Specifically, I'm going to cut a hole in the roof of a LIONEL 15" aluminum, smooth-sided coach to fit a standard size vista dome. It will be offset to replicate the prototype Budd dome, so the typical, center-of-roof cars won't work for me.
Any "how to's" involving cutting aluminum (including prep work, tools needed, etc.) would be welcome.
Thanks for any assistance.
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Having a friend with a machine shop would be a plus.
Having a factory dome car with the dome removed to provide measurements and locations is a must.
I have a set of Weaver Wabash Aluminum 20" cars that I would like to add domes to (2) coaches and the observsation car to make a Bluebird consist. As far as machining goes, I think locating a start hole in the center of the car width wise and matching it to the location of the factory dome car and Wire EDM it to size would be the best way to go. It would require only partial submersion as not to soak any striping decals and may require minimum paint touch up after the EDM process.
Roy Boy, I had a PW 2531 done by a machinist buddy when I was in Chicago 20+ years ago with an offset like the CZ dome obs cars. Gave him the shell marked with where the cut should go, and a dome--a week later he gave me back the cut shell and dome which fit great. Need to find one in metro Atlanta.
I have a new dome on the way, a LIONEL dome for measuring the hole, and a Budd drawing of the prototype to get pretty close to a prototype representation of the offset.
Chas, I'd never heard of Electrical Discharge Machining with wire before your post--thanks. I'll check that as well. Since the donor car is primed and w/o decals, I'm not concerned about paint or decals.
Domes for the Bluebird would be sweet! Hope you can do it.
While a milling machine would be nice, you can do it with a few drill bits, hacksaw and files. Cover the roof with a couple of layers of masking tape and carefully layout the hole. Drill holes at the corners inside of the line and cut with the hacksaw also inside the lines. Then finish with files.
I knew a German immigrant who learned the trade in Germany. The first year they used only hand tools and among other objects they had to make a perfect cube in steel using only saws and files.
The alloy used in these cars is pretty soft and easily worked with hand tools.
Pete
Chas, if you get domes from Weaver, I'd be very grateful if you would send me the dimensions--length and width--since I have three NOS 21" aluminum cars manufactured in the '80's that need modern, standard domes. Hope you can oblige.
Norton, thanks for an alternate approach; it sounds very feasible with hand tools--I think I have everything except, perhaps, a suitable file(s).
And here I am with a Weaver N&W dome wishing I had a regular roof insert to replace it 
If I thought we could do a swap I'd be all over it, but removing your piece of roof so my dome would fit would leave your piece of roof too short for my purposes.
This is a fascinating project. Please keep us posted, Carl.
Great project! Good luck. Carl - Please post the results.
PTC and Howard, I will for sure keep you advised of my progress.
Bob, it would drive me crazy to buy scale sized passenger sets and be stuck with a dome the prototype never used; i.e. 20% of the 5-car set is "wasted $$$" for a car you don't want.
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