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Disneyland Casey Jr. Train ride build log

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Exador

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Discussion starter · #1 ·
I've started up building a replica (well close anyway) of the Fantasyland train engine, in brass, to run on my new garden railroad. I'll post some today and continue if interest is shown. Casey will be electric, battery powered and radio controlled. All the required tubing is on order so I'm starting on the cab and rear coal/water bunker. The batteries will be in the bunker. I use Adobe Illustrator to layout the parts, print them and adhere them to the sheet to be cut out.

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Once the bunker parts are cut they are soldered together. Then I punched the rivets for the corner braces. They will be bent, trimmed and soldered in place.

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Well that's it for now. All my work is by hand. I don't have any CNC tools. More to come if there is interest.
Chris
 
Discussion starter · #3 ·
Tom Bowdler said:
What is your rivet punching method?
Click to expand...
It's actually very rudimentary. I used my drill press to create a die in some 1/2" brass square. I made it with a ball drill from a Dremel set. I then did some dots in illustrator matched to the image I am working from. I printed that, cut them out and taped them to the brass sheet. I left the ball in as a punch, jigged up everything square and hand-embossed the brass sheet. Crazy, but it worked!
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Discussion starter · #5 ·
Minor update. Tubing came so I cut the boiler and drilled it for the stack then soldered in the stack. I turned the cylinder ends and soldered them into the tube. They still need finishing. Everything that's painted gold on the prototype, I'm leaving as polished brass. Till next time!


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Discussion starter · #6 ·
Here are the components that have been made. The wheels are aluminum. I used 10mms thick blanks. They came threaded 8mm so I made a threaded bar as a turning tool. Took them down to 7.5mm. I used a Bachmann big hauler driver as a pattern for the flanges. The whistle is solid so I will cut the V and paint the inside black. Have a great Tuesday.
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Discussion starter · #7 ·
Cut and bent the chassis today. Jigged up the components with masking tape and drilled 2 holes through the chassis for each section. Waiting on the motor, cylinder connecting tubing and the main and worm gears. Next is the very cartoonish front catcher. Happy hump day!

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Discussion starter · #8 ·
Worked some yesterday and this morning. His hat/light and pilot are coming along. Threaded some stock to back fill the wheel holes. The blanks came threaded 8m. I glued in with epoxy and will shave off and drill the mounting holes on the lathe. Face insert is done and will be held in with a small machine screw. NFL divisional starts in 30min!!!
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Discussion starter · #9 ·
Shortened the boiler to the correct size. Mounted the cylinders. Drilling the wheels for the axles and side rod kingpins today. Did a scratch coat to check the colors. Best match with rattle cans!

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Discussion starter · #11 ·
He's coming along nicely. Final painting the wheels today. As to the garden layout, I've been knocking around the idea of a skyway attraction (now gone from Disneyland) to run the length of the layout, scaled at about 1:20. Did the 3d work for printing last night. With a lot of elbow grease you can get a perfect finish. Back to the workshop!
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Discussion starter · #20 ·
I remade the axles this morning for a larger machine screw on the wheels. The 2.5mms didn't do the job. Changed to 6/32. Now I need to put the wheels back on the lathe and drill out the centers. Painting the roof the proper blue is on today's list.
 
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Exador
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