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Post by gwr1509 on Feb 15, 2021 19:50:11 GMT
Hello and welcome to my new project “Locomotive Ser. 629 (ÖBB 77) 4-6-2T locomotive on 5” gauge”. I started this project about 10 years ago. In the meantime, other model construction had to be completed. The original plans from the year 1913-14 were studied and partially constructed in CAD for 1:11 and I created many pictures and researched the model from the original. Plans were acquired through the Austrian State archives. Some details about the ÖBB 77 (Austrian Federal Rail Company) in original and converted for model: 77.28_06.08.2017 by Helmut Jarosch, auf Flickr 77.250_20.11.2010 by Helmut Jarosch, auf Flickr Cylinder Bore: 475mm > 43,2mm (1,7”) Diameter Driving/Coupled wheels: 1574mm > 143,1mm (5,6”) Bogie and Trailing wheels dia: 994mm > 90,4mm (3,6”) Length over buffers: 13268mm > 1206,2mm (47,5”) Speed: 90km/h (56mph) > First construction year: 1914 There are no casting parts or finished components for this locomotive available, so everything (better said: the most) is manufactured by me in the own model workshop. I am not averse to new techniques (CNC, 3D printing, ...) and I also use them. I think there will be a long construction period, but if there is interest for you, I will report here in the forum. Most of it is shown in pictures as my English is no longer up to date, but I hope it will improve with your help. Thanks to all who look in and support me with their knowledge during the construction, this will be a long project. To start, I milled all the parts for the bogie truck on my Emco FB2 (converted to CNC myself). 77.72_0001 by Helmut Jarosch, auf Flickr 77.72_0002 by Helmut Jarosch, auf Flickr The main frames are laser cut mild steel material with 3mm (1/8”) in thickness and 43 5/64in long. Quite a bit of work was drilling the over 400 holes per frame. 77.72_0003 by Helmut Jarosch, auf Flickr 77.72_0004 by Helmut Jarosch, auf Flickr Now the beginning of this construction has been made and let us see how it goes on. Greetings Helmut
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Post by steamer5 on Feb 15, 2021 20:05:07 GMT
Hi Helmut, I’m in for the long haul! You are off to a great start, looking forward to updates as you post.
Cheers Kerrin
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lennart
Involved Member
Currently building a Kennion's Chub as a first steam loco
Posts: 74
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Post by lennart on Feb 15, 2021 20:33:12 GMT
Hello,
this looks like a very inetersting project.
It is pretty odd that an Austrian and a German talk to each other in english but then the others that read this would understand it, too.
I spotted a 3D-printed wheel on the 4th picture, not sure if it is a dummy or a casting pattern. If you intend to have them cast I could recomend a foundry. The Hepako foundry in Syke, Lower Saxony, is specialised in one-offs and other small stuff that most other foundrys wouldn't want to deal with. I have no personal experience with the company but several other model engineers had some parts cast by them and were happy with both the quality and the price.
Have you already decided to build her with the standard chimney or the Giesl ejector?
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mbrown
Elder Statesman
Posts: 1,719
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Post by mbrown on Feb 15, 2021 20:41:09 GMT
Good to see someone else building a loco in the Continental European tradition of design! Your CNC work is way ahead of my old fashioned techniques and I look forward to seeing a lot more of your methods. Is this a Golsdorf design, by the way? I find his locos strangely impressive without being able to say quite what the fascination is!
Best wishes
Malcolm
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johnd
Part of the e-furniture
Posts: 281
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Post by johnd on Feb 15, 2021 22:11:43 GMT
Helmut,
Looking forward to following your build, your English descriptions are excellent, please continue with them.
Full steam ahead.
Daggers
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Post by coniston on Feb 15, 2021 23:52:36 GMT
Hi Helmut, I look forward to seeing and reading about your build, it will be very interesting I am sure. So far your work looks to be excellent.
Chris D
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stevep
Elder Statesman
Posts: 1,070
Member is Online
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Post by stevep on Feb 16, 2021 9:34:53 GMT
Your English is way better than my German. Keep posting pictures and descriptions.
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Post by hunslet on Feb 16, 2021 15:03:58 GMT
Hallo Helmut Woher hast Du gelernt so gut Englisch sprechen können? Fehlerfrei und klar, viel spaß beim Bau🛠 Diese ist sprach übung für mein mangelhafte sprachkentnisse. Ich baue momentan Evans 5Zoll B1.
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Post by gwr1509 on Feb 16, 2021 19:20:11 GMT
Hello, many thanks to you for the friendly reception and the kind words. Information about the original locomotive: Constructed by locomotive director Mr. Prossy and Engineer Mr. Steffan of the Southern Railway (Südbahn). Since the locomotive Ser. 629 proved itself excellently on the Southern Railway, the Imperial Royal Austrian State Railways (KkStB) with his Engineer Mr. Gölsdorf took over this locomotive with minor deviations. Over the time there were different versions. Concerns the chimney in round (Prüßmann), flat (Giesl-Ejektor) or Kobel. First building locomotives were equipped with Walschaerts valve gear, later with Valve control Capriotti or Lentz. A total of 85 units of this series were built in Austria until the year 1927. From 1938 the series 629 was renamed series 77. lennart : this 3D-printed wheel was a first attempt with PLA. Now I print models for the castings with PolyCast filament. The horns with oversize for the bogie are waiting on machining. All wheels are ready printed with the 3D-printer and shipped in the near future to the foundry. Thank you very much for your offer with the foundry in Syke. If it is necessary, I'll be happy to come back to you. For the chimney the round design is planned, so I can change between Prüßmann and Kobel. 77.72_0005 by Helmut Jarosch, auf Flickr 77.72_0006 by Helmut Jarosch, auf Flickr 77.72_0009 by Helmut Jarosch, auf Flickr 77.72_0010 by Helmut Jarosch, auf Flickr First attempt at a coupled wheel casting. 77.72_0007 by Helmut Jarosch, auf Flickr And this is one of my ladies in the workshop Emco_FB2_CNC by Helmut Jarosch, auf Flickr Greetings and thank you again. Helmut
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Post by gwr1509 on Feb 20, 2021 19:29:23 GMT
Hello, it´s going on slowly. Today the part 1 of the rear buffer beam (steel 1,5mm) was milled on the FB2-CNC and holes only centered. All holes are pre-drilled once with the 1.6mm drill. Rear side of the original locomotive: 77.72_0011 by Helmut Jarosch, auf Flickr Result in the workshop: 77.72_0012 by Helmut Jarosch, auf Flickr 77.72_0013 by Helmut Jarosch, auf Flickr Greetings and a nice weekend Helmut
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Post by gwr1509 on Sept 15, 2021 15:30:14 GMT
Hello, now there is no turning back . Last weekend I was able to pick up the cast wheels. I am very satisfied with the quality. For motivation, I put the wheels together on the frame. IMG_3418 by Helmut Jarosch, auf Flickr IMG_3417 by Helmut Jarosch, auf Flickr Regards Helmut
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Post by coniston on Sept 15, 2021 18:16:05 GMT
Lovely looking castings.
Chris
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Post by davewoo on Sept 16, 2021 5:16:38 GMT
This is a great project Helmut, as a dinosaur with very little in the way of computing skills I am in awe of anyone that can do this, please keep posting as you progress. I agree with Chris the castings are lovely, most envious!
Dave
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Post by 92220 on Sept 17, 2021 8:16:40 GMT
Hi Helmut.
Lovely looking castings, but what material are they cast from? Those spokes may be too thin to stand the loads and hammerings from use on tracks that tend to have very uneven rail joints. When I had my wheels cast, they were cast in 316L stainless steel. The spokes are scale section, and cast iron was considered to be too brittle, and easily cracked. The casters advised me of the contraction rate for the stainless, so that I could make the patterns to the right sizes, and the castings ended up within 0.003" of scale size on diameter, so spokes also dead to scale section. The stainless was easier to machine with HSS (sharp!) than with carbide tips. I guessed that was because the carbide tips I had, although brand new, were not as sharp as I could get the HSS tools. Carbide these days, can be ground much sharper.
Bob.
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Post by gwr1509 on Sept 19, 2021 16:25:04 GMT
Hello,
because of the thin spokes I agree with you. Therefore the wheels are made of steel castings C45 (I think the new designation = 1.0446). I do hope that the spokes will take the mechanical strain off.
Regards Helmut
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Post by ettingtonliam on Sept 19, 2021 21:51:31 GMT
Did no one consider Spheroidal graphite (SG) iron? Much less brittle than ordinary grey iron, machines easily, just prone to producing more dust than grey iron. Its only slightly more expensive. The tender wheels for Locomotion have very slender spokes, and they were cast with a solid back, which had then to be machined away leaving the spokes in fresh air so to speak. Theres a note on the drawing suggesting furnace annealing before machining. I just put them in the fire at the end of an evening, and lifted them out of the ashes in the morning. I don't know if it did any good, but it didn't seem to do any harm.
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Post by gwr1509 on Oct 1, 2021 18:19:30 GMT
Evening all, it continues with the machining of the horns for the bogie. Each pair horns is fitted with 14 screws and nuts M2 to the frame and when this is all happens, the final dimensions then takes place in the milling machine. The next job is making the axleboxes. 77.72_0017 by Helmut Jarosch, auf Flickr 77.72_0018 by Helmut Jarosch, auf Flickr 77.72_0019 by Helmut Jarosch, auf Flickr Regards Helmut
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Post by gwr1509 on Oct 16, 2021 15:55:55 GMT
Hello, it continues with the processing of the axleboxes for the bogie. The oil grooves were milled in on both sides with a 1mm end mill. With this little end mill it is a very slow work , but I like this grooves. 77.72_0020 by Helmut Jarosch, auf Flickr 77.72_0021 by Helmut Jarosch, auf Flickr Regards Helmut
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Post by 92220 on Oct 17, 2021 9:17:45 GMT
Hello, because of the thin spokes I agree with you. Therefore the wheels are made of steel castings C45 (I think the new designation = 1.0446). I do hope that the spokes will take the mechanical strain off. Regards Helmut Hi Helmut. That's good. The steel castings should be fine, and also easy to machine. It's going to be a lovely looking loco!! Bob.
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Post by gwr1509 on Oct 30, 2021 17:14:07 GMT
Hello, got a little further. Now the keeps are fitted and than bore out the axle diameter. 77.72_0022 by Helmut Jarosch, auf Flickr Regards Helmut
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