Fast "Forward".....LNER Gresley teak gangwayed/corridor stock.

[John Candy]

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.

[John Candy]

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.




 
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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.

[IanT]

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

[John Candy]

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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[IanT]

"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

[cabbage]

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.

[John Candy]

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.

[Doddy]

Diagram 167 = Cambridge Buffet Express 

An unexpected surprise, but a delight to see it included.

[John Candy]

Diagram 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!

[John Candy]

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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[hornbeam]

Hi John, how are you planning on doing the roofs?

Regards

Simon

[John Candy]

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.

!

[John Candy]

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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[hornbeam]

Thanks John, looks like I may be using these great designs to add to my coaching fleet.

[John Candy]

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)