Balanced Air Brakes from Scratch: Difference between revisions

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== Build Gallery ==
== Build Gallery ==
=== Air Tank ===


<gallery widths="300px" heights="300px">
<gallery widths="300px" heights="300px">
File:FreightTruckAirBrakes1.jpg|I started with the air tank.  It is constructed using 2 inch diameter PVC pipe (schedule 40) with a pair of caps.  A hole was drilled and tapped for 10-32 threads to accept a Clippard fitting.  An adhesive dot was placed over the hole before painting.
File:FreightTruckAirBrakes1.jpg|I started with the air tank.  It is constructed using 2 inch diameter PVC pipe (schedule 40) with a pair of caps.  A hole was drilled and tapped for 10-32 threads to accept a Clippard fitting.  An adhesive dot was placed over the hole before painting.
File:FreightTruckAirbrakes2.jpg|PVC glue was applied to the threaded hole before inserting the Clippart CT4 1/16 hose barb fitting.  Be careful with the glue.  As you can see it will remove paint.
</gallery>
 
=== Brake Shoes ===
 
<gallery widths="300px" heights="300px">
File:FreightTruckAirBrakes4.jpg|In an effort to save money I decided to cut brakes from a ring of aluminum purchased from [http://www.mcmaster.com McMaster-Carr].  The pipe has a 4 inch inside diameter and a 6 inch outside diameter.
File:FreightTruckAirBrakes4.jpg|In an effort to save money I decided to cut brakes from a ring of aluminum purchased from [http://www.mcmaster.com McMaster-Carr].  The pipe has a 4 inch inside diameter and a 6 inch outside diameter.
File:FreightTruckAirBrakes5.jpg|A 1/2 inch width of the aluminum pipe was parted off on the lathe. Here it has been [https://en.wikipedia.org/wiki/Marking_blue blued] and marked for cutting.
File:FreightTruckAirBrakes5.jpg|A 1/2 inch width of the aluminum pipe was parted off on the lathe. Here it has been [https://en.wikipedia.org/wiki/Marking_blue blued] and marked for cutting.
</gallery>
=== Mechanical Drawings ===
<gallery widths="300px" heights="300px">
File:CabooseBrakes BrakeShaft.jpg|Brake Shaft for Caboose Trucks.  Two required per truck.
File:CabooseBrakes BrakeShaftDetail.jpg|End detail of Brake Shaft.  Turn ends down to 3/8 inch on lathe.  Drill and tap for 8-32 threads 1/4 inch deep.
File:CabooseBrakes BrakeHanger.jpg|Brake Hanger, four required per truck.
File:CabooseBrakes BrakeShaftStrut.jpg|Brake shaft strut, two required per Brake Shaft.
</gallery>
</gallery>

Revision as of 23:13, 27 October 2015

by Daris A Nevil

Fall 2015

During the summer of 2015 I began studying air brakes and how live steam modelers incorporate working air brake systems on their trains. I was well into building a Kitsap Live Steamers caboose kit and decided to add a fully operational balanced air brake system to the caboose.

This is my first attempt at building operating air brakes, and I am quite pleased with the results. Air brakes will certainly be added to my other equipment.

Equipment

Here is a spread of Clippard parts used for the balanced air brake system.
  • Clippard parts:
    • UDR-17-1 : Stainless steel double-acting cylinder, 1 inch stroke, 1-1/16 inch bore, 5/16 inch shaft
    • CT4 : #10-32 to 1/8” ID Hose Connector, designed for Clippard's Polyurethane hose
    • T44-4 : Tee fitting, 1/8 inch ID
    • URH1-0804-BKS : Urethane tube 1/8 inch ID
    • TV-3SP : 3-Way Toggle Valve, ENP Steel Toggle, 1/8" NPT
    • MCV-2 : Check Valve, #10-32 Ports
    • 15090-1 : 1/8” NPT to #10-32 “L” Fitting

Tools and Supplies

Build Gallery

Air Tank

  • I started with the air tank. It is constructed using 2 inch diameter PVC pipe (schedule 40) with a pair of caps. A hole was drilled and tapped for 10-32 threads to accept a Clippard fitting. An adhesive dot was placed over the hole before painting.

    I started with the air tank. It is constructed using 2 inch diameter PVC pipe (schedule 40) with a pair of caps. A hole was drilled and tapped for 10-32 threads to accept a Clippard fitting. An adhesive dot was placed over the hole before painting.

Brake Shoes

  • In an effort to save money I decided to cut brakes from a ring of aluminum purchased from McMaster-Carr. The pipe has a 4 inch inside diameter and a 6 inch outside diameter.

    In an effort to save money I decided to cut brakes from a ring of aluminum purchased from McMaster-Carr. The pipe has a 4 inch inside diameter and a 6 inch outside diameter.

  • A 1/2 inch width of the aluminum pipe was parted off on the lathe. Here it has been blued and marked for cutting.

    A 1/2 inch width of the aluminum pipe was parted off on the lathe. Here it has been blued and marked for cutting.

Mechanical Drawings

  • Brake Shaft for Caboose Trucks. Two required per truck.

    Brake Shaft for Caboose Trucks. Two required per truck.

  • End detail of Brake Shaft. Turn ends down to 3/8 inch on lathe. Drill and tap for 8-32 threads 1/4 inch deep.

    End detail of Brake Shaft. Turn ends down to 3/8 inch on lathe. Drill and tap for 8-32 threads 1/4 inch deep.

  • Brake Hanger, four required per truck.

    Brake Hanger, four required per truck.

  • Brake shaft strut, two required per Brake Shaft.

    Brake shaft strut, two required per Brake Shaft.

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