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"Master Builder - Cars" -- Page 1

The "Master Builder - Cars" Certificate was the 6th certificate out of seven I earned. Frankly, I saved this one for the end because, until I got involved with the Achievement Program, I had never even detailed a freight car, let alone built one from scratch. While I felt totally comfortable scratchbuilding structures, when I looked at freight cars, I was completely baffled. Thus, of all the certificates, this one was the hardest for me, but, in the end, probably the most gratifying. My learning went from Zero to 100, and I found out it's not all that hard to build cars!

Even though the requirements state that four of the eight cars must be scratchbuilt, because this was new learning to me and I wanted to improve both my skills and my comfort level, I opted to scratchbuild seven.

I earned this certificate on October 6, 2004.

The NMRA regulations for this Certificate state (as usual, I1ve edited these for this website; please visit www.nmra.org for the complete set):

You must build eight operable scale models of railroad cars. There must be at least four different types of cars represented, and one of these must be a passenger car.

Each of the eight models must be super detailed with either commercial parts or scratch built parts.

At least four of the eight models must be scratch built. [Then the hard part:] You must earn a score of at least 87-1/2 points on four of the eight models in either an NMRA sponsored contest or in AP Merit Award judging.

So after panicking a while and reading lots of car construction articles in magazines (there aren't as many as you think!) I dove in.

I took a load of construction shots of each of the cars I scratchbuilt, but to save on server space (and lower the boredom factor), I just included a few for each of the cars. Also, it would be nuts to include the full contest documentation for each of the four judged cars, so I'm just including highlights (in red) here.


Car #1: Pacific Fruit Express Reefer

Judged at Thousand Lakes Region 2004 convention: 
    Construction: 30 of 40 points
    Detail: 16 of 20 points
    Conformity: 22 of 25 points
    Finish & Lettering: 22 of 25 points
    Scratchbuilding: 14 of 15 points

   TOTAL POINTS: 104 of 125 points -- Merit Award Winner   

This is the very first car I ever scratchbuilt, and I have to say, it remains one of my favorites.

The entire underframe of the car was scratchbuilt from styrene, including the bolsters and all crossbearers. The car has a "K-style" brake system, to which I added complete piping.
Car sides are built of scribed styrene sheet, with corner braces made from styrene strips and Tichy nut/bolt/washer castings.
Before I learned a few tricks, I made each halfof the roofwalk supports from individual pieces of styrene.
The end of the car. The ladders were scratchbuilt from brass "L" and wire stock, and soldered with a resistance soldering unit (also scratchbuilt, from an article on the web!), grabirons and coupler lifters are bent from brass wire, and poling pockets were made from styrene. The brake hose is from Details West.
Here's the final car. Because I'm fortunate enough to have an Alps printer, even the decals were scratchmade -- I drew them in Adobe Illustrator. The car is prototypically painted in Reefer Orange and Oxide Red.

 

Car #2: Pennsylvania RR Flatcar (non-riveted version)

Judged at Thousand Lakes Region 2004 convention: 
   
Construction: 35.5 of 40 points
    Detail: 15 of 20 points
    Conformity: 24 of 25 points
    Finish & Lettering: 23 of 25 points
    Scratchbuilding: 14 of 15 points

   TOTAL POINTS: 111.5 of 125 points -- Merit Award Winner   

I didn't want to build all "boxes" for cars (reefers, boxcars, etc.) so I found a great "scratchbuild your first car" article by (NAME) in Model Railroader that held my hand in building a flatcar. There were two versions discussed in the article -- a riveted and non-riveted version. At the time I had no idea how to make rivets, so I opted for the latter.

Here's the underframe. As with the reefer, all parts are scratchbuilt from styrene strips.

The underside of the car is completely prototypically piped with an AB-brake system (parts by NAME).
The hardest part of this car, believe it or not, was figuring out how to make the stake pockets. (Yes, Tichy also manufactures those, but I wanted to scratchbuild as much of this car as I could.) After making several attempts at bending flat brass stock, friend Les Breuer suggested using styrene "C" channel, and adding "ears" on either side. A brilliant solution, seen here.
The finished car has individual boards on the deck, along with the full compliment of grabirons and stake pockets.

Car #3: Pennsylvania RR Flatcar (riveted version)
Judged at Thousand Lakes Region 2004 convention: 
    Construction: 37 of 40 points
    Detail: 16 of 20 points
    Conformity: 22 of 25 points
    Finish & Lettering: 22 of 25 points
    Scratchbuilding: 14 of 15 points

   TOTAL POINTS: 111 of 125 points -- Merit Award Winner   

Somewhere along the line I figured out how to make a riveter (similar to the one from Northwest Short Line) out of an old drillpress. (I wrote an article about doing this which will appear in Railroad Model Craftsman magazine in late 2005.) So I was hot to trot to try it on the flatcar.

So I made another one, similar to the one above. This one, however, had full riveting on both the underframe and the sides. If you look closely at this shot, you can see the lines of rivets, embossed into scale 1"x2" styrene strips.

Except for the rivets -- which about doubled the amount of time spent building the car -- this flatcar is identical to the one above. Here you can see a closeup of the brake wheel, to which I added a watch gear and small piece of wire to represent a ratchet and pawl.
The end of the car features scratchbuilt grabirons, coupler lifters, and poling pockets, as well as a Details West air hose.
From this view the car looks a lot line the one above. However, again, there is full riveting on the sides and underframe. And to this car I added a .020" Tichy rivet to each of the stake pocket "ears."

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