Postby webenda » Sat Nov 01, 2025 6:22 pm
So, I sent this:
Can you analyze the following instructions for building a box car kit, optimize or make suggestions regarding the assembly process?Instructions
1. Assemble and mount metal underframe to wood floor. This assembly is held in place by means of the two bolster mounting blocks, part #3049. The round portions of the blocks fit into the predrilled holes in the wood floor as shown in drawing and held in place by means of two #4-40 screws used with two flat washers. Proper placement of cross braces can be determined by referring to the drawing and to the metal sides to be used.
2. Assemble wood ends, wood roof, and wood floor together using #20 wire brads and cement if desired. Make certain that the wood body is assembled with the floor, roof, and ends square with each other.
3. Use a #70 drill to drill the holes necessary for mounting the brake platform, ladders, brake housing, and roof walk supports and a #70 drill for the grab iron mounting holes and brake wheel mounting hole. The location of metal roof over the metal ends. If too tight, sand off ends of wood roof until metal roof fits snuggly over metal ends. The ends may now be mounted, making sure that they are centered from side to side and are flush at the roof, so that the metal roof will fit down properly over the ends.
4. Press the metal roof down over the wood roof making sure that it overlaps the ends and that it is down all the way. PLEASE NOTE: In our roof stamping operation, a curved corner results due to the die cut-off. File this small corner (or tip) flat with plane of end and side flange. Fasten down by nailing through each of four holes about ¼”‘ from each end. Next nail roof ribs in the center after which the ribs are gently bent over the edge of the roof and nailed in place. There are only Il roof ribs on this car. The first rib on each end is 7/8″ from the end. For cars with wood roof walks: Cut 10 pieces 11/32 long from 1/16 sq. bass wood strip.
File or sand one side of each piece to match contour of roof at center. Cement these pieces in center of raised roof panel sections using Walthers Goo or Adron Alphelcement or Epoxy. Make sure they are centered on the roof and edges are in a straight line. Cement roof walk to these pieces, centering the walk over the ends. Cut four pieces from 1/16 sq. basswood long enough for end walk supports. Cement first piece to roof 1/8″ from end, second piece 1/2″‘ from end. Cement end walk to these pieces. Drill holes for roof grabs through both end walk and supports.
5. For Cars With Brass Blaw-Knox Roof Walks: Trim ends of roof walk to 10 and 9/16″‘ overall; this will leave a crossbar at each end. Lay on roof ribs and center both ways. Glue or solder sides of walk to roof ribs. Pin roof walk end supports to end of car so that the walk is supported straight out from the last rib. Glue or solder the walk to the support. Fasten end walks flush to roof walk with outer end fastened to roof. Drill for corner grabs thru perforations in end walk. If you choose to solder roof walks in place, start at center and work to the ends making sure the walk stays lined up over center of roof. After this is done, roof walk supports, roof end platforms, and roof hand holds can be installed. Fasten AB brake set in place using model airplane cement and mount coupler pockets, first drilling mounting holes. (Coupler pocket on scale car only).
6. Before installing the painted and lettered sides, the entire car as built so far should be painted. The roof, ends. and underbody are painted according to the paint and scheme list which is included in the kit. The matching colors for the All-Nation kit are stated on the carton label. The metal parts should of course be cleaned with a good solvent such as naptha or lacquer thinner to remove traces of oil or solder flux. At the same time the car is painted the ladders, steps, grab irons, door channels and doors which will be used on the sides should also be painted.
7. The final step in completing this kit is to install the sides, mount the doors and hardware, and touch up the heads of the escutcheon pins used to mount the sides and hardware. The sides are mounted by sliding them underneath the side overlap on the ends, and fastening in place with escutcheon pins. It may be necessary to trim the ends to ensure the sides laying flat. Do this carefully, removing the same amount from each end.
----Wayne----
Back when I was growing up, if you didn't start someth'n, there wouldn't be noth'n.
--Merle Haggard