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PenBits PK005 Assembly Instructions Manual

Sprung bogie kit bachmann/nrm prototype deltic
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ASSEMBLY INSTRUCTIONS
PK005
SPRUNG BOGIE KIT
BACHMANN/NRM
PROTOTYPE DELTIC
PenBits Model Railways
www.penbits.co.uk
c/o 12 Fieldside, Long Wittenham, ABINGDON, Oxon, OX14 4QB

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  • Page 1 ASSEMBLY INSTRUCTIONS PK005 SPRUNG BOGIE KIT BACHMANN/NRM PROTOTYPE DELTIC PenBits Model Railways www.penbits.co.uk c/o 12 Fieldside, Long Wittenham, ABINGDON, Oxon, OX14 4QB...

  • Page 3: Table Of Contents

    Spring Winding Warranties Bearing Carriers Subframes Deltic Bogie Bolster Deltic: Preparing the Locomotive Modifying the Bogie Drive Fitting Wheelsets Springs, Bogie Assembly and Rolling Test Deltic Sideframes Pickups and Power Final Assembly (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 4: General Notes

    The instructions are available on line in both HTML and pdf formats. The HTML versions have one page for each major section, whilst the pdf versions have a single file for each kit. Structure (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 5: Printing

    Any remnants of the tag may be cleaned up using a flat file. We have tried to avoid putting tags on mating faces, but there are some instances where they need to be removed (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 6: Slots

    In places which can't be reached by a file, e.g. in acute corners of the etch, the cusp may be pared away with a sharp knife. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 7: Folds

    Green Label flux may be rinsed away with water; a little added citric acid will neutralize it. Liquid or paste fluxes can be washed away either with a proprietary flux cleaner or a 50/50 mix of methylated spirits and water. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 8: Spring Winding

    Keeping the coil on the armature, you can stretch or compress the spring axially to get the coil spacing you need. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 9 Trim off the waste at the ends of the spring. File the ends of the spring flat, using the free end of the armature to support it. Reset the armature in the chuck to the desired length of the spring. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 10: Warranties

    However, as the fitting of the kit by the user is out of our direct control, we can make no warranty, expressed or implied, as to the performance and continued serviceability of the locomotive following modification. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 11: Bearing Carriers

    Put the subframes in their containers safely to one side for now. Test fit the axle bearings on the 2mm replacement axles. They should be a free running fit. Remove any burrs or swarf from the front and rear faces of the bearings. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 12 This will help minimise any unwanted distortion in the fret. Note that Fold 3 is a jig fold, made along the tags at the base of the carriers. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 13 Stick a length of double-sided tape, large enough to take one of the carrier frames, onto a clean, flat, heatproof working surface. Ensure the tape is firmly smoothed down (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 14 Unfold Fold 3 and separate the individual bearing carrier assemblies from the frame. Take care, as the top parts of the carriers are quite fragile at this stage: it may be (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 15 Keep the bearing clamped in the vice while soldering; this will act as a heat sink and prevent melting of the joint between the bearing and carrier. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 16 That completes the bearing carrier assemblies. To finish off, clean them up to remove any flux residues, and put the carriers and subframes safely away in their respective containers. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 17: Subframes

    Fit the baseplates into the subframes, noting that the lugs on the sides of the baseplates engage in the recesses in the lower edges of the subframe, and solder the joints between the two. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 18 When fixing the stretchers to the subframes, it is convenient to work with the subframes inverted and the stretchers supported on heatproof blocks. Fit the end plates across the subframe ends; support them against a block and solder in place from the inside. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 19: Deltic Bogie Bolster

    Check that the nut is central between the stiffeners and flat to the face of the bolster top. Run generous fillets of solder around the nut and the Upper Stiffeners. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 20 Keep solder clear of the places where the inner and outer bolster frames will fit. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 21 Again holding the 180° folds of each traction ear firmly together, run a good fillet of solder under the traction ear where it engages with the Central Stiffener. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 22 Clean up the bolster assembly to remove all flux residues. If you wish to chemically blacken the bolsters and subframes, do it at this stage. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 23: Deltic: Preparing The Locomotive

    Similarly remove the other bogie. Fix the four sole plates to the lower face of the chassis plastic moulding as shown, using an epoxy resin glue or double-sided tape. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 24 M2 screw and 5.5mm washer. Ensure that the bolster can rotate with the chassis sole plates resting on its shoulders, and allow the glue to set completely. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 25: Modifying The Bogie Drive

    When removing the idler axles, support the moulding on a hard surface with some kind of slot or hole to receive the axle. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 26 B1-1B, in which configuration it will perform perfectly adequately and retain much of its hauling capacity. If you wish to take this option, you can skip the remaining steps in this section. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 27 - any tightness will be down to dust or swarf. We now re-assemble the drive train in its articulated form as per the diagram here. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 28 Check that the three idler gears rotate freely together they before disassembly. If any tightness is present, strip down the gears and ensure that they are clean and free from any kind of swarf or dust residues. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 29: Fitting Wheelsets

    Bachmann axle bearings and the second bearing carrier. Note that the ears at the tops of the bearing carriers face outwards towards the ends of the axle. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 30 If there is binding when one axle is raised, open out the Bachmann axle bearings just a fraction more, up to a maximum of 2.3mm. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 31 If it is a driven axle, slide one of the Bachmann final drive gears into position centrally. The gear should be a tight fit on to the axle, sufficient to transmit drive forces without slipping. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 32 Lubricate the bearings with a light machine oil and ensure that the oil is taken in to all the axle-bearing interfaces. That completes the assembly of the wheelsets. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 33: Springs, Bogie Assembly And Rolling Test

    ...and clip the shorter arms into the spring retaining ears. Put the bolsters safely to one side. Return to the primary suspension wires and check that the epoxy resin beads have set hard. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 34 ... and locate the bearings in the tops of their mainframe slots. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 35 You now have a rolling bogie with fully functioning equalized primary suspension. Do a hand-powered rolling test to check for any tight bearings, wobbly wheels etc. It is easiest to correct such things at this stage. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 36 Remove the springs from the bearing carriers and return all components to their storage trays. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 37: Deltic Sideframes

    Remove the undertray. Be careful not to overstress the moulded end stretchers. Start by cutting through the coupler moulding, as close to the line of the backs of the stretchers as you can... (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 38 Remove the moulding which links the brake shoes, cutting as shown so that no part of the blocky moulding at the top of the shoe will interfere with installation of the central wheelset. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 39 If you wish to solder a coupling to the bogie subframe, it is as well to do it now before attaching the plastic outer frames. Note that if you are using 'American' style pickup it might be advisable instead to fit an insulating coupling mount. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 40 Note that the production version of the end stretchers is slightly different to that shown here. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 41: Pickups And Power

    They act on the outer wheelsets only, as there is limited space to fit pickups to the centre wheels. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 42 (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 43: Final Assembly

    Thread the spring through the slots in the ears of the bearing carrier of the outer axle. Thread a second spring through the hole in the other ear of the central bearing carrier. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 44 Use a screwdriver to spring the springs outwards and downwards on to the outer faces of the secondary suspension seats. Push the springs downwards so that they slide over the secondary and then the primary suspension seats … (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 45 IMPORTANT NOTE: If you need to remove the body subsequently, please DO NOT at any stage attempt to pull the chassis from the loco by pulling on the bogies, as this may damage the secondary spring mountings. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

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