Balanced Air Brakes from Scratch: Difference between revisions
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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. | 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. | ||
File:BalanceAirBrakesReservoirCaboose.jpg|The air reservoir is mounted underneath the caboose. A 1/2 by 1/2 angle was welded to the frame of the caboose, and the reservoir was secured with an | File:BalanceAirBrakesReservoirCaboose.jpg|The air reservoir is mounted underneath the caboose. A 1/2 by 1/2 angle was welded to the frame of the caboose, and the reservoir was secured to it with an automotive hose clamp. | ||
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Revision as of 11:50, 17 November 2015
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
- 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
The following tools were used in the construction of the truck brakes:
- Drill Press
- Low-cost wire welder (110 Volt AC) from Harbor Freight
- Lincoln Innershield NR-211-MP flux core welding wire, 0.035 inch
- Lathe (for turning brake shoes and brake shafts)
Build Gallery
Air Tank
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.
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
Assembling Brake Shafts
Brake Pads
Final Assembly
Video Demo
This video demonstrates the failsafe operation of the balanced brakes, along with how to disable the brakes once activated. Video by Daris A Nevil, August 2015.
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