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'Indian Railways' 4-Wheel Tanker - Brass 1:87
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 Posted: Sun Feb 14th, 2021 04:46 pm
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tusharpc
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Finally the brass sheet is immersed face down in a small bath of ferric chloride (etchant),
hot water is poured in another bath surrounding the etching bath to keep the solution warm,
this speeds up the etching process.

It took me about an hour and a half to etch through the 0.01” brass,
with occasional stirring and moving to ensure no etched away particles remain clinging to the brass.

Areas that require a half etch, for a relief feature or a bend line,
are exposed approx half way through the etch.





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 Posted: Sun Feb 14th, 2021 04:52 pm
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tusharpc
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When complete, the sheet is wiped down,
and rinsed in plain water, to stop the etching process.

The remaining vinyl covering the desired brass parts is carefully peeled off with a Xacto blade,
and the brass etch parts are ready for bending.

I’m very happy with the accuracy, sharpness and ease of the brass etch,
using mainly DIY and cheap spares available at home.





Brass parts are then bent based on fold lines (that were half etched).
And parts are soldered together.

I found using solder paste and a hot air solder gun ($45 on Amazon),
work wonders for control and precision.

The gummy/tackiness of the paste, hold small parts slightly,
allowing for a quick hot air solder.










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 Posted: Sun Feb 14th, 2021 09:52 pm
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Almostretired
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Thanks, Tushar, for posting this process.

I am familiar with etching circuit boards,
but I never thought to use the process like you did, to "cut" pieces from brass sheet.
Very clever.

I am intrigued by the hot air soldering instrument you used.
So I just spent a few minutes looking at the amazing retailer's website and was confused.
Are these also sold as "hot air reworking stations"?

Would you care to specify the one you are using?




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 Posted: Mon Feb 15th, 2021 07:48 pm
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tusharpc
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Almostretired wrote:  
Thanks, Tushar, for posting this process.

I am familiar with etching circuit boards,
but I never thought to use the process like you did, to "cut" pieces from brass sheet.
Very clever.

I am intrigued by the hot air soldering instrument you used.
So I just spent a few minutes looking at the amazing retailer's website and was confused.
Are these also sold as "hot air reworking stations"?

Would you care to specify the one you are using?

 
Thanks @Almostretired

I felt the conventional way of photo resist etching has too many steps,
and involved too many chemicals with several areas that could lead to inaccuracies,
the vinyl mask method leaves most of the precision stuff to the machines,
and just involves the one ferric-chloride chemical.

Besides, the vinyl cuter has multiple other uses as well,
including cutting thin styrene and decals.


Hot air soldering station:

This is what I have: link  This one is $45 as of Feb 15th 2021.
(yes it may be termed as a "reworking station" that works just as well)

It's important to ensure it can reach at least 400F or a bit more; power of 7-900 watts,
and reviews say they have good grounding (for safety).

The kits are good if you don't have any other instruments for soldering,
but just the device is good enough if you have other stuff.

Note

Don't confuse this with a standard hot air gun, available to seal stuff or shrink tubes,
they are cheaper but don't heat up enough for solder.


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 Posted: Mon Feb 15th, 2021 08:12 pm
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tusharpc
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3D printed resin parts:

Just like their 2D counterparts, 3D designs were created in Auto-CAD as well,
and exported as .stl files, to a resin 3D printer.

I won’t go into much detail on these here,
as many YouTube videos and online articles cover this well.

It's impressive what this little printer can produce in terms of size and detail,
at pennies worth of material.

Sure it takes a while (3-4 hrs for a print),
but if you compare it with scratchbuilding it yourself, and in large repetitions,
the resin 3D printer wins hands down.





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 Posted: Mon Feb 15th, 2021 08:18 pm
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tusharpc
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Final assembly:

Once all the brass parts are soldered,
I use Zap- A-Gap medium CA glue, to attach the resin parts.

Quick coat of primer and we’re done!


I used intermountain 38" semi scale wheels
which are held in place by resin 3D printed bearings (this ensures electric isolation).
 
And Kadee whisker couplers that are held in place by 3D printed draft gearboxes,
and a #2-56 screw (as is tradition)

:old dude:

Next on the agenda is weathering and decaling, but I’m going to leave that for another day.
(I don’t have the decals yet and maybe I will invest in an airbrush for weathering)

Before I splurge on an airbrush, I’ve set a goal,
to have at least 5 different stock cars or locos built in this process,
so I have enough subjects and justification for the sprayer.


Some more build and finished pictures below, enjoy,
and would love your comments and suggestions,
or any ideas that may spark to do this better?

- Tushar


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 Posted: Mon Feb 15th, 2021 08:20 pm
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tusharpc
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 Posted: Thu Feb 18th, 2021 08:56 pm
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Almostretired
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Wow, I am truly impressed!
Thank you for sharing.

I see some public libraries are offering 3D printing as a service,
my daughter's library is one of them.

Hoping my library gets on board with it some day, too.




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 Posted: Fri Feb 26th, 2021 10:16 am
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Si.
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Hi Tushar  :wave:


Great to see you Posting here on Freerails !  :thumb:


I am the Worlds BIGGEST railway modelling DIY fan.  :P

But when it comes to 'repetition', methods can prevent MADNESS.  :Crazy:


Your DIY home etched-brass, is an awesome way to avoid printed-masks.


It would be really good to see a 'mini-Thread' on the sticky-vinyl material ...

... in the Freerails 'Paper Cutting Machines' Forum.  L:


I have etched electrical PCBs, of copper on glass-fibre backing before ...

... but without using any complex silkscreen-printing or suchlike.


Your results, along with the resin 3D-printing look ACE !  :bow:

I count myself as a 'tankcar fan' as well !!  :java: :cool:


:moose: :moose: :moose: :moose: :moose:


Si.




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 Posted: Fri Feb 26th, 2021 05:23 pm
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Kitbash0n30
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Scratchbuilding while taking advantage of non-stereotypical tools and techniques,

cool stuff!






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