Details on the lids, the steps, handrails, and bearing blocks are the parts that were made during the last month. Most of these parts are directly made from the works drawings of the wagon. These drawings show the parts with dimensions and with almost all the details. This makes making the Solidworks drawing also a lot easier.
The first things to make were the angle profiles on the lower top of the lids. I had no small profiles at hand, so they are built up from two strips of 1 mm sheet metal.
With the CNC mill, this small die was made, for forming the ends of a profile.
In the vice of the shaper, the 1 mm strips are formed.
The surplus is cut and filed away...
Scribing the curve...
....to make the corners of the profile.
I don't know if these top profiles are used to stiffen the lids, or if they are designed to give support to the feet of the people who have to climb on the lids to pull them open. I can imagine that this way operators could walk on the lids, without the risk to slide away and fall off the wagon.
Hand grips
Hand grips on lids, wagon corners, and doors.
With a simple homemade bending tool the grips are made of 2 mm steel wire (welding rods)
With this tool is easier to make all the 12 grips of the same size and shape
The ends, by which they will be riveted on the lids, are flattened (squeezed) in the vice, between some hardened blocks
The hand grips used to open the lids are ready for drilling and riveting.
Profiles (footrests?) and hand grips riveted on the lids
A photo of the wagon at Fond de Grass "Train 1900"
With the Gressel profile bender, small shackles are bent.
The shackles and hooks, that are used to connect the opened lids, if both sides had to be open simultaneous.
The hooks on the real wagon.
The same bending tools are used to make the side and door grips. These are made of 2,5 mm wire.
Steps
On one side the wagon has steps, to climb on top of the wagon. They are made of 1 mm steel plate.
The curved handrails were also bent with the Gressel bender. A bit of trial and error was needed to make two mirrored parts with identical shapes and dimensions.
Most of the details were made.
Bearing blocks
The bearing blocks (horn blocks) are an exact copy of the ones used on the Omk open wagon and Beer wagon.
The shaper comes to use for making the back plate of the bearing blocks.
Milling them to shape
and boring out the 37,5 mm hole.
The body of the bearing block is turned from 40 mm stock material
The bearing blocks (horn blocks) are almost completed.
Next are the leave springs and the turning of the wheel castings.