by a Japanese enthusiast
Latest report ->
Live Steam From Castings
by a Japanese enthusiast
Latest report ->
The Second Project "C53"
< Start of New Project > 10 May 2006
< Casting Pattern Making > 10 Aug. 2006
< Leaf Spring Set And All > 20 Nov. 2006
< Start Erection of Frames > 20 Feb. 2007
< Rear Side Frames > 20 Apr. 2007
< Status of the Castings > 20 May 2007
< Expansion Link Brackets > 20 Jun 2007
< Parts for the Main Frames > 20 Jul. 2007
< Complete Chassis > 20 Aug. 2007
< Leading & Trailing Wheels > 20 Sep. 2007
< Equalizing System 1 > 20 Oct. 2007
< Equalizing System 2 > 20 Nov. 2007
< Bogie Truck 1 > 22 Dec. 2007
< Bogie Truck 2 > 20 Jan. 2008
< Rear Pony Truck 1 > 20 Feb. 2008
< Rear Pony Truck 2 > 20 Mar. 2008
< Driver Truck Modification > 20 Apr. 2008
< Driving Wheel Cutting 1 > 20 May 2008
< Driving Wheel Cutting 2 > 20 Jun 2008
< Driving Wheel Assembly 1 > 20 Jul. 2008
< Driving Wheel Assembly 2 > 20 Aug. 2008
< Driving Wheel Assembly 3 > 20 Sep. 2008
< Driving Wheel Assembly 4 > 20 Oct. 2008
< Brake System 1 > 20 Nov. 2008
< Brake System 2 > 20 Dec. 2008
< Brake System 3 > 20 Jan. 2009
< Brake System 4 > 20 Feb. 2009
< Cylinder Block Design > 20 Mar. 2009
< Cylinder Block Casting > 20 Apr. 2009
< Cylinder Block Cutting 1 > 20 May 2009
< Cylinder Block Cutting 2 > 20 Jun 2009
< Cylinder Block Cutting 3 > 20 Jul. 2009
< Castings for Cylinder Assembly > 20 Aug. 2009
< Valve Liner 1 > 20 Sep. 2009
< Valve Liner 2 > 20 Oct. 2009 New
Building the New Shay (A 1920s Shay in 3/4" Scale)
Kozo Hiraoka
This is Kozo Hiraoka's latest model steam
locomotive construction guide book that was
issued few weeks ago. Apart from the fact
that the author is Japanese as I am, I think
this is world's number one book in this field
! The main content is construction manual
of 3/4" scale 1920s Shay which was published
serially in Live Steam magazine. If you had
already read the magazine, you will agree
with me that Kozo's serial far surpassed
other articles in the magazine. From the
serial, I had learned a lot of techniques
of both construction and designing for model
locomotive. Moreover, the author presents
many appendixes for the book, e.g. redesigning
of the New Shay for 1-1/2" scale, how
to design copper boiler and safety valve,
how to utilize o-rings, etc. You can get
new and powerful technology of model engineering
from the book. I am proud that such excellent
book was written by a Japanese.
The First Project "William"
< Introduction >
"If you buy one, you have to pay money
for a luxury car. If you build, you need
skill of a professional machinist."
This is understanding of Japanese modellers
about the livesteam locomotives. Actually
the famous OS's variety is rather cheaper
choice in Japan. To obtain a scale model
of Japanese latest tender loco, we have to
pay more than $20,000 for 3 1/2" gauge
and $50,000 for 5" gauge! Also even
if we try to scratch-build, Japanese guidebooks
were already sold out several years
ago. These are both causes and effects of
lower population of livesteamers in Japan
than in USA or U.K. However, in recent years,
number of full scale steam locomotives revived
in this country, consequently many of official
garden railway rose and it brought up amateur
livesteamers. I found one of such a garden
railway in my neighborhood and it made me
become
a livesteamer!
This story isn't a guidance for beginners,
because I am still a beginner! This is a
documentary of a man who wish to build a
locomotive by himself. Nobody knows if
he will complete the job or not.
< What shall I build? >
With too much ambition and poor finances,
I determined to build a loco from castings.
Luckily I got the old Japanese guidebooks
from a chap and purchased English books through
the Internet. I chose Martin Evans' 3 1/2"
gauge 2-6-2 tank loco, "William",
as a first job because of its simplicity,
nice looks and suitable size for both construction
and service.
< Modification >
I have to transform the dimensions from imperial
to metric so as to suit to Japanese tools
and materials. As you know:
1" = 25.4 mm
But I adopt:
1" = 25.6 mm
Because the latter formula transforms 1/32"
to 0.8mm while the former transforms 1/32"
to 0.79375mm! Of course I have to obey the
former formula just at the backgauge and
the frame spacing. Also I have to change
threads from ME to metric.
Later on I modified the appearance of the
loco because my wife said the original William
don't looks like a locomotive! William is
a freelance but simulated powerful engine
with a fat boiler. I guess it looks too boxy
for her. I changed the scale from 1/16 (3/4"scale)
to 1/12 (1"scale) imaging narrow Japanese
national railroad. To increase width and
height I will alter chimney, dome, cab and
running boards, on the other hand I leave
functional devices, boiler, wheels, valves
and cylinders, as they are.
< Workshop >
Following are tools in my workshop
Lathe - Myford S7 and accessories
Miller - Japanese small one
Machine vise
Bench vise
Vertical slider
Rotary table
Files - Nicolson's variety
Drills, taps and dies
Hacksaw with high speed steel
Surface plate and height gauge
Digital caliper gauge
Propane blowpipe - Sievert set
I was eager to have the Myford Super 7 for
its popularity in the model engineering world.
However no second hand metric one is available
and a new one costs almost double of U.K.
price! I spent almost of the budget to get
it and have no money to renew the miller.
My old miller is a tiny one and suitable
for HO model construction. So I have to do
milling operations mainly using a vertical
slider in the lathe. I never recommend for
new comer to purchase all of the necessary
tools at start. The reason is not only for
its cost but also he cannot judge a tool
is suitable for his work or not. In my opinion,
Asian cheap tools which you can get at do-it-yourself
shop aren't suitable for our purpose. If
there is no model-engineering supplier around
your residence, you can buy tools from commercial
companies for industry. They usually reject
personal trade. But if you explain what you
want to do and how it brings profit to them,
they accept you and you can get professional
tools with bargain price!
< Handmade Tools >
Die holder for tailstock : The arbor is made
from a commercial blank arbor.
Wobbler : With brass ball and case hardened
2mm steel wire.
Cutter arbor : Ring and arbor are silver
soldered before turning.
Castings from "Reeves":
Key items, 2 driving wheels and 1 cylinder
block, were out of stock in the supplier
at start. So I first tackled with the boiler
instead of the chassis.
P.S.
The above mentioned is a condition in October
2000. I have done many modifications for
my first project. Please refer following
report.
< Outer Boiler > 1 Nov. 2000
< Inner Boiler > 1 Nov. 2000
< Complete the Boiler > 1 Nov. 2000
< Pony Trucks > 1 Nov. 2000
< Main Frames > 1 Nov. 2000
< Axlebox > 1 Nov. 2000
< Knuckle Coupler > 1 Nov. 2000
< Axle Driven Pump > 23 Feb. 2001
< Driving and Coupled Wheels > 18 Apr. 2001
< Wood Pattern for Cylinder Block > 14 Jul. 2001
< Coupling Rods > 25 Aug. 2001
< 3DCG > 20 Sep. 2001
< Cylinders and Pistons > 20 Nov. 2001
< Piston Valves > 20 Nov. 2001
< Connecting Rods > 20 Dec. 2001
< Crossheads > 20 Apr. 2002
< Motion Plates etc. > 20 Jun. 2002
< Expansion Links > 30 Aug. 2002
< Valve Gear Parts > 26 Oct. 2002
< Cab Reverser > 26 Oct. 2002
< Air Testing > 7 Dec. 2002
< Smokebox > 15 Jan. 2003
< Superheater > 20 Feb. 2003
< Drain System > 26 Mar. 2003
< Grate, Ashpan and Firedoor > 20 May. 2003
< Fittings 1 > 20 Jun. 2003
< Fittings 2 > 20 Jul. 2003
< Emergency Hand Pump > 20 Aug. 2003
< Mechanical Lubricator > 20 Sep. 2003
< Safety Valves & Water Unit > 21 Oct. 2003
< First Steaming Up > 20 Nov. 2003
< Running Boards > 20 Dec. 2003
< Whistles 1 > 20 Jan. 2004
< Whistles 2 > 20 Feb. 2004
< Brake Gear > 20 Mar. 2004
< Chassis Painting > 20 Apr. 2004
< Outer Dome > 20 May. 2004
< Sand Dome > 20 Jun. 2004
< Lagging & Cleading > 20 Jul. 2004
< Loading Boiler > 21 Aug. 2004
< Bending Rolls > 16 Oct. 2004
< Platework 1 > 19 Nov. 2004
< Platework 2 > 20 Dec. 2004
< Platework 3 > 24 Jan. 2005
< Detail Work 1 > 20 Feb. 2005
< Detail Work 2 > 20 Mar. 2005
< Detail Work 3 > 20 Apr. 2005
< Detail Work 4 > 20 May. 2005
< Detail Work 5 > 20 Jun. 2005
< Perfection > 20 Jul. 2005
< Tacet > 21 Aug. 2005
The loco was completed on July 2005. Thank
you very much!
This serial report will be reopened someday...
< LINKS >
"LIVE STEAMING"
Immence information about live steam and
model engineering. Recommended
"Hobby Mechanics"
Australian supplier of castings, tools and
accessories
"Discover Live Steam"
Online magazine with huge information about
the live steam
"Building Miniature Live Steam Locomotives in 1/8 scale
"
A full scratch livesteam locomotive construction
report. Recommended
"BLACKGATES ENGINEERING"
Supplier of drawings, castings, tools and
materials
"REEVES 2000"
Revival of the "world's largest stockists
of ME supplies"
"E & J WINTER"
Australian ME supplies
"Bailey Steam Engineering"
Manufacture and restoration of all types
of models