Coach construction


Construction techniques

My coach design techniques are going through a major change at the moment as the result of new technologies becoming available.

Production status

Apart from the LMS PI suburban coach set none of the coaches listed on my website have been completed, but I am currently revising the SECR Birdcage carriages which got as far as being partially etched. When those are complete I will apply the same techniques to all the others.

The website prices will clearly indicate when something actually becomes available – they will also appear on the News page.

Kit contents

The current plan is to produce kits including everything you need from rail level upwards (paint, glue and battery excluded) – usually suitable stock for each loco as it is produced.

    Wheels – steel  – with 3Dprinted overlays for Mansell type

    Bogies – JVR J-type – etched with etched/3D printed side overlays, ball-raced axles

    Carriage ends complete including buffers and all fittings – 3D printed with flexible 3D printed gangways where fitted. Couplings & hoses.

    Etched sides with polycarbonate glazing and laser cut and engraved ply inner walls.

    Laser cut and engraved ply floor and partitions

    3D printed seats and internal fittings

    Etched luggage racks

    All parts below floor level are 3D printed – except the etched solebars

    3D printed ventilators and lights where visible

    LED interior lighting – battery powered

    Removable roof – most probably ply, partially cut as planks just like the real things.

Note that 3D printed parts are high resolution in UV cured high strength & high temperature tolerant resin

Prices may change a little as a result of level of detail and construction methods.

The website loco prices page gives all the diagram numbers for the coaches currently planned, but this list may expand or contract as production gets nearer.

Specifications may vary.   Sample instruction drawings for LMS PI suburbans carriages are shown below.

JVR J-type bogie

LMS 9' bogie (JVR J-type)
LMS 9′ bogie (JVR J-type)

 JVR J-type bogie – possibly the simplest form of fully compensated bogie. The central structure is flexible, with outer parts hung onto the centre of bogie sides with clearance allowed for movement.

Still to add – centre pivot and spring,
                   dummy central bolster
                   dummy brakes

First class compartment

LMS PI - 1st class compartment
LMS PI – 1st class compartment

Typical construction of a single 1st class compartment. In practice these are usually in groups with continuous side panels and droplight panels.

Note that the compartment partitions normally have roof racks on both sides (obviously excluding the end partitions).

3rd class compartment

LMS PI - 3rd class compartment
LMS PI – 3rd class compartment

Typical 3rd class compartment construction  – similar to 1st class but no seat rests.

Composite coach – complete interior

LMS PI - compo - body inner assembly
LMS PI – compo – body inner assembly

Typical construction of a composite coach – made up of the above two types of compartment but with continuous floor & side panels. Note the droplights are in groups of  1st & 3rd compartments.

Brake 3rd coach – complete interior

LMS PI - brake 3rd - body inner assembly
LMS PI – brake 3rd – body inner assembly

Typical construction of a brake 3rd coach

Roof

LMS PI - 3rd class roof assembly
LMS PI – 3rd class roof assembly

Typical roof construction. The top panel is wrapped around the formers and glued together. The cantrails are added, the cornice/gutter strips are folded and glued in place below the cantrails. The bits projecting down from the cornice hold the coach sides in place.

The roof is removable – held down at each end by a screw.

Still to add – the LED lighting in each compartment, the ventilators and rainstrips.

Still to follow – external side structure, underframes and variations for brake coaches,