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

[John Candy]

Link to screenshots of the STL modules 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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[John Candy]

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.

[Dave796]

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.

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

[Keith Bucklitch]

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

[John Candy]

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.

[Anthony Terranova]

Hi John,

Fantastic work.

Did you ever get around to the seating?

Kind regards

[John Candy]

Did 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?

[IanT]

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

[John Candy]

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

[Anthony Terranova]

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 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.

[IanT]

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

[Anthony Terranova]

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.

[Anthony Terranova]

Side elevation

[John Candy]

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.

[Anthony Terranova]

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?