I recently purchased the tooling for the big Harmon passenger cars in standard gauge - they are about 28" long and about 4.5 inches wide and tall. Cast roof, floor and ends. One of the guys on this forum (will let him come forward) asked me to build a set for him to match the late 1940's Hiawatha set, including the Skytop that I can print on the 3D printer. He also encouraged me to document the development of the set, so here goes:
The patterns are at the foundry for the cast parts, I modified the patterns to remove some weight, but within the limits of the casting process - they will still be heavy.
I am designing new sides, which will be .040 aluminum and fastened to the roof and floor (sample car attached). That allows me to model pretty much any smooth side modern passenger car, and all of the Milwaukee cars are unique, round and oval windows and the like. The sides will be cut out on a high pressure water jet, giving me extremely tight tolerances and affordability at the same time and letting me cut the unique shaped windows.
Here's some first photos of the details, the Skytop end print ended last night after 33 hours of print. Also a CAD screen shot of one of the sleeper car window designs.
Will be a 10 car train. We'll see if the Super 381 can handle that!
Jim Waterman