BRL-142/143 Class 142/143. Building Instructions

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1 Peter Besant Tel BRL-142/143 Class 142/143 Building Instructions SCALE MODEL PRODUCT FOR ADULT MODELLERS ONLY. WHITE METAL CONTAINS LEAD WASH HANDS AFTER USE. MAY CONTAIN SMALL PARTS. ETCHED BRASS HAS FUNCTIONAL SHARP EDGES - HANDLE WITH EXTREME CARE

2 Thank you for purchasing this kit. This instruction pack should provide a guide for building this model given some experience of soldering and the basics of etched kit construction. Please read all the pack before starting to build. Drawings and photos are essential for builders to acquaint themselves with the prototype they wish to model. For builders of modern image in 7mm, consider joining MIGO+1, the Modern Image Gauge 0/1 organisation. For more details see the MIGO+1 Website at Transfers are available from Fox Transfers. 2

3 Instructions About these kits These kits cover the loving named Nodding Donkeys of the second generation DMU s, and are intended to be used on branch line and secondary services. They have had a somewhat mixed life, but all the same have proven to be a mainstay of the short journey and if you are really desperate the odd long one too! As a general rule, the Class 142 s are used in the North of the country, with some working in the south west, and the 143 s in the south west and Wales. They can be finished in some quite colourful schemes. The kits were originally intended to be powered using a Portescap RG4/1219 motor gearbox unit and the instructions still reflect this option. With the RG4 difficult to find, a modification can be undertaken to use a Mashima 1833 and the appropriate mounting bracket is included in the kit. One motor should be ample power per twin car set, but if you assemble the kit as per the instructions, it will be easy to back fit a second motor to the other car if desired. Assembly is divided into three sections: a) Chassis b) Chassis mounted interior c) Car body Reference to the drawings will clearly show the folds that must be made to most etched components, as they are formed into their desired shapes. To avoid repeating this throughout the assembly sequence check each etched component as you go, and if required, push through any rivet detail from rear, using a punch on a suitable surface, such as the smooth side of a sheet of hardboard. 3

4 Parts List Etchings Pre formed bodies (2) 4 lost wax air horns 1 pair lost wax tight lock coupler units 1 lost wax central coupling bar 8 Frame bushes Fine mesh for horn cover grills Requires 3 1 wheels Sprung & Flexible hoses for couplings Glazing Opaque Wire 2 Screws/nuts/solder tags Castings - Section A 142/1A - 8 Axleboxes (142) 142/1B 8 Axleboxes (143) 142/2A-D - 4 RH & 4 LH Central damper units (24 pieces) 142/3A-C 16 Main damper units (32 pieces) 142/4 A-E 2 RH & 2 LH Brake Cylinder sets (12 pieces) 142/5 A C 4 RH & 4 LH Traction rod sects (16 pieces) 142/6A-C - 2 Solebar mounted box units (6 Pieces) 142/7-4 UF Butterfly handles 142/8 4 UF equipment boxes (2 types) 142/9 2 UF equipment boxes 142/10-4 Tank cradles (2 in 142 only) 142/11 - Short UF tanks 142/12-2 Long UF tanks 142/13-2 UF boxes with Grill 142/14-4 Tank filler caps 142/15-2 UF Compressor units 142/16-2 Silencer units 142/17A-C - 2 Exhaust Assemblies (6 Pieces) 142/18-2 Engine units 142/19A&B 2 Oil Sumps(4 Piece) 142/20 2 Oil Filters 142/21 2 Engine Assemblies 142/22 2 Engines Assemblies 142/23A-E 6 Gearbox Assemblies (14 Pieces) 142/24-2 UF Equipment panels (142 only) Section B 6 Cab control levers (4 Brass pins and 2 cast handles) Section C 142/25A - 2 Cab fronts (142) 142/25B 2 Cab Fronts (143) 142/26A - 2 Inner ends (142) 142/26B 2 Inner ends (143) 142/26C - 2 Gangway frames 142/27 34 Window Frames (142) 142/28-2 Cab roofs (143) 142/29 2 Roof fairings 142/30-4 Roof vents (143) 142/31 Roof aerial 142/32-2 Cab Vents (143) 142/33-1 Lavatory vents (143) 4

5 Note Repeat assembly sections for second car except where noted. Section A Fold up main chassis unit (A1). Fold up left & Right solebars (A2/A3) and solder to slots in A1. Fit solebar bottom flange/axlebox base units (A4/A5) as shown making sure that the units with the cut outs for mounting the air cylinders assembly are to the very front of the chassis. Add gussets (A7/A8) to solebars, where indicated by half etched lines. Fit cast axlebox unit (142/1 A or B dependant on whether your are building the 142 or 143) to the recesses provided in A4/A5. Add both cast central (142/2) and main damper (142/3) assemblies as shown removing shaded portion on each main damper for 142. Assemble and fit the cast air cylinder units and the traction rod units (142/5) as shown, passing through etched safety loops, which fold down from chassis floor. Form and fit etched step units (A6) into recesses provided in solebar. Fit the three types of cast solebar box unit (142/6) into the recesses provided on the front faces of solebars (2 on LH solebar and 1 on RH). 143 Only Fold and fit main equipment boxes (A9) adding A10 to front faces. Fold and fit secondary equipment boxes (A16/A17) noting the asymmetrical location of these. Add cast Butterfly Handles (142/7) into holes provided. Fit two cast tank cradles (142/10) into recess provided on underside of forward right hand solebar and fit one cast short tank (142/11) to these. Fit the remaining pair of cast tanks, 1 short (142/11) and one long (142/12) to the holes in lugs folded down from the chassis floor just forward of inner axle. 142 Only Fold and fit equipment boxes (A9/A10), and fit the two cast handed boxes (142/8) to the recesses provided in the ends of A9/A10. Add cast Butterfly Handles (142/7) into holes in the cast boxes. Add cast box with brackets (142/9) to the etched lugs on the underside of the forward left solebar. Add cast equipment panel (142/24) to recess provided under forward right hand chassis outboard of solebar. Add one cast tank cradle (142/10) under forward left hand solebar and fit one cast short tanks (142/11) to this as shown, and into corresponding lug folded down from chassis floor. Fold down remaining four lugs and fit one cast short tank (142/12) and one long tank into the holes in these as shown. 5

6 Fit cast grilles UF box (142/13) to fold down platform adding etched framing (A16). 142 & 143 Fold up fuel tank (A14) and fit to chassis floor, where indicated. Add circular discs (A15) and cast filler caps (142/14) through holes in solebar. Fold up etched cradle (A23), adding cast compressor unit (142/15) as shown. Add control lever (A13) into slot on nearby etched panel. 142 Only Fold and fit 2 x A17 one into slot in front buffer beam and one into slot in forward right hand solebar. Fit cast silencer unit (142/16) to etched platform adding rest of exhaust (142/17) assembly to rear of right hand solebar where marked. DO NOT FIT FINAL VERTICAL SECTION HOWEVER. Add bracing strip (A18) below coupling slot on front butter beam. 142 & 143 On 143 A18 are the front steps which should be folded and fitted into the slots provided. There are also steps provided for the 142, but not all units have them. Fold and fit if required. Form coupler pivot boxes (A20) and fit to rear of front beam. Construct tighlock coupler units adding checker plate overlays (A31) and fit these to pivot within A20 using brass rod. Fold A19 and fit behind the lower central cut out in front beam as shown. Solder two diameters of brass rod (not provided) in place and connect to coupler unit as shown using sprung and flexible hoses. Fold up A21 and fit to rear of front beam adding lost wax air horns. Fit fine mesh behind horn cut out in front beam. Fold and fit A24 units and fit to recessed areas provided in solebars. Fit cast engine unit (142/18) adding Oil Sumps (142/19), oil filter ((142/20) and Engine Assemblies (142/21 & 142/22) and add etched overlays (A11/A12) as shown. Add cast gearbox unit assembly (142/23) as shown and fit cast transmission shaft assembly to these. The main part of the traction shaft passes through the central safety loops that fold down from the chassis floor. 6

7 Fold the inner coupling bar pivot box (A22) and solder to rear of inner beam. The lost wax central coupling bar can easily be fitted by securing one end with a soldered pieces of bar soldered to the pivot box and on the other end, use a 10BA nut and bolt. This will allow you to split the units. RG4 Version Form motor housing (A28) with RG4 inside, and add A29 and A30 to inside faces of w irons. Solder 1/8 th frame bushes to the holes in these. Secure housing to chassis using lugs and slots provided (do not solder). Fit wheel set and tighten gearwheel. Add pickup set to one side only (your choice) using hole provided. Mashima Version Form motor housing (A28) with RG4 inside and add A29 and A30 to inside faces of w irons. Secure housing to chassis using lugs and slots provided and tack solder the outside of the housing in place as you will be cutting away the residual parts of A28. The idea here is to get the axles in the right position before cutting the floor to accommodate the Mashima motor. When happy, remove the RG4 motor housing that protrudes through the floor. Fold up the new motor housing and add the Mashima motor. The pre-cut hole in the floor will need enlarging to accommodate the new motor. Once you have done this, the new motor assembly should drop in. You will need to fabricate a bracket to secure the motor in place using scrap brass from the kit. Form compensated w iron unit (A25) and laminate with A26 & A27. Fit to compensation cradle lugs on chassis and add wheel set and pick up assembly (on same side as the pick up on driven axle). Fit solder tag in place using screw and nut and solder. Lead from motor to this. Solder lead from motor to rear pick up, and connect with wire supplied to forward pick up as shown. If desired two further pick up units can be purchased and fitted to the trailer car (on same side), and wired up by routing wire beneath central coupling bar, but this should not be necessary. Preserving this option is the reason that pick up locating holes have been included in every W iron. Also these will be required should you wish to fit a second motor 7

8 Section B Fold up main floor unit (B1) Solder in place cab bulkhead (B2) and form and fit B3 to B2 in recess provided. Add lever (B4) and fit into recesses provided in cab floor section. Fit partitions B7/B8/B10/B12 in slots provided, and form all seats B9 & B11 and fit into slots provided. (On one car leave out 1 x B 11 and fit instead the lavatory partition unit B13). Assemble control console (B14/B15), adding 2 x B16 into grooves provided on top of console (142 only). Fit unit to floor (slots are provided in 143). On Cl/142 the position of the assembly will be critical as the front edges of B16 must butt fit to the inner cab front unit. The option of fitting the entire control console assembly to the inner cab front of Cl/142 is offered. Add the cast control levers and pins to the control console as shown. Solder completed floor assembly onto top of chassis unit as indicated by half etched lines. Be sure to position carefully by reference to the main body (C1) and the cast cab and inner end units. (It is suggested that the floor unit with lavatory partition is fitted to the motorised car). Section C Fit cast ends (142/25) into main body etching adding cast cab roof (142/ only). 143 only Fit cast roof vents (142/30) driving cab (142/33) vent and lavatory vent (142/32 - one car only drill out hole ) 142 only Fit cast window frame (142/27) units adding nickel silver window lights as shown (Class 142). Note that the inner left hand window on one car only should not have a window light unit fitted. 143 only The integrally etched window lights in this position on one car only should be neatly removed. Fold and fit door units (C2) adding plasticard step tread units to Cl/143. 8

9 142 only C3 are the two grill panels which should be fitted to each end of the cast roof fairing unit. This should be fitted to roof AFTER the ten roof ribs (C14) have been fitted in the recesses provided in the 142 roof. Add grab handles (C15) to slots adjacent to doors, and on Cl/143 add the safety rails (C16) to insides of doors. Fold and fit lower panels to bottom of 142 sides C9- C13. Fit cast gangway frame into inner end (142/26), and add etched panel (C14) to recess in inner end Cl/143 only. Assemble gangway unit (one only per twin car set duplicates of some parts included), using parts C4/C5/C6/C7. Add wire to holes in C6 and note that the laminated C7 unit fits into the central slots in the lost wax central coupling bar. This allows the gangway unit to pivot prototypically, but means that it will be necessary to complete full assembly of the gangway when the final joining of all the sections of the two cars are carried out. The gangway guide plates (C8) are fitted to each cast inner end, above the gangway frame, in holes that you will have to drill out. Fit etched windscreen frames to front end castings: Class 142 parts C16/C17/C18 adding windscreen wipers and lamp bracket (C19/C12/C9) Class 143 part C10 adding windscreen wipers and lamp bracket (C11/C12/C9) Add door control lights (C13) to Cl/143 as shown. Add one door control button (C22) to Cl/142 to the right of inner door on side of inner end casting, as shown. In order to facilitate easy removal of the bodies from chassis, the width of the interior seating and bulkheads are somewhat narrower than the prototype, and it is suggested that some plastic strip is fitted down the inside of the body sides adjacent to partitions and bulkheads, thus sealing them visually when bodies are mounted on their chassis/interior units. Assembly is now complete and should be repeated with the exceptions noted, for the second vehicle. All units should then be painted and glazed, and the opaque sheet fitted inside the lavatory window (on the modified body shell). Obviously this body shell should be fitted on the relevant chassis. 9

10 There are two types of destination insert for the 142, check which one you want and I would suggest that these are fitted after painting with a destination added. The bodies are designed to be a tight fit onto the chassis/interior units and should be secure enough for normal operation. No other fastening is provided for, but the bodies can of course be glued or mounted in other ways to the chassis if you are absolutely satisfied that you will not need access to the interior. 10

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