instructions 1:48 O-SCALE BENT C ASSEMBLY FOR LOBATO TRESTLE 2014 John Palecki Structures rev 1

Transcription

1 instructions 1:48 O-SCALE BENT C ASSEMBLY FOR LOBATO TRESTLE 2014 John Palecki Structures rev 1

2 CONGRATULATIONS ON YOUR BRIDGE PURCHASE! THE LOBATO TRESTLE is a famous spot on the Cumbres & Toltec Scenic Railroad. It is north of Chama in New Mexico and crosses Wolf Creek. The prototype Lobato structure includes six plate girder spans and five bents. The tallest is about 75' with four stories. The Cascade Creek Trestle is near Osier, Colorado and is also used by the Cumbres & Toltec Scenic Railroad. The Cascade is longer with eight spans and seven bents; the center three five stories at about 95' tall. Both trestles are originally part of the Denver and Rio Grande Cumbres Pass Line between Chama and Antonito. They were both designed by the same engineer and were produced at the same time in the 1880s. The design has unique features. The girder spans are riveted together into one solid length with no expansion connections, except at one end abutment. The single-width bents are on pins so they can rotate slightly as the structure changes length in varying temperatures. The taller bent legs taper in size to be widest in the middle, with interesting curved-sided plates on the outside. The trestle consists of six deck girder spans of two lengths and five bents of varying heights. The model uses three different heights: a one-story bent 17 high, two two-story bents 47 high and two four-story bents 77 high. These instructions cover the assembly of the 77 bent. You can visit the prototype. The Cumbres & Toltec Scenic Railroad uses the bridge in the daily operations. It is on private land so the train ride is the best way to visit Lobato Trestle. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 2

3 KIT WARRANTY FIRST, please inspect the parts carefully through the packaging before opening. Some parts are quite thin so until you are comfortable with them preserve their integrity with cautious handling. Spare parts are not easily available because of the variability of my production.. JOHN PALECKI STRUCTURES WARRANTY: I am very proud of the quality of my kits. I personally packed your kit with care. I also inspect every part before it is packaged and boxed. DEFECTIVE PARTS: If you find a part that cannot be assembled due to manufacturing defects, I will replace the part. RETURNS: If you determine the kit is not what you expected I will take it back and refund your payment within 30 days of receipt of the kit, provided you purchased it directly from John Palecki Structures. Please note I cannot take back kits that have been started or have parts missing. Contact us via the information below before returning a kit. SUITABILITY: Because I can not control how the modeler assembles, installs or uses this bridge model John Palecki Structures cannot assume responsibility for any results the modeler may have in the model, application or use of the model. The model is to be used indoors only and kept out of direct sun and heat. The warranty applies only to the original purchaser. This kit is not suitable for children. It is a complex model to be assembled by experienced modelers. John Palecki Structures 3339 Collingwood Street NE Roanoke, VA USA john@jpstructures.com (best way to communicate) Thank you for purchasing a John Palecki Structures bridge kit! instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 3

4 KIT CONTENTS ETCHED BRASS PARTS: Bent C 6) Frets OTHER PARTS PER EACH BENT: 2) cast resin footings with threaded fittings and screws 1) Brass footing drill guide Brass wire for rods Brass tubing for turnbuckles Brass escutchion pins for rod links Brass rod for pins MEDIA: 1) CD-ROM with the instructions and photos 1) Assembly view drawing instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 4

5 INSTRUCTIONS INDEX SECTION ONE: SECTION TWO: SECTION THREE: SECTION FOUR : Pre-assembly..6 Common Parts Assembly...26 Bent C Assembly..30 Finishing instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 5

6 SECTION ONE: Pre-assembly instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 6

7 SECTION ONE: Pre-assembly-1 Bridge Kit Basics The entire trestle consists of four 54 deck plate girders span, one 40 deck plate girder span, and five bents of 47, 77, 77, 41 and 17 height. The bridge floor is wood with a walkway attached. The complete Lobato kit uses a 17 Bent A, two 47 Bent B and two 77 Bent C. These instructions are for Bent C. 40 span 17 bent 4-54 spans 77 bent 41 bent 77 bent 47 bent instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 7

8 SECTION ONE: Pre-assembly-2 Bridge Kit Basics The top layer of lacing bars and tie plates are on one part that solders on top of the Lacing. They are called the Overlay in the instructions. They are on a mini-fret that holds the small parts in alignment during soldering and is removed later. Each bent leg and strut beam are assembled in a similar manner. The prototype uses C-channels for the beam sides. Solid plates and angled (zig-zag) lacing bars connect the C-channel flanges. The etched model beams simulate this construction with these details: Overlay mini-fret. Top Overlay Top Lacing Sides Slots Tabs The C-channel flanges and the bottom layer lacing bars are on one piece. Slots line up with the Side tabs. These parts are called Lacing in the instructions. The beam legs and brace struts connect with flat plates called Gussets. Bottom Lacing Bottom Overlay The C-channel side etching is flat. They may have rivets. There are small tabs along the edges. They are called Sides in the instructions. Strut 1 assembly instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 8

9 SECTION ONE: Pre-assembly-3 Tools & Supplies The primary tools for assembling an etched brass bridge kit are quite simple but essential: 1. Brass cutters- MUST HAVE! Use a sharp, new cutter for cutting brass parts from the fret. The Xuron Micro Shear 440 is my favorite. The Micro-Shear 410 or other fine flush-cutting electronics clipper is necessary. Many of you will already have experience with brass frets so use what you know. I find it safer to cut the tab near the fret frame first, then trim it off the part later. 2. Soldering tool- The bents must be soldered together for strength. A resistance soldering tool works for most all of this kit especially if you are an experienced user. An electronics solder station may work better for some soldering, such as the edge connections on the thin parts. Micro-Mark has a lower priced resistance set, or consider the American Beauty line as well as the PBL unit for better quality and heat control. 3. Solder- Solder comes in several forms and alloys. A search of the internet will reveal a different opinion on every site. Some say electronics solder requires a too high temperature. This kit has no low-temp white metal castings so that is not an issue. I used regular tin/lead 63/37 electronics solder since I am most familiar with it. Model building solder is available from Tix and other brands. Use what you are familiar with, what you can obtain or what your favorite reference states. 4. Flux- Flux is critical to any type of solder and soldering. It is what makes soldering work. Flux is an acid that removes surface oxidation as the heated solder metal flows. Brass is covered with a layer of oxide no matter how clean it looks. That oxide layer prevents the solder atoms from bonding to the brass. Electronics solder contains flux, or flux can be applied in liquid or paste form. Also, anytime heat is applied to a connection new flux must already be available in the connection. New flux is activated by heat. Reheating a joint will not reactivate the old flux. 5. Calipers- Accurate dial or digital calipers are necessary for cutting to length some parts and for checking dimensions. 6. Other tools- X-Acto knives, tweezers, fine razor saw, small files, fine sandpaper, pin vise, whatever is in your modeling tool box! 7. Work surface- Your bench must be flat so you can reliably assemble the bents without a twist. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 9

10 SECTION ONE: Pre-assembly-4 1. Read through the instructions before starting. Get comfortable with the assembly. 2. Leave all the parts together on their sprues and frets until needed. Handle parts carefully at all times to avoid bending them. Store them flat so they don t bend. The lacing strips are very delicate! 4. The brass is etched to precise dimensions but is subject to small amounts variability on the feature edges. Adjustments, trimming and cleaning may be necessary. 5. Double check part locations before attaching. Note the various assembly features on the brass parts. Make sure you understand which way to face parts before committing. 6. Many of the fret tabs are attached to the part tabs to make a cleaner edge on the part, especially on the beam sides. Do not cut the fret tabs flush to the part without checking. 7. The only actual size assembly drawing is the large assembly drawing. Don t use the instruction images for part size reference. 8. You will accidentally bend brass parts throughout the assembly process. Brass can be straightened a few times without damage. Also, see page 12 on why some parts have a curve. 9. Mistakes can be corrected by reflowing the solder- easier than AC adhesives! 10. The bridge needs to carry the weight of your locos. Please assemble it carefully! 11. There is a lot of detail work involved with this model. Assemble it straight and true so it is easier to install on the layout. Please read through the instructions again before starting! instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 10

11 SECTION ONE: Pre-assembly-5 A WORD ABOUT SOLDERING ETCHED BRASS: The Lobato bents in 1:48 etched brass are very imposing and wonderfully large. To be strong enough to support brass locos and take a knock or two on the layout they must be soldered. Soldering brass is simple in concept- if the brass parts are clean and aligned the solder flows into the connection with the flux removing oxidation as it heats. Wire solder can be fed in by hand, it can be cut into small lengths and placed at the joint, or paste solder can be applied to the joint. Heat can be created using the resistance soldering tool or with a good electronics soldering station. Carrying this out can be initially frustrating for the first-time soldered kit builder. When you look at these instructions you will likely note my assemblies became a little messy as the parts were added. I burned the brass with the tool, put too much solder on and so forth. Remember this: My finished assemblies are rock-solid. I got better as I built. Cleaned and painted they look great. Take your time, understand the assembly, and vary from these instructions as you see fit. Resistance Soldering creates lots of heat energy for soldering heavy parts- a light touch on the pedal is wise! instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 11

12 SECTION ONE: Pre-assembly-6 A WORD ABOUT MAKING ETCHED BRASS: Etched brass can take on a frustrating characteristic that is unavoidable but simple to adjust for: ETCHED BRASS CAN BOW ITSELF. When the brass sheet stock is made to thickness, it is run through rollers at high pressure. All metal has grain, and this grain is packed more tightly at the surface of the rolled brass than inside. The sheet ends up with tension near the surface of the metal. But the tensions are balanced out by each other so it stays flat. When one side is extensively etched, such as for the rivets in this kit, the tension is relieved on that one side. Now the tension on the other side can pull a bit harder. A bow in the metal is the result. Another cause of bow is that the brass sheet is made on a roll. It may hold some residual bend. Bending the metal the opposite way will straighten it out. To adjust for it: Cut out the brass, then bend it straight. A part that is thoroughly straightened will stay straight. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 12

13 SECTION TWO: Common Parts Assembly instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 13

14 SECTION TWO: Common Parts Assembly-1 Strut 1, the Caps and the Shoes are common to all three bent sizes. The frets are different for Bent C compared to the Bent A & Bent B frets. That is due to fitting the parts on the master sheet. Begin the kit assembly with the Cap and Shoes. Bent C fret - Cut out all the cap and shoe parts. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 14

15 SECTION TWO: Common Parts Assembly-2 Assemble the Shoe base parts. X20 These boxes are the part callout numbers on the frets. X18 X20 There will be a small fillet around here. - Bend the X18 shoe base into a rectangle. (Bends always go toward the bend line.) Test fit the X20 shoe plate. It fits on top of the X18 base. - Solder the X20 plate in place. Make a good fillet all around the inside. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 15

16 SECTION TWO: Common Parts Assembly-3 Attach the mounting flanges. 2 x X21 Wire solder works great here. - Solder the X21 flanges into the slots. Make them square to the X20 base. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 16

17 SECTION TWO: Common Parts Assembly-4 Add the details and complete the shoes. 2 x X22 The rivets are oriented on the detail strips as shown. - Solder on the X22 detail strips as shown. The four closely spaced rivets go next to the flanges. - File the space between the flanges smooth. The leg bottoms will bear on those surfaces (as on the prototype). instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 17

18 SECTION TWO: Common Parts Assembly-5 Start the Caps. Stack these parts. X15 Rivets face up X12 between Clamp to solder. X11 Rivets face down - Stack the three layers together with solder paste between them. Place X11 rivets down, X12 between and X15 rivets up. - Line up the slots carefully, clamp and solder. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 18

19 SECTION TWO: Common Parts Assembly-6 Complete the Caps. X16 X13 X14 X14 X13 Guide touches in center but clears rivets - Attach the X13 and X14 pin plates. Note the differences in the slots and tabs. The plates must be angled to fit the leg angle. They angle toward the X14 side. Use the X16 guide as shown to hold and check the angle. - Clean up the parts to finish. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 19

20 SECTION TWO: Common Parts Assembly-7 Make the Pin assemblies, two each per bent. X19 Shoe pins 3/64 rod 3/32 rod X17 Cap pins - Make the Shoe pins. Cut the 3/64 brass rod.44 long. - Solder one X19 Shoe Nut onto the rod close to the end. - Make the Cap pins. Cut the 3/32 brass rod.38 long. - Solder one X17 Cap Nut to one end. - Leave the other nut off each type for layout installation. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 20

21 SECTION TWO: Common Parts Assembly-8 Assemble Strut 1 next. It is the top brace strut on all three bents. It is a small assembly that will require a bit of care with the soldering tool heat. NOTE: These instructions for Strut 1 are the template for all the other beams. There are added details to assist in understanding the concepts of holding, aligning and soldering the any beam parts. Strut 1 fret included with Bent C looks like this - Cut out the parts for Strut 1 and replace them into the fret openings so their reference is not lost. - X4 and X5 are not needed due to that detail being added to the legs after the brass was layed out. - Save aside the X2, X7 and X9 parts in the fret. They are assembled to the bent legs later. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 21

22 SECTION TWO: Common Parts Assembly-9 Create the beam assembly fixture for Strut 1. This fixture holds the beam sides parallel for soldering the first part accurately and square to the sides. Styrene stop Styrene base 2 x X3 Line.25 from side edge Cut a piece of.080 or so styrene for the base about 1 wide and 5 long. - Scribe lines as shown. Make sure the cross lines are square to the edge. - Bend the X3 parts and glue them glue with AC adhesive them as shown. - Glue a styrene stop as shown. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 22

23 SECTION TWO: Common Parts Assembly-10 Assemble the top lacing to the sides. Use the fixture to solder the first lacing so the sides are in position. The remaining parts are assembled without a fixture. NOTES: The X10 sides are angled as shown. All the struts are similar. Always match all the lacing slots into the side tabs before soldering. Most beams are not symmetrical like this one. Make sure the sides have no bends for easier assembly. An electronics soldering iron works well and is the safest on the thin metal. Or, heat carefully with resistance iron on a low setting. Make sure both ends are touching. X6 Run the solder iron along the edge while applying wire solder 2 x X10 Top Bottom - Place the X10 sides into the fixture rivets facing out. Check the angled ends- the top is where they angle in. - Place the X6 top lacing with the rivets facing down. Line up the tabs carefully. (X6 is shorter than X8.) - Apply flux and solder. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 23

24 SECTION TWO: Common Parts Assembly-11 Continue assembling by attaching the bottom the lacing. X8 - Remove it from the fixture. Solder the X8 bottom lacing onto the other side rivets down. Check the tabs and slots. - Clean off excess solder etc. from both the X6 & X8 lacing surfaces. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 24

25 SECTION TWO: Common Parts Assembly-12 Attach the top layer overlay mini-frets. NOTE: This method uses paste solder. X1 Line up these edges Solder dots - Add dabs of paste solder to the X1 overlay contact spots on the lacing. - Place an X1 top lacing mini-fret. Line up the edges on the plates. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 25

26 SECTION TWO: Common Parts Assembly-13 Solder the top overlay mini-frets. Resistance soldering iron tip - Apply heat to the connections. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 26

27 SECTION TWO: Common Parts Assembly-14 Solder the top overlay mini-frets. X1 - Repeat for the other X1 overlay mini-fret. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 27

28 SECTION TWO: Common Parts Assembly-15 Complete the Strut 1 assembly. Clipped, filed and in generally good shape. - Repeat for the other X1 lacing mini-fret. - Cut off the mini-fret. Resolder any loose connections. Clean up excess solder with a file, solder wick, knife, etc. Clean flux with isopropyl alcohol or flux cleaner. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 28

29 SECTION TWO: Common Parts Assembly-16 Strut 1 completed. Clipped, filed and in generally good shape. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 29

30 SECTION THREE: Bent C Assembly instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 30

31 SECTION THREE: Bent C Assembly-1 Bent C frets page 1. Bent C Legs are made in four sections: Upper, Mid 1, Mid 2 and Lower in that order. Each fret contains parts for two legs. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 31

32 SECTION THREE: Bent C Assembly-2 Bent C frets page 2. Bent C has four Struts and the Caps and Shoes. Strut 1 and the Caps and Shoes are common to all the bents although the fret layout is different for Bent C. Assembly instructions for them are in the previous section. Read the instructions before removing parts because the gusset plates and rivet strips can stay on the frets until the legs are assembled. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 32

33 SECTION THREE: Bent C Assembly-3 Start by assembling the struts. Make the strut beam assembly fixture for Bent C. The one fixture will hold Struts C2, C3 & C4 3 x C2-3-4 Move the last C2-3-4 to this line for Strut C4 Line.25 from side edge Cut a thick piece of styrene for the base about 1 wide and 9 long. -Scribe lines as shown. -Bend the C2-3-4 parts and glue them as shown. -Glue a styrene stop square to the length as shown. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 33

34 SECTION THREE: Bent C Assembly-4 Assemble Strut C2. C2-2 Rivets face down. 2 x C2-5 sides Rivets face out. Angled ends lean in on the top side. - Place the C2-5 strut sides in the slots with the rivets out. Place the C2-2 top strut lacing rivets down. Solder the tabs and the edges. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 34

35 SECTION THREE: Bent C Assembly-5 Continue assembling Strut C2 lacing. C2-3 Rivets face down. - Remove from the fixture and solder the C2-3 lacing to the bottom. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 35

36 SECTION THREE: Bent C Assembly-6 Attach the C2-2 bottom overlay to Strut C2. Solder paste is applied at the contact points. Cut the angle flanges from the mini-fret. C2-2 Rivets face up. - Solder the C2-6 bottom lacing. Apply solder paste to the contact points. Align the lacing and clamp. Solder with the resistance tool. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 36

37 SECTION THREE: Bent C Assembly-7 Solder the Strut C2 top overlay. C2-1 Mini-frets trimmed. - Solder the C2-1 top lacing mini-fret the same as the bottom. - Trim off the mini-frets. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 37

38 SECTION THREE: Bent C Assembly-8 Add the Strut C2 angle flanges. Angle flanges sit on lacing flange and against the overlay. - Solder angle flanges in place as shown. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 38

39 SECTION THREE: Bent C Assembly-9 Strut C2 completed. Assembly complete. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 39

40 SECTION THREE: Bent C Assembly-10 Assemble Strut C3. The instructions for the C3 & C4 are shown in an abbreviated form. Assembly is the same as for C2. C3-3 bottom lacing C3-6 bottom overlay 2 x C3-4 sides Sides with lacings soldered C3-2 top lacing C3-1 top overlay Top Bottom Angle flanges soldered. Overlays soldered and mini-fret trimmed. - Solder the top & bottom lacing rivets down, solder the overlays rivets up and finish with the angle flanges. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 40

41 SECTION THREE: Bent C Assembly-11 Assemble Strut C4. Move this side holder to the last line. C4-3 bottom lacing 2 x C4-5 sides C4-4 bottom overlay Sides with lacings soldered C4-2 top lacing C4-1 top overlay Top Bottom Angle flanges soldered. Overlays soldered and mini-fret not trimmed. - The fixture requires a change for Strut C4. Pull up the last C2-3-4 side holder and glue at the last line on the fixture. Then solder the top & bottom lacing rivets down, solder the overlays rivets up and finish with the angle flanges. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 41

42 SECTION THREE: Bent C Assembly-12 Assemble the leg sections starting with Bent C Upper. The Bent C assemble the same as the other beams. The upper and lower leg sections have a taper so it is important to make the fixture carefully. Place the sides so the tab and slot positions match. BCU3 bottom lacing 2 x BCU5 sides CU3 CU2 CU1 Line.25 from side edge BCU1 top lacing - Assemble the fixture. Check the fit of the BCU1 & BCU3 to verify the fixture, especially the stop location. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 42

43 SECTION THREE: Bent C Assembly-13 Attach the Bent C Upper bottom and top lacing. BCU3 BCU1 - Solder the lacing rivets down. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 43

44 SECTION THREE: Bent C Assembly-14 Attach the Bent C Upper overlays. The top side is the large plate with the curved sides. BCU4 top overlay Top BCU2 bottom overlay - Solder the BCU2 & BCU4 overlays rivets up. Line them up using the pin holes at the upper end and center them on the lower end. BCU4 will overhang the sides a bit instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 44

45 SECTION THREE: Bent C Assembly-15 Solder the Bent C Upper overlays. BCU4 The overhang of the plate is correct. Solder these bars from the bottom side. BCU2 - Start with the BCU4 top overlay inside bars can be reached from the bottom. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 45

46 SECTION THREE: Bent C Assembly-16 Attach the Bent C Upper pin hole plates. BCU6 - Solder the BCU6 plate on both sides by lining up the holes. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 46

47 SECTION THREE: Bent C Assembly-17 Bent C Upper leg section completed. Top view Bottom view Assembly complete. Side view instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 47

48 SECTION THREE: Bent C Assembly-18 Assemble the Bent C Mid 1 leg section. BCM1-5 top lacing 2 x BM1-1 sides 3 x CMID Line.25 from side edge BCM1-3 bottom lacing - Assemble the fixture per the previous beams instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 48

49 SECTION THREE: Bent C Assembly-19 Solder the Bent C Mid 1 bottom and top lacing. BCM1-5 BCM1-3 Solder the sides carefully so the slots are clear on both ends of the bottom. - Solder the lacing rivets down. The sides are symmetrical regarding the tabs and top/bottom. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 49

50 SECTION THREE: Bent C Assembly-20 Mark the Bent C Mid 1 overlays. BCM1-5 top lacing BCM1-5 top lacing BCM1-3 bottom lacing BCM1-3 bottom lacing.698 Scribe a line. - Lay out the overlays to understand how they fit. Scribe a line.698 from the end as shown. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 50

51 SECTION THREE: Bent C Assembly-21 Solder and trim the Bent C Mid 1 overlays. BCM1-3 BCM1-5 Scribed line. BCM1-5 - Solder the overlays. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 51

52 SECTION THREE: Bent C Assembly-22 Bent C Mid 1 leg section completed. Assembly complete. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 52

53 SECTION THREE: Bent C Assembly-23 Assemble the Bent C Mid 2 leg section. It assembles similarly to the previous leg section. BCM2-5 bottom overlay BCM2-4 bottom lacing 2 x BM2-2 sides BCM2-3 top lacing BCM2-1 top overlay - Layout all six parts to understand the fit and location. The sides are NOT symmetrical regarding the tabs and ends. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 53

54 SECTION THREE: Bent C Assembly-24 Solder the Bent C Mid 2 lacing and overlays. Keep all the long slots clear BCM2-4 bottom lacing Scribe a line..698 BCM2-1 top overlay BCM2-3 top lacing BCM2-5 bottom overlay - Solder the lacings. Keep the bottom long slots clear. - Scribe a line on BCM2-1.XXX from one or both ends. - Solder the overlays with the BCM2-1 aligned with the lines. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 54

55 SECTION THREE: Bent C Assembly-25 Bent C Mid 2 leg section completed. Top view Bottom view Assembly complete. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 55

56 SECTION THREE: Bent C Assembly-26 Assemble Bent C Lower. The concept is the same as the Bent C Upper. Make the fixture carefully. BCL3 bottom lacing NOTE: Production BCL6 sides will correctly end at the tabs 2 x BCL6 sides CL3 CL2 CL1 Line.25 from side edge BCL4 top lacing - Assemble the fixture. Check the fit of the BCL3 & BCL4 to verify the fixture, especially the stop location. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 56

57 SECTION THREE: Bent C Assembly-27 Attach the Bent C Lower bottom and top lacing. Keep the slots clear BCL3 BCL4 - Solder the BCL3 & BCL4 lacing rivets down. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 57

58 SECTION THREE: Bent C Assembly-28 Solder the Bent C Lower overlays. Keep the slots clear BCL2 bottom overlay BCL7 top overlay The overhang of the plate is correct. - Solder the overlays. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 58

59 SECTION THREE: Bent C Assembly-29 Attach the Bent C Lower pin hole plates. BCL11 BCL10 BCL5 BCL9 BCL10 BCL8 - The pin hole pile-on plates are soldered in the order shown. Line them up carefully using the hole. NOTE: BC11 production part is a little different from these photos but it fits the same. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 59

60 SECTION THREE: Bent C Assembly-30 Bent C Lower leg section completed. Bottom view Top view Assembly complete. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 60

61 SECTION THREE: Bent C Assembly-31 Assembled Bent C leg sections are impressive in parts but wait until they are assembled! This end with the tapering rivets fits here This end with the tapering rivets fits here Top view Bottom view Bent C Upper Bent C Mid 1 Bent C Mid 2 Bent C Lower instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 61

62 SECTION THREE: Bent C Assembly-32 Begin assembling the Bent C leg sections using the template. Bent C Upper Bent C Mid 1 Bent C Mid 2 Apply solder paste to the contact side of the gusset plates. Bent C Lower - Line up and test fit the leg sections on the template. - Apply paste solder to the flat connection areas. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 62

63 SECTION THREE: Bent C Assembly-33 Solder the Bent C sections together. Note the use of spacers per the instructions. Use.016 (one full thickness) of filler for the Upper-Mid 1 connection. Use.032 (two full thicknesses) of filler for the Lower-Mid 2 connection. - Because the Upper and Lower sections have added plates at the pin holes, support the ends of the beams with scrap frets. Solder one side at a time. Check the side alignment and beam box shape twist as the plates get soldered. Note: The Mid 1-Mid 2 connection is not shown instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 63

64 SECTION THREE: Bent C Assembly-34 Bent C leg sections soldered. All 10 slots must be fully clear for the strut gussets - Make sure all the bottom plate slots for the strut gussets are clear to insert a half-thickness etched part. Use a hobby knife to scrape or shave solder or brass that is in the way. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 64

65 SECTION THREE: Bent C Assembly-35 Add the Strut 1 gussets. X2 X7 X9 X4 X5 X9 X7 - Assemble the Strut 1 gussets. - Solder the X2 detail plate and the gussets in place square to the beam. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 65

66 SECTION THREE: Bent C Assembly-36 Add Strut 2 gussets. C2-11 C2-8 Bent C Upper C2-7 C2-9 C2-7 C2-4 C2-4 C2-10 Bent C Mid 1 - Assemble the Strut 2 gussets. - Solder them to the Upper-Mid 1 connection plate. - Solder the C2-10 & C2-9 detail strips as shown. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 66

67 SECTION THREE: Bent C Assembly-37 Add Strut 3 gussets. C3-8 C2-7 Bent C Mid 1 C3-11 C3-9 C3-11 C3-5 C3-5 C3-8 Bent C Mid 2 - Assemble the Strut 2 gussets. - Solder them to the Mid 1-Mid 2 connection plate. - Solder the C3-8 & C3-9 detail strips as shown. NOTE: Strut 2 photos shown, it fits the same as Strut 3. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 67

68 SECTION THREE: Bent C Assembly-38 Add Strut 4 gussets. Bent C Mid 2 C4-7 C4-8 C4-10 C4-7 C4-6 C4-10 C4-6 C4-6 Bent C Lower - Assemble the Strut 4 gussets. - Solder them to the Mid 2-Lower connection plate. - Solder the C4-6 & C4-7 detail strips as shown. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 68

69 SECTION THREE: Bent C Assembly-39 One leg of Bent C sections soldered. 2 x BCL-12 - Solder the BCL12 rod plates. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 69

70 SECTION THREE: Bent C Assembly-40 One leg of Bent C complete. - Repeat the leg section steps for the other leg. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 70

71 SECTION THREE: Bent C Assembly-41 Start the final bent assembly. Test fit the struts. - Test fit all the struts. Look at the following detail photos to see how they fit. They should fit over the gussets so the legs maintain their position over the template. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 71

72 SECTION THREE: Bent C Assembly-42 Solder Strut 1. Verify the fit is close here Apply light pressure here - Strut 1 fits over the gussets and contacts the leg. To solder the leg flat to the gusset solder from the inside. Press down lightly with the resistance iron tip and hold until the connection is secure. NOTE: Double check your work as you go. Verify you have not introduced a twist in the leg. The mid leg sections must be flat against the template. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 72

73 SECTION THREE: Bent C Assembly-43 Solder Strut 2. Verify the fit is close here - Strut 2 fits over the gussets up to the detail angle flange. Solder with pressure from the inside of the gusset. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 73

74 SECTION THREE: Bent C Assembly-44 Solder Strut 3. - Strut 3 fits the same. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 74

75 SECTION THREE: Bent C Assembly-45 Solder Strut 4. - The big Strut 4 fits like the others. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 75

76 SECTION THREE: Bent C Assembly-46 Make the Brace Rods by starting with the fixture. Escutcheon pins at all center marks - The Brace Rods are made on the rod fixture. Glue the Rod Template sheet to a board. Drill a hole to fit the escutcheon pins at each center mark. Glue an escutcheon pin into the holes. Clip the heads off. Somewhere else on the board drill two holes using a BCU7 Rod Link for a template. The holes must be a loose fit for the pins. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 76

77 SECTION THREE: Bent C Assembly-47 Make the Brace Rods. Turnbuckle tubing in place End formed into loop - Make the turnbuckles. Cut the 1/16 brass tubing into.188 lengths. NOTE: The prototype turnbuckles are a solid and not open like many other turnbuckles. The tubing is a good method for modeling them. - Bend one end of the.020 brass rod around one pin. - Slip on the turnbuckle tubing and bend the other end of the rod. NOTE: The prototype uses a method where the heated end of the rod is upset into a closed loop. If you can work the brass loop end to touch the rod the appearance will be a bit more realistic. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 77

78 SECTION THREE: Bent C Assembly-48 Solder the Rod Links onto the Brace Rods to complete the rod assemblies. Assembled before soldering Solder this end only Clip the pin short with a small amount protruding BCU7 Keep this space clear of solder Pins are in the drilled fixture holes - The rod assemblies are easier to install if the BCU7 Rod Links are assembled first. Use the two holes to hold the pins, links and rod. Use a minimum of solder so the separation is not filled. - Solder the turnbuckle tubes 1.50 from a pin as shown C-C instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 78

79 SECTION THREE: Bent C Assembly-49 Attach the rods assemblies to the gussets. Soldered and clipped at the leg bottom Soldered and clipped at the Strut 4 gussets - Fit the rod assemblies to the gussets. Use the full length pin and clip it after soldering. The turnbuckle end goes to the lower area of the bent story. NOTE: If a rod assembly are a bit short, reheat the links while applying tension to the links. The pins may resettle a little further out in the rod loop. Do not install the rod assemblies into the bent bottom story with excessive tension. Without a strut across the bottom the legs will be pulled in. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 79

80 SECTION THREE: Bent C Assembly-50 Rods installed in the Bent C Lower story. - The turnbuckles are always closer to the bottom of the bent story. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 80

81 SECTION THREE: Bent C Assembly-51 All the Rod Braces installed. - Install the remaining rod assemblies. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 81

82 SECTION THREE: Bent C Assembly-52 Attach the Shoe and Cap. - NOTE: Production BCL6 sides will be cut back like this X17 X19 - Slip the shoe Pin Assembly into the shoe and foot. Don t attach the other nut until the bridge is installed, or use a bit of removable adhesive (Goo-type) to hold it on. - Repeat for the cap Pin Assemblies. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 82

83 SECTION THREE: Bent C Assembly-53 Bent C is complete! Cleaning and painting is next. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 83

84 SECTION FOUR: Finishing instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 84

85 SECTION FOUR: Finishing-1 Painting. If you can assemble this kit you likely will not need completely detailed painting info. Use your method and paint of choice, whatever you are familiar and comfortable with. Acrylic paint is OK on the brass if it is clean. Here are some painting ideas and suggestions: -The brass has to be very clean for the paint to spread and adhere properly, especially with acrylics. Whatever you use to clean the flux and debris off please read the labels and cautions. Follow all appropriate health and safety requirements. Here are ideas for cleaning: Commercial flux cleaner in a spray can. Some of these are safer than others but still effective. Isopropyl alcohol. Use a large plastic container to soak the assembly. Then use a brush to dislodge the flux. Other organic solvents are not recommended due to safety constraints. Citrus-based solvents or Simple Green. High concentrations should be used. After any cleaning the assembly must be rinsed in warm, soapy water, then rinsed. Some modelers dip the brass in vinegar to give the unetched areas tooth for the paint. This will change the surface finish coloring. -Bridges start as either black or silver. The Lobato Trestle was originally black, but was painted over with silver. The original black shows through, the amount depending on the year. Start with a dull coating of the base color, then weather using the method of choice. Streaking a silver base with a black wash would work to give a present day appearance. -Weather using airbrushing, chalks or drybrushing techniques. For weathering references, see the documents on the instruction disk and look on the web. Rust and dirt will collect on the girder flanges for example. instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 85

86 SECTION FOUR: Finishing-2 Making a bridge. There is another set of instructions for a complete installation. Refer to them for all the details. Here are a few notes if you are using the bents in different manner: - The footings are to be screwed in from underneath with the screws. - The shoes attach with the 2-56 screws. Note they go in at an angle to match the shoe. There is a small raised line next to the hole. That should point to the bridge center line. Do not overtighten these small screws. - Each bent has a brass Base Drill Guide. The center hole is the bridge center line. Drill a hole to fit the footing screw at the other marks. - Space the footings according to the girder span length. - Connect (glue or solder) the girder ends together into a continuous length. Use a sturdy, straight board or metal C-channel and tape the girders together. Set them across the abutments and level the bents underneath using shims. Then connect the girders to the bent caps. - The girder ends rest on the base plates included in the girder kit. The prototype also has large, cast iron blocks that are set on the abutments. The cast model abutments have these blocks cast in place. I hope you enjoyed your kit building experience! I welcome your comments and photos. Your suggestions are how I can improve future models so please let me know what you think. Thank you, John Palecki instructions: 1:48 O SCALE LOBATO TRESTLE BENTS page 86