The hornblocks, which have the function of taking up the axle boxes and are made of brass. On the real locomotive they are cast, but for the model they are milled out of brass rods. This is because square material was not available.
The real thing; the hornblocks are visible at the top of the picture.
The milling machine, now running without any strange noises.
A carton box was used to catch the flying brass chips. Otherwise, they end up all over the place.
Making the first reference face.
With a small edge, they will fit inside the frame.
The top of the hornblocks has a small oil box.
A radius is made with a radius cutter. I didn't have one in 10 mm, as I originally designed, so it was changed to 8 mm. In Solidworks this is quickly done and checked that this change does not interfere with other components.
Drilled oil boxes in the upper parts.
The recently bought bandsaw came to use, for cutting the side parts to length.
An orderly test fitting; this way I'm able to keep the left- and righthand part apart
With a carbide mill the sides are cut.
Drilling 3mm holes has been done on the drilling machine.
The horns are than used as a drilling guide for the holes in the frames
With M3 bolts and nuts, the hornblock is fixed to the frame.
The frames were laser cut, which gives accurate overall dimensions.
No afterwards milling or straighting is therefore necessary. Only a slight touch up with smooth file is sufficient.
The front hornblocks have a cut-out, to give room to the cylinders
Although the hornblocks are made from three separate parts, this will not have many consequences concerning the strength. A live steam working model is experiencing much lighter loads and forces than the real thing.
Axle boxes are the next parts to be made.
A general overview.