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Redneck Bending Tool
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 Posted: Tue Aug 4th, 2020 09:10 pm
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corv8
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Purchased a started - "Exacta" caboose kit from the dark ages (Fourties).


When unpacking, I realized why it was never finished... 

The body consists of one piece of very flat copper, apparently cast,
but looking like copper sheet.

The initial owner found no way to bend the body so it would look acceptable,
all corners were round; so he gave up.


I have built heavy (road) trucks for a living all my life,
so it was a challenge to adapt my BIG tools for this task.
(when I learned the trade, we bent complete truck frames from flat steel sheet)


Built a basic bending tool which has the essentials of our large machine back then
(it weighted 20 tons)

A piece of flat hi-grade steel 12 mm thick which represents the bottom die,
and a piece of steel plate as the "sword" which will be lowered on the sheet to be bent.

The "table" got a cut 3 mm deep, with edges camfered to 45°.
The "sword" is simply a piece of steel cut exactly at 90°.

Instead of the huge rams which press down the sword, I substituted two 10 mm bolts + nuts.
Welded the bolts to the "sword" and drilled respective holes in the "table" 
Total time spent - 25 minutes.


Pictures show the contraption with the caboose body clamped in it. 
Operation was successful, it has four nice corners now.
 
Have to fabricate a smaller version for the cupola corners too.












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 Posted: Fri Aug 7th, 2020 06:13 am
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Traingeekboy
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Good idea.

Now I need welding gear.





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 Posted: Thu Aug 27th, 2020 07:48 pm
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corv8
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Only a picture of the caboose as it looked last weekend... 

Got all corners to 90°, cupola was difficult...
 
Then, as roof was missing I fabricated the respective pieces from copper sheet
(the body is copper too) from scrap left from the gutters of my house. 

Soldered all together... no glue on this thing!
State of the art in 1950!







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 Posted: Fri Aug 28th, 2020 05:18 am
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2foot6
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Looking good.


Is it common to have copper gutters in Vienna these days?

They were common in Australia, but not these days,
too expensive, but they last a long time.


.....Peter




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 Posted: Fri Aug 28th, 2020 06:54 am
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corv8
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When I built the house twenty years ago,
I did everything in copper.

Have many gables and dormers where copper was needed where tiles met walls...
So I did the gutters in copper too. 

Wasn't so expensive as I did everything with my own hands... 
Think the expensive part is the labor of the person who cuts and solders on the roof.




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 Posted: Sat Aug 29th, 2020 07:21 pm
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corv8
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Out came the rattle cans.... 
My special blend for Armor Yellow.... and red primer for underframe and roof.
 
Have deliberately used 0.5 mm wire for grab irons, and 0.8 mm for platform railings,
as I feel "scale" parts wouldn't be appropriate on a 70 year old car.

Found that there is no right angle on the whole carbody....
Seems the kit was distorted from the factory,
and the person who first tried to bend it to shape made things worse.

Cast underbody is not symmetrical....
Tried to improve the mess, with limited success. 







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 Posted: Sat Aug 29th, 2020 07:31 pm
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Traingeekboy
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Really nice work on the assembly and finish.







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 Posted: Sun Aug 30th, 2020 03:55 am
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2foot6
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Apart from the problems you have had with the model,

it has come up looking really well.


Just needs truck/bogies and couplers to finish it off.

:apl:

....Peter.




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 Posted: Sun Aug 30th, 2020 04:12 am
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Michael M
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Looking good!

Any thoughts on lettering?




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 Posted: Sun Aug 30th, 2020 04:26 am
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pipopak
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Ah!.  The good old days!.

In order to build a kit, first you should make the tools...

Jose.




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