds in the 1930s (the last were built in 1938) would have ran on underframes with angle-iron trusses.
The compartment side had doors to each compartment; on the corridor side were large windows which were NOT fitted with sliding ventilators.
The maximum module length is 332mm (a package containing shorter modules will be provided later).
The files to print the sides are at
https://gauge3.info/downloads/LNER/D140_FK_52_6.zip
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The 61ft 6in Buffet Car to D167
The most numerous type of Buffet Car was to D167, built 1933 to 1937, on angle-truss underframes. Some Lots had gas cooking equipment and others electric equipment, leading to variations in underframe fitments.
The maximum module length is 286mm (a package containing shorter modules will be provided later).
https://gauge3.info/downloads/LNER/D167_Buffet.zip
All the larger windows (on both sides) were fitted with top ventilators of the deeper, sliding, pattern (available in an accessory pack they are an interference fit into the window aperture.).
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The ends suitable for all the above diagrams are at
https://gauge3.info/downloads/LNER/Gresley_9ft_end_gangwayed.stl
The domed roof end
https://gauge3.info/downloads/LNER/Gresley_roof_end.stl
The LNER/Pullman type gangway connector
https://gauge3.info/downloads/LNER/Gangway_Connector.zip
Underframe accessories (battery boxes, dynamo, vacuum brake parts)
https://gauge3.info/downloads/LNER/underframe_detail(1).zip
Window top ventilators (3 types)
https://gauge3.info/downloads/LNER/window_vents.zip
The seating and other interior parts will be packaged into bundles appropriate for each carriage type and uploaded once the files for the remaining diagrams have been completed.
When assembled, the ends and roof dome will require a little sanding to blend with the adjoining edges.
NOTES ON PRINTING : I am printing my parts at 80 microns and each side will take around 100 hours to complete (i.e. 200 hours per coach). Printed at greater than 100 microns, the tumblehome section will have obvious "steps", rather than shallow,easily removed, striations.
Currently undergoing final checks to the files prior to uploading:
D111/D154/D282 52ft 6in PBV (Passenger Brake Van)
D113 61ft 6in PBV (Passenger Brake Van)
D143 61ft 6in BCK (Corridor Brake Composite)
D182 52ft 6in TO (Third Open)
D216 52ft 6in TO (Third Open)
D217 52ft 6in BTO (Brake Third Open)
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"each side will take around 100 hours to complete (i.e. 200 hours per coach)"
Not sure my nerves could take that John - I worry about 16 hour prints. But excellent effort!
Regards,
IanT
IanT,
For "extended prints you really need a cube frame or delta type printer. The amount of shaking that a moving bed type would give the print base could free it.
Ian,
I have just completed two prints, one taking 31 hours, the other 42 hours!
Currently printing is the third module of one side of the D5 semi-open First .... indicated time 44hrs.
There have been three power "blips" over the past couple of days but the UPS ensured the printer kept going.
Regards,
John.
Diagram 167 = Cambridge Buffet Express
An unexpected surprise, but a delight to see it included.
8) 8) 8) 8) 8)
QuoteDiagram 167 = Cambridge Buffet Express
An unexpected surprise, but a delight to see it included.
Yes, I remembered!
John.
P.S. A note for anyone who has downloaded D120,zip before today ..... the file now includes the ducket/guard's lookout (which I forgot to include in the original upload) plus a couple of minor "tweaks" which you would be hard-pressed to notice!
Another Trio of Gresley Coaches.
Link to screenshots of the STL modules https://gauge3.info/LNER_modules/index.html
The 61ft 6in D143 BCK (Corridor Brake Composite)
This coach consisted of three third class compartments, two first class compartments, two lavatories (all served by a side corridor) and guard's luggage section.
BCK coaches were most often added to the ends of express services, to be detached at major junctions and attached to connecting services over secondary routes or to through services of another company.
They were built between 1930 and 1940 and the earlier Lots ran on turnbuckle underframes.
The files to print the sides are at
https://gauge3.info/downloads/LNER/D143.zip
The large windows on the corridor side were NOT fitted with sliding vents.
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The 52ft 6in D216 TO (Third Open).
53 coaches to this diagram were built 1935/36 and ran on angle-truss underframes.
The internal layout was a single open saloon, with six and one-half 2+2 seating bays and a pair of lavatories at one end.
Bucket style "tourist" seating was fitted to most and all the large saloon windows were fitted with the deeper pattern sliding ventilators (included in the accessory pack).
The files to print the sides are at
https://gauge3.info/downloads/LNER/D216.zip
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The 52ft 6in D217 BTO (Brake Third Open).
Just two to this diagram were built 1935/36 and ran on angle-truss underframes.
There were a pair of lavatories at the inner end, three 2+2 seating bays and a large guard's/luggage compartment, which occupied almost half the length of the coach. Open coaches were often used as excursion stock and needed plenty of space to accommodate prams (in the days before folding "baby buggies")!
Bucket style "tourist" seating was fitted and all the large saloon windows were fitted with the deeper pattern sliding ventilators (included in the accessory pack).
The files to print the sides are at
https://gauge3.info/downloads/LNER/D217.zip
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The ends suitable for all the above diagrams are at
https://gauge3.info/downloads/LNER/Gresley_9ft_end_gangwayed.stl (non-brake ends)
https://gauge3.info/downloads/LNER/Gresley_8ft_6in_end_gangwayed.stl (narrower brake ends)
The domed roof end
https://gauge3.info/downloads/LNER/Gresley_roof_end.stl
The LNER/Pullman type gangway connector
https://gauge3.info/downloads/LNER/Gangway_Connector.zip
Underframe accessories (battery boxes, dynamo, vacuum brake parts)
https://gauge3.info/downloads/LNER/underframe_detail(1).zip
Window top ventilators (3 types)
https://gauge3.info/downloads/LNER/window_vents.zip
The seating and other interior parts will be packaged into bundles appropriate for each carriage type and uploaded once the files for the remaining diagrams have been completed.
When assembled, the ends and roof dome will require a little sanding to blend with the adjoining edges.
Still to come are:
D111/D154/D282 52ft 6in PBV (Passenger Brake Van)
D113 61ft 6in PBV (Passenger Brake Van)
D182 52ft 6in TO (Third Open)
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Hi John, how are you planning on doing the roofs?
Regards
Simon
Hi Simon,
The inner ends of the domed sections have a 3mm rebate and I will print roof hoops of matching profile to fit along the length of the body as supports for planks/strips of suitable wood.
These will then be filled and sanded and I may cover with tissue and apply "dope" (as used by aircraft modellers).
That's the current plan but it could be that I will end up printing the roof in sections!
Regards,
John.
roofend.jpg !
Link to screenshots of the STL modules https://gauge3.info/LNER_modules/index.html
The 52ft 6in Passenger Brake Van (D111/154/282)
Built between 1928 and 1938, the earlier Lots ran on turnbuckle underframes with Fox pattern 8ft bogies.
Diagram 282 ran on the angle-truss underframe.
D111 had NO ducket, the other diagrams a single ducket.
The five files to print the sides are at
https://gauge3.info/downloads/LNER/D111.zip
For D111 the "no ducket" module should be fitted both sides.
The longest module is 198mm.
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The ends suitable for the above diagram are at
https://gauge3.info/downloads/LNER/Gresley_8ft_6in_end_gangwayed.stl
The domed roof end
https://gauge3.info/downloads/LNER/Gresley_roof_end.stl
Still to come are:
D182 52ft 6in TO (Third Open)
D113 61ft 6in PBV (Passenger Brake Van)
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Thanks John, looks like I may be using these great designs to add to my coaching fleet.
Link to screenshots of the STL modules https://gauge3.info/LNER_modules/index.html
The 61ft 6in Passenger Brake Van (D113/D245)
Built between 1930 and 1938, the earliest Lot to D113 ran on turnbuckle underframes with Fox pattern 8ft bogies. 8ft Gresley bogies were fitted from 1931 and, from 1936 on D245, Gresley 8ft 6in bogies with angle-truss underframes .
Be aware that earlier 61ft 6in PBVs (to D43) had different panelling and door spacings.
The files to print the sides are at
https://gauge3.info/downloads/LNER/D113.zip
The longest module is 190mm
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The ends suitable for the above diagram are at
https://gauge3.info/downloads/LNER/Gresley_8ft_6in_end_gangwayed.stl
The domed roof end
https://gauge3.info/downloads/LNER/Gresley_roof_end.stl
Still to come is the D182 52ft 6in TO (Third Open)
Link to screenshots of the STL modules https://gauge3.info/LNER_modules/index.html (https://gauge3.info/LNER_modules/index.html)
The 52ft 6in D182 TO (Third Open).
Coaches to this diagram were built 1934/35 and ran on turnbuckle underframes and Gresley 8ft 6in bogies.
The internal layout was of two saloons (smoking and non-smoking), with six and one-half 2+1 seating bays and a single lavatory at one end (on the side of the coach having the two-abreast seating). Apart from the turnbuckle underframe, the main external difference between this and D216 was the panelling on the side opposite the lavatory.
The seating was conventional (not the bucket type as fitted to the 2+2 arrangement in D216) and, having arm rests , made it more like first class than third, since the car seated just 39 (compared with 52 in the D216).
All the large saloon windows were fitted with the deeper pattern sliding ventilators (included in the accessory pack).
To summarise, the internal differences compared with D216 : -
D182 divided into two saloons, seating 39 in a 2+1 seating layout and just a single lavatory (luggage racks fitted in vestibule on opposite side to lavatory... hence different external panelling).
D216 just a single saloon, seating 52, with 2+2 seating layout (majority fitted with tourist-style "bucket" seats) and a pair of lavatories at one end.
The files to print the sides are at
https://gauge3.info/downloads/LNER/D182.zip
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The ends suitable for the above diagram are at
https://gauge3.info/downloads/LNER/Gresley_9ft_end_gangwayed.stl
The domed roof end
https://gauge3.info/downloads/LNER/Gresley_roof_end.stl
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After considering using stripwood to "plank" the roofs of my coaches, I have decided to print them.
As I print each type, the files are being added to gauge3.info as STL/zip downloads.
The first to be printed is the D120 32ft 4-wheel PBV and the files are at
https://gauge3.info/LNER_modules/page13.html
The 61ft 6in, 52ft 6in and 51ft 1.5in patterns will be added over the next few days.
The full index of 3D print files can be viewed at www.gauge3.info
John.
P.S. 61ft 6in roof now added.
Quote from: John Candy on Feb 13 2023 20:37NOTES ON PRINTING : I am printing my parts at 80 microns and each side will take around 100 hours to complete (i.e. 200 hours per coach). Printed at greater than 100 microns, the tumblehome section will have obvious "steps", rather than shallow,easily removed, striations.
Hi John,
New on here, have been doing a few experiments and have found that printing parts vertically on edge results in much less layer lines, in fact coach roofs came out smooth enough to paint.
A 5mm brim gives enough area to stick to the bed on a Prusa i3.
I'm preparing a short article to help Ashley fill a page or two in the newsletter.
Regards
Dave
John.
On my (albeit gauge 1) model of the buffet car, I have been struggling with the roof creation for some weeks. My aim is to 3D print these although I have experience of creating the roofs using strips of thin ply glued onto formers, and with blocks of balsa wood to form the ends. The body of the roof is fairly straight forwards as can be seen in the image attached. The roof includes the rain strips and cantrails. Because of the size of my print bed, if I split the body, I can fit half the roof vertically for printing, with good results. To align the roof halves, they incorporate dowel holes, with steel dowels inserted for strength. Any subsequent joint can be disguised using plastic putty as supplied for Airfix kits etc.
It is creating the double curved ends so that they align properly with the carriage end panels. The closest I have achieved so far leaves a gap of about 1mm between the top of the panel and the edge of the roof. A friend made a good attempt at creating the end curves using Solidworks (I work in Fusion 360) but even though I could import his files as .obj files, it was impossible to get Fusion to accept them as 'native' files that could be subsequently worked on to extend the rain strips etc over the ends. If there is anyone out their well versed in Fusion who would like to have a go at forming the roof ends for me, or at least adding the rain strips, I would be happy to send them the files to have a go at.
Keith
Keith,
Afraid I do not use Fusion, only OpenSCAD which is a programmer's language as opposed to a graphical/drawing interface.
Have you tried rescaling my component to see how closely it matches your end?
Options I can offer are:-
a) I should be able to import an STL file from your Fusion drawing and then then "doctor" it and export as a STL file.
b) I could adapt my OpenSCAD file to match your end and roof and export as STL (I would need your STL file for the coach end).
Regards,
John.
Hi John,
Fantastic work.
Did you ever get around to the seating?
Kind regards
QuoteDid you ever get around to the seating?
I have a selection of 1st and 3rd class seats (including Tourist "bucket" style) together with Ist class and buffet car tables.
I didn't prepare the buffet car seating since I then turned my attention to other more urgent matters and didn't revisit the Gresley stock. The Gresley carriage parts are printed and in boxes, awaiting their turn.
I will send you a zip file of the items I prepared, almost 4 years ago.
John.
P.S. Is the email registered with your forum profile your current email?
I've found modifying STL files to be a challenge John.
I've imported a STL 'model' into Solid Edge but the original STL doesn't seem to have enough data to easily get back to a usable 3D 'model' - at least one that SE can fully manipulate and dimension.
I had an STL of a wheel that didn't meet the G3S standard (the flange was too deep). I couldn't just change the STL model as such but I was able to slice (cut) the flange off the wheel. Then I simply added a correct (new Solid Edge) flange to the modified hub/spoke to form an assembly to export as a new STL, which printed successfully. But I couldn't just change the original STL model using the normal SE tools...
So, with reference your reply to Keith above, does SCAD have the capability to import STLs and convert them back into usable SCAD code that can be re-written to produce a new model?
Regards,
IanT
Ian,
The "import" command does not convert the STL to OpenSCAD instructions but OpenSCAD code can operate on the rendering of the STL file.
To show what I mean, I have quickly prepared attached.
The step has been imported twice but in the lower example I have removed a section.
With your example of the wheel it would be possible to construct an annular module and remove ("difference" command) that from the STL object.
Hope this makes sense.
Regards,
John
Screenshot (38).png
Quote from: John Candy on Jan 04 2025 23:21I have a selection of 1st and 3rd class seats (including Tourist "bucket" style) together with Ist class and buffet car tables.
I didn't prepare the buffet car seating since I then turned my attention to other more urgent matters and didn't revisit the Gresley stock. The Gresley carriage parts are printed and in boxes, awaiting their turn.
I will send you a zip file of the items I prepared, almost 4 years ago.
John.
P.S. Is the email registered with your forum profile your current email?
Quote from: John Candy on Jan 04 2025 23:21I have a selection of 1st and 3rd class seats (including Tourist "bucket" style) together with Ist class and buffet car tables.
I didn't prepare the buffet car seating since I then turned my attention to other more urgent matters and didn't revisit the Gresley stock. The Gresley carriage parts are printed and in boxes, awaiting their turn.
I will send you a zip file of the items I prepared, almost 4 years ago.
John.
P.S. Is the email registered with your forum profile your current email?
Thanks John. Yes, that is my email address. I'm eagerly awaiting the delivery of my Neptune m4 max, then I'll get cracking. Probably do seats in resin.
I've got underframe drawings, so could make an interesting project.
Ah, I did wonder how that could work John. In some ways this is similar to what I've done with the 'wheel' I mentioned. I had to 'delete and then add' whereas you are kind of applying a direct 'overlay' but I get the general idea. I haven't touched SCAD for some five years now and I understand that there's been some major updates recently. I thought this might be one of them but I see it's simpler than that.
The SCAD approach does seem easier I will admit.
Regards,
IanT
Modified_Wheel_Parts.jpg
Not to detract from John's excellent work but I had a go at clip top buffers heads tonight. I need to find some more information on the stocks to do those.
Side elevation
Hi Anthony,
I am attaching a photo which you may already have seen....it is from NRM and has been published in books.
It shows the conventional buffers in the extended position on a Gresley underframe dated 1938.
Are you planning to have the heads cast in nickel silver from 3D printed patterns?
I an not sure printing in plastic would withstand the shock loads imparted by heavy Gauge 3 stock.
My GWR autotrailer buffer heads were cast from my PLA patterns to fit my PLA guides.
Regards,
John.
P.S. For those not familiar with Gresley GNR/LNER corridor stock, it was fitted with buckeye couplers and Pullman pattern gangway connectors which acted to absorb buffing loads when coupled to similarly fitted stock and the conventional side buffers were then retracted. The arrangement was very effective in preventing "telescoping" in a collision by keeping the the carriages "in line" and preventing overriding.
DSCN6764.JPG
Thanks John.
That was my intention but I need to find some dimensions of preferably a cross section and front elevation. They'll be done in castable wax resin like jewelers use and then turned into lost wax castings from there.
Not sure on buckeyes, that might be beyond me but in a rake, you wouldn't know anyway.
I've already got several works drawings of rivetted and welded underframes and details for a turnbuckle. Don't think the buffers are shown on them though. My new Elegoo Neptune 4 max will be here this week. Print capacity is 420 x 420 x 480mm, so she'll eat through it.
Might try orange PLA in future to skip one of the steps of painting the teak finish, it's worth a try I guess?