Brake Modifications to the New Open Wagons

Both of the new open wagons include electrically-operated parking brakes on one bogie.  Parking brakes are essential as most of the track is on a grade due to the topography of the site.

A simple wiring modification now means that the parking brakes can be controlled from the loco control panel as well as the from the switch mounted inside the end of each wagon.  This is much more convenient when driving and avoids having to reach forward to the switch box attached to the wagon.

To avoid any problems if both switches are operated simultaneously in opposition, the wiring includes resettable fuses (Polyswitches) which limit the battery current to a safe level.

Both wagons have now been modified, so either can be used next to the loco.  The wagons are positioned to face in opposite directions to allow for running in either direction.  The loco control panel can easily be moved between the wagons as required.

Linear actuator to operate parking brakes.  (Photo by Mini Train Systems)

Loco control panel as supplied with brake switch blanked off, at lower left.  The brake switch in the wagon is at top left.  The red switch on the right is a battery isolator switch for the locomotive.

First step - installing a 4-way connector on the brake switch box ready for external control.

Final step - installing a DPDT momentary toggle switch on the loco control panel, with a 4-wire cable to plug into the wagon's brake switch box.

Delivery of New Open Wagons

 An exciting day with the delivery of two open wagons which were part of the original order placed with Mini Train Systems from early 2023.  

Although considerably overdue, it was great to finally receive the wagons.

The wagons have flexible seating arrangements, and have been supplied with one longitudinal seat and a total of four transverse seats which can be fitted in various positions.  

Each wagon has an electrically actuated parking brake on one bogie, operated from a switch inside the wagon, with power supplied from a small sealed lead acid battery.  The battery is recharged when the wagon is connected to the locomotive, and can also be recharged separately if needed.  The need to recharge should be infrequent as power is only required to apply or release the brakes, otherwise they remain in the last commanded setting.

The intention is to use one wagon as the usual "driving wagon" rather than have a dedicated "driving truck".  This was the original reason for fitting a parking brake to one wagon, then it was decided to make both wagons the same, i.e. both with parking brakes, so they could be used interchangeably.  This will make it simpler, e.g. if operating in the reverse direction on the railway.

Preparing to crane the crate from the truck

The wagons were well packed inside.

After removing the top and one side of the crate, we were able to slide each wagon sideways onto the track.

Ready for the first test run..

Completing the Passing Loop

In the same delivery with the two open wagons, was also a 10 m radius point needed to complete the passing loop at the rear of the garden near the dam.  The point was transported, by train of course, and unloaded close to the installation site.

Later the same day, with the area conveniently shaded, the temporary curved track sections were unbolted, some of the ballast removed and the new point test fitted in place.  The temporary track sections had been in place for about 6 months, meaning that the passing loop had been in use as the through track for a considerable time - see Tracklaying in the Passing Loop.

The accuracy of the prefabricated track sections was such that the fixing bolts all fitted with no adjustments needed.  With some temporary packing with pieces of wood, it was possible to run trains over the point at low speed.

The tracks on both the main line and passing loop both need additional ballast to raise them to match the height of the point, which is dictated by a large tree root which we don't want to disturb.

There is still quite a bit of work to be done, including digging out the ballast to slide in long timber sleepers on which the linear actuator will be mounted to control the points, as well as connecting the 12 V power from the nearby solar panel and battery and installing the receiver for wireless remote control of the point.

The new point roughly in place.  The long timber sleepers ready for the linear actuator mounting are to the right of the track.

The partly exposed conduit is for a 12 V power cable from the solar panel and battery installation which is located in a more sunny spot mid way along the passing loop, from where power is fed to the points at both ends.

First Steam Loco on Springdale Miniature Railway

Another Denmark resident, Rob Otway, brought over his 0-4-0 steam loco for a run.  The loco, 7 1/4" gauge of course, is a scaled up version of a "Juliet" loco originally designed for 3 1/2" gauge.  Rob and two other members of the Northern Districts Model Engineering Society built three similar locos at the same time, with completion around 2016.

As the Springdale Miniature Railway doesn't have any specific unloading facilities, Rob brought an existing ramp to allow the loco to be gently rolled down from his trailer onto the track.

After an initial run light engine in the clockwise direction, Rob decided the railway's grades would be better running anti-clockwise, so we we turned the loco by running onto an old sheet metal sign laid on one of the level crossings and swivelling it around by hand.  The three available wagons owned by Springdale Miniature Railway provided a decent load especially on the grades of up to 3%.

The video tells the story...

To provide a method of safeworking with two operating locomotives, a token or staff system was implemented so that only one loco was permitted onto the main line at any time. 

Due to fire restrictions in the Denmark shire over the summer, a repeat of the steam run won't be possible for many months.  Even in October, the trains carried pressure sprayers filled with water to take care of any minor outbreaks, which luckily didn't eventuate.

Driving Truck to Open Wagon

The first wagon on the railway, the "interim" driving truck, worked fairly well but didn't look realistic. 

The "interim driving truck" in its original form.

Another problem was that the wood used to make the underframe had a slight twist which meant the whole underframe also had a twist, so that diagonally opposite corners were about 5 mm lower than the other corners.  When constructed, 3 mm packing was inserted at the bogie bearing points to compensate for the twist in the underframe so the wagon would track correctly and not derail.

One option was to build another steel underframe similar to the brake van and re-use the bogies, etc. to make a new open wagon.

In view of the still impending arrival of two open wagons from Mini Train Systems, it was decided to live with the existing underframe and make a new body loosely based on the WAGR GE open wagons.  Conveniently, there are a couple of GE's "preserved" (i.e. rotting away) near the old Denmark station site.

A visit to the local Mitre10 to investigate suitable plywood, resulted in the purchase of 290 x 19 mm pine boards which were a good size for the sides and ends, and easier to handle and cut compared to plywood.  The boards were flat and straight with no twist.

A V-shaped bit in the route quickly made grooves for simulated boards on the sides and ends.

The new wagon body quickly took shape with aluminium angles inside and outside to join the corners, sized to match the angle irons on the original GE wagons.  Packing under opposite corners ensured the body sat level, largely masking the inherent twist in the underframe.

The basic plywood seat can slide back and forth a bit to allow the wagon to be used in either direction.

A timely purchase of a new 3D printer allowed printing of larger parts including cosmetic ribs for the ends of the wagon, based on the dimensions of the prototype's pressed metal ribs.

The handrails and vacuum brake hoses are also 3D-printed.  Further work is still required to design and print ribs and simulated door details for the wagon sides.

 

Building a Brake Van

The design for a brake van was loosely based on the proportions of the WAGR ZF 4-wheel brake van but adapted to suit the available DNC bogies.  The length of 1150 mm was dictated by the length of the storage track in the garage and the impending arrival of two bogie open wagons from Mini Train Systems.

The welded underframe is made up from 30x30 and 40x40 square steel sections.  The use of 30x30 for the side members matched the proportions of the ZF's 4-wheel underframe, but it complicated the design by requiring tapered ends on the 40x40 cross members.  All good practice at fabrication.

The bodywork at this stage is basically a mock-up made from leftover MDF board.  The eventual plan is to build a more detailed body resembling the WAGR brake van.

Testing the seating position

Handbrake lever connected via cable and pulleys to one bogie

It was decided to press the brake van into service with the temporary bodywork, so it received a couple of coats of Manor Red paint, as well as some metal and 3D-printed details to give some character, as well as working lights at both ends powered from a small LiPo battery.

The brake van has proved to be a useful addition to the railway.  It is quite comfortable to ride in and easy to get in and out of.  In the future, it might be possible to devise a sliding door to disguise the large opening in the side.

Learning to Weld - Building a Low-Floor Wagon

This project started life as a way to learn to weld, using 25 x 25 mm square steel tube salvaged from a pallet on which a ride-on mower was delivered.  After a few practice welds, I realised there was enough square tube to fabricate a low-floor wagon which would be useful for various duties.

The welder - gasless, flux core variety.

The first step was to fabricate one sideframe, and test the strength of the welds by supporting each end on a brick and standing on the middle.  It passed.

After the success with the first sideframe, I ordered a basic welding table which would greatly assist in aligning the overall frame straight and level.

The wagon frame taking shape on the welding table

Within a relatively short time-frame, a rolling wagon emerged from the workshop.  The low level floor is a piece of chipboard which rests on conveniently located lugs which were already attached to the side pieces.  

Short lengths of 25 x 50 mm rectangular tube, left behind by the previous owner of the house, provided attachment points for the bogie pivots and couplers.

I purchased flat bar from the local hardware store to fill in the end parts of the frame.

Welded areas received a good clean-up and a coat of anti-rust primer, followed by an all-over application of Colorbond Manor Red - the railway's standard wagon colour.

The low-floor wagon is routinely used to transport the lawnmower (normal size, not ride-on) and other garden tools to far flung parts of the garden, and also the carry the wheelie bin to the front gate.