PenBits PK017 Assembly Instructions Manual

Sprung bogie kit bachmann class 44 / 45 / 46

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ASSEMBLY INSTRUCTIONS

PK017

SPRUNG BOGIE KIT

BACHMANN

CLASS 44 / 45 / 46

PenBits Model Railways

www.penbits.co.uk

c/o 12 Fieldside, Long Wittenham, ABINGDON, Oxon, OX14 4QB

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Summary of Contents for PenBits PK017

Page 1 ASSEMBLY INSTRUCTIONS PK017 SPRUNG BOGIE KIT BACHMANN CLASS 44 / 45 / 46 PenBits Model Railways www.penbits.co.uk c/o 12 Fieldside, Long Wittenham, ABINGDON, Oxon, OX14 4QB...
Page 3: Table Of Contents
Altering the Drive Train Mouldings Inner Worm Bearing Retainer Reassembly Bachmann 'Peak': Wheelsets Bachmann 'Peak': Springs, Bogie Assembly and Rolling Test Bachmann 'Peak': Cosmetic Bogie Frames and More Rolling Tests 64 61 Bachmann 'Peak': 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 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: Co1 Bogies
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 45° will do. 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 This should set the correct alignment. That completes the bearing carriers. Clean them up to remove any flux and grease residues and put them, and the subframes, away in their respective containers. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 17: Bachmann Co1 Bogies: Subframes
Make the two main longitudinal folds in each Mainframe. Each fold is in three parts carried over the cross members under each axle slot. Ensure the folds are at a true right angle throughout. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 20 Mainframe. Take the pair of Secondary Seats for that side and place them on the jig. Place another block on the jig to act as a fence. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 21 Check that the main bodies of the wheel bearings will pass through the holes in the Axle and between the legs of the Lower Axle, filing the etches as required. Fold up the Axle and Lower Axle etches. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 23 70° from the side of the frame. Fold the frame returns to 90°. Completed horncheek and return folds. Fold up the two sides of the frame. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 24 Remove the Pony Flitching etch (S10) from the fret. Check that the 8 thou spring wire will pass the hole in the etch. Drill it through 0.3mm if necessary. Fold up the seat for the pony truck's control spring… (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 25 Invert the etch and fold the outer primary spring seats. Invert the etch again and fold up the side plates. Offer up the Pony Frame (S7) to the Pony Flitching (S10). (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 26 Mainframe (S4) a small amount. Adjust the folds so that they are equal and fit snugly against the sides of the Pony Flitching (S10) etch. Hold the components firmly together in alignment… (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 27 Remove the Pony Bearer etch (S6) from the fret. Fold in the four spring retaining ears around the etch, and reinforce the folds with solder. Fold up the two sides of the etch. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 28 Drill it through 0.3mm if necessary. Fold up the two arms of the etch. Support the Mainframe assembly inverted, with the top plate of the Pony Frame resting on a parallel surface. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 29 Remove the Pony Axle assembly and solder the Outer Pony Frame in position. Test the fit of the Pony Axle assembly. If necessary, make further adjustments to the Outer Pony Frame location until the desired fit is achieved. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 30 Mainframe. Remove two of the Primary Splint (S11) etches from the fret. Make the 180° folds in the Primary Splints, with the half-etched folding tag on the inside of the fold. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 31 Check the assembly for squareness, and that the sides are vertical. Reinforce the Mainframe folds, under each axle, with fillets of solder. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 32: Bachmann 'Peak': Bolster
Pass the screw through the pivot hole from the plain side of the etch, thread on the nut and tighten the assembly. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 33 Locate the tags at the inner and outer projections of the Frame firmly into their slots in the underside of the Base and solder them up. Keep solder away from the other parts of the frame for now. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 34 Check that the foldovers are parallel with the rest of the etch, and reinforce the second folds with solder. Fold up the small stiffener bracket at the top of each leg. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 35 180° folds firmly closed and solder them up. The completed Inner Leg foldup. The lower cross piece is a spacing and alignment jig which will be removed later. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 36 Make the inner fold in each sideframe support and reinforce the folds with solder. Fold in the small support brackets at the tops of the legs. Support them well to prevent them from distorting. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 37 Apply flux to the joint between the foldovers and the outer faces of the legs, crimp the 180° folds firmly closed and solder them up. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 38 Hold the Outer Leg etch firmly in place, correctly aligned and with joints pushed fully home, and hold closed the joints between Frame and Base. Solder up the Outer Legs and Frame. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 39 A tight fit can be addressed by light filing on the radiused edges: they have been drawn to be slightly over-size with half-etched guide marks to help preserve the correct shape. That completes the brasswork for the bogie bolster. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 40: Bachmann 'Peak': Preparing The Locomotive
Check that the hole in the Pivot Plate is large enough to make a free running fit with the body of the M1.5 pivot bush fitted to the Bolster. Open it out with a round file if required. Fold up the central flange of the Pivot Frame… (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 41 Fold up the flanges on either side of the Pivot Plate. Adjust the folds in the Pivot Frame to fit the Pivot Plate, and solder the two together. Reinforce the folds around the Pivot Frame with solder. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 42: Fitting The Pivot Frame
Within the bogie apertures in the chassis casting, degrease the area around the pivot holes and ensure that any lumps or bumps are scraped away. Check that the Pivot Spacers lie flat against the casting. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 43 Also cut four rectangles 11mm x 3.5mm from 20thou plastic card. These pieces of plastic card serve both as mechanical spacers and electrical insulators between the Pivot Frame and the chassis casting. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 44 2mm screws. Refit the Pivot Frames to the chassis block, securing them with the screws. Shorten the 2mm screws, as required, so that they end flush with the face of each fixing nut. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 46: Bachmann 'Peak': Modifying The Bogie Drive
Put the moulding safely to one side for now. Discard the inner wheelset, bearer and spring. Unclip the two driven wheelsets from the drive unit moulding and put them to one side. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 48: Altering The Drive Train Mouldings
We used the blind end of a 1.4mm drill, held in a pin chuck, to push the axles through. Cut the worm gear idler axle to the length marked. Chamfer the edges of the cut end with a file. Altering the Drive Train Mouldings (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 49: Inner Worm Bearing Retainer
Take great care at all stages not to damage the retaining lugs for the main axle bearings. Inner Worm Bearing Retainer Remove one of the Worm Bearing Retainer etches (D1) from the fret. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 50 Fit the inner worm bearing into position between the two plastic upstands. Fit the slots formed at the sides of the Worm Retainer around the upstands and slide the Retainer downwards so that it rests on the bearing. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 51: Reassembly
Refit the worm gear and the three idler gears and axles (the worm shaft can be left to one side for the time being, to allow for unpowered testing later on). That concludes the modifications to the bogie drive units. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 52: Bachmann 'Peak': Wheelsets
Humphrys, in Model Railway Journal No. 248. W e have used these successfully and can recommend them. An alternative design is available from Brassmasters, Ref A403 at www.brassmasters.co.uk/accessories.htm. The photo shows one of Mark's shorting (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 53 The following operations check the differential movement between the drive train and the bogie subframe. Repeat them for each bogie in turn. Collect together the Drive Unit, brass bogie Subframe, Bearing Carriers, axles and Bachmann axle bearings for the bogie. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 54 2.3mm. That concludes the test. Unclip the axles from the Drive Unit and put them to one side, ensuring that each axle bearing is kept with its respective Bearing Carrier. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 55 Check that the axles are a free running fit in the Pony Truck bearings. If you start with pin-point axles like those above, you can turn down the ends to represent the cylindrical extensions that the prototype has. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 56 Fit the other wheelset to the other Pony Truck, initially using the same number of washers (if any) as the first one. That completes the assembly of the wheelsets. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 57: Bachmann 'Peak': Springs, Bogie Assembly And Rolling Test
Splints towards the inner end of the bogie, and fit them through the holes in the tops of the Bearing Carriers. It's easiest to do this with the Splints upside down to start with, as shown. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 58 Primary Spring Seats… …to the point at which they spring inwards and back up into the seats. Turn the bogie round and insert the outer wheelset into its slots. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 59 The Pony axle is placed upside down in this photo. Place the Pony Axle on to the wheeling jig, with the Pony Bearer on top. Lower the subframe over the Pony Axle and Bearer. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 61 Bolster, to push the secondary springs outwards, one side at a time. This technique becomes more essential after you have fitted the bogie sideframes and drive units. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 62: Bachmann 'Peak': Cosmetic Bogie Frames And More Rolling Tests
NEM socket: squeeze its tails together and pull it from the socket. Reduce the projection of the NEM socket to no more than 2mm from the inside face of the buffer beam, or remove it altogether. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 63 If you have modelled the extended ends of the carrying axles, cut away the moulded versions. We drilled 0.8mm in each corner of the aperture, and used a piercing saw to cut between the holes. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 65: Bachmann 'Peak': Final Assembly 64
Special thread locking compounds can be bought. Nail varnish, or paint, will also do the job. Refit the Bolsters on to the Subframes. Clip the drive shafts - the ends with the rounded pins - into the sockets on the worm shafts. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
Page 66 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 spring mountings. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

PenBits PK017 Assembly Instructions Manual

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