Making Models From Scratch

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Good to know that the paint I've got in will do. :okay:

Likely I will be painting the individual parts / assemblies as I make them, and then sanding back lightly on surfaces that do need to be subsequently glued. Given the size of the model, combined with the complexity of some of the signwriting on the car, I think this is probably the easier way to go about this.

I forgot to say that I often paint and then sand card models where I can; it means the surface has a much smoother finish and looks much better for it.
 
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Reynard

Reynard

Guru
I forgot to say that I often paint and then sand card models where I can; it means the surface has a much smoother finish and looks much better for it.

You mean like get the base coat on, then sand it, then another coat of paint etc? A bit like doing the varnish on wood then.

Useful to know. :okay:
 
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Reynard

Reynard

Guru
Anyways, first pics. Apologies as to the state of the tablecloth...

Completed wheel, plus the components to finish the main structure of the other three.
NR1F6943_small.jpg


Front of completed wheel.
NR1F6940_small.jpg


Rear of completed wheel.
NR1F6941_small.jpg


Haven't started sanding the tyre sidewalls yet, as it was far too cold in the garage to stay in there for very long. Plus there are some uneven sections on what will be the "tread" of the tyre that needs filling in a bit as well.
 
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Reynard

Reynard

Guru
That's it yes. I suppose it's not that odd if you think about it, as card is basically wood in another form, so it reacts like wood.

No, it's not odd at all. :smile: Both are different styles of composite material, but that use the same fibre type i.e. cellulose.

Card is essentially chopped strand mat to all intents and purposes, whereas wood, in its various guises, has those fibres in a much more directional layout.

Sorry, it's the engineer in me. I can't help it... :blush:
 
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Reynard

Reynard

Guru
Anyways, current progress... I now have all four wheels in various stages of build, with the one on the left completely finished:

NR1F6945_small.jpg


I have also (finally) worked out what's going on with the rear suspension and am thinking about how to make the various parts. It's a live axle as fitted to the Ford Cortina / Mk1 & Mk2 Escort, four links, with the damper just forward of the hub on the lower link. The top of the damper attaches to the main chassis rail. There is also a Panhard rod in there (diagonally from axle to chassis), but I've not added it to the sketch.

NR1F6946_small.jpg


Have decided after a lot of thought to go down the laminated card route for the chassis, simply because it's the easiest. I will cut each layer out in one piece, and I will add the wire pegs to take the bumpers and side irons as I'm doing this. Actually, I envisage taking the wires all the way across from one mount point to the other (cutting a channel in the card), because it will add strength to the structure as well.

And I've had a lightbulb moment when it comes to reproducing that complicated shape reliably multiple times... :idea:

I was watching my mum prepare a lace pattern this afternoon, transferring the image from a printed scan to a piece of card. She secures the two together with a bit of masking tape, and then using a pin on a handle, puts a hole through both, and thereby reproducing the pattern exactly onto the card - on which she then works.

So I will do the same, using my chassis drawing as a template and putting a pin hole on all the main points. Then all I need to do is join the dots on the card with a pencil and then use a craft knife and steel ruler to cut it out. :smile:

N.B. I have made a few modifications to the front of the chassis after having gotten my mitts on a couple of better photos.
 
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Reynard

Reynard

Guru
It's been way too cold to work on the wheels in the garage - glue dust in the house is most definitely NOT a good idea, so I've made a start on the chassis, ironwork and assorted gubbins. Used mum's lace making awl to prick through the drawing onto the card beneath, which gives me an eminently repeatable method for getting each layer of the chassis.

The first two layers. I'm going to need six of these. Oh, and I've nicked some card from mum's stash of lace making supplies, because I've run out of cereal packets!
NR1F6947_small.jpg


The first three layers all laminated together. And yes, I *did* have a gluey mishap with a sheet of newspaper... :blush: You can see where I've put reinforcing sections of wire at the stress raisers where the mount points for the ironwork meet the chassis "rails". That was done by carving out a channel with a knife and then glueing the 10mm sections of wire in. It was less faff in the end than running the wire all the way across, and just as effective. (Also, my supplies of suitable wire is limited, so I can't afford to be wasteful.)
NR1F6948_small.jpg


I've also started making the bumpers and side irons - this is front bumper and left hand side iron. Gives me something to do while I wait for other bits of glue to dry. It was easier to use an awl to make the holes that fit over the wire pegs than to use a drill, as I had more control over the process.
NR1F6949_small.jpg


All the wire pegs to take the bumpers and irons are in. Method was the same as for the reinforcing sections. The wire was pre-bent before fitting, but will only be cut to size at the assembly stage. You can see how the chassis platform compares to the drawing, as well as seeing where I've made modifications to the front of the car after getting my mitts on some better photos. I figured I'd rather take the pain of laminating the pegs into the structure at this stage, rather than drilling holes later on, as I didn't want to risk breaking something and then possibly having to start from scratch again. Although this, in its own way was also a fiddly process with the potential for things to go very wrong, but bonding the pegs directly into the layup is inherently stronger anyway, so was worth a few squeaky bum moments along the way.
NR1F6953_small.jpg


And yes, it all fits together! :girldance: Well, so far, anyway. A mock-up with a completed wheel just to see how things are looking.
NR1F6952_small.jpg


The next stage with the chassis is to cut the other three layers, laminate those together, then carve out the channels on the inside layer of that half before glueing the whole shebang together. And I need to finish the wheels...
 
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Reynard

Reynard

Guru
Spent some time last night going through the photos again, and I've realised that while I can make the two separate halves of the chassis platform, I can't actually stick them together until I've worked out what to do with the front suspension. It's a double wishbone, damper, stub axle assembly, where the pickup points for the upper wishbone, and the top damper mount attach to the main chassis rails.

The damper mount isn't a problem, but the wishbone requires more thought. Namely, do I laminate wire pegs into the platform to take the wishbone, or do I laminate the pegs into the wishbone and drill holes in the platform? I'm thinking it's more likely to be the latter, but until I've actually designed the parts, I'm not sure.

The friend who is giving me some technical help has managed to source some photos of the rear suspension from a similar car for me, which will be mightily useful.

And I've had to re-make the front bumper. OK, there wasn't anything inherently wrong with the first iteration thereof, but last night's cogitation made it clear that it was much easier in the long run to add some of the front ironwork at this stage rather than faff around with small, fiddly parts later on.
 
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Reynard

Reynard

Guru
A bit more progress - will update with some photos in the next day or so.

Have been working on the front suspension assembly. I've made the brake discs (they're about the size of a 2p coin!) and I've just about got my head around the stub axles. The issue with the latter is that I need to find a suitable compromise between realism and the part being sturdy enough. It's a fairly complicated structure to which several things attach (upper wishbone, lower wishbone, steering arm, brake disc and wheel), and I don't want the thing collapsing on me.

I've also made the upper half of the platform that makes up the main rails of the chassis. And I've been vindicated by waiting to join the two halves together. I wanted to sort out the front suspension first as I'm still not entirely sure how I'm going to attach the top wishbone to the chassis. But I now that I've finally got my mitts on what's going on with the rear suspension (thanks to a kind friend who is helping me on the technical side of the build), I *definitely* need to add some extra pegs.

On some Higmans, the upper link from the rear axle attaches directly to the side of the chassis, which definitely isn't the case with this particular car. Unfortunately, the photos I have weren't clear enough for me to see where it *does* attach to. But I now know that the alternative fitting is to a sponson located between the two rearmost nerf bars, so I shall go with that arrangement.

That now also means I can get on with building the rear axle. Out of knitting needles.

Oh, and all four wheels are now built. I just need to sand down the last one, and then I can paint them.
 
A bit more progress - will update with some photos in the next day or so.

Have been working on the front suspension assembly. I've made the brake discs (they're about the size of a 2p coin!) and I've just about got my head around the stub axles. The issue with the latter is that I need to find a suitable compromise between realism and the part being sturdy enough. It's a fairly complicated structure to which several things attach (upper wishbone, lower wishbone, steering arm, brake disc and wheel), and I don't want the thing collapsing on me.

I've also made the upper half of the platform that makes up the main rails of the chassis. And I've been vindicated by waiting to join the two halves together. I wanted to sort out the front suspension first as I'm still not entirely sure how I'm going to attach the top wishbone to the chassis. But I now that I've finally got my mitts on what's going on with the rear suspension (thanks to a kind friend who is helping me on the technical side of the build), I *definitely* need to add some extra pegs.

On some Higmans, the upper link from the rear axle attaches directly to the side of the chassis, which definitely isn't the case with this particular car. Unfortunately, the photos I have weren't clear enough for me to see where it *does* attach to. But I now know that the alternative fitting is to a sponson located between the two rearmost nerf bars, so I shall go with that arrangement.

That now also means I can get on with building the rear axle. Out of knitting needles.

Oh, and all four wheels are now built. I just need to sand down the last one, and then I can paint them.

You know, I almost understood that...
 

LeetleGreyCells

Un rouleur infatigable
A bit more progress - will update with some photos in the next day or so.

Have been working on the front suspension assembly. I've made the brake discs (they're about the size of a 2p coin!) and I've just about got my head around the stub axles. The issue with the latter is that I need to find a suitable compromise between realism and the part being sturdy enough. It's a fairly complicated structure to which several things attach (upper wishbone, lower wishbone, steering arm, brake disc and wheel), and I don't want the thing collapsing on me.

I've also made the upper half of the platform that makes up the main rails of the chassis. And I've been vindicated by waiting to join the two halves together. I wanted to sort out the front suspension first as I'm still not entirely sure how I'm going to attach the top wishbone to the chassis. But I now that I've finally got my mitts on what's going on with the rear suspension (thanks to a kind friend who is helping me on the technical side of the build), I *definitely* need to add some extra pegs.

On some Higmans, the upper link from the rear axle attaches directly to the side of the chassis, which definitely isn't the case with this particular car. Unfortunately, the photos I have weren't clear enough for me to see where it *does* attach to. But I now know that the alternative fitting is to a sponson located between the two rearmost nerf bars, so I shall go with that arrangement.

That now also means I can get on with building the rear axle. Out of knitting needles.

Oh, and all four wheels are now built. I just need to sand down the last one, and then I can paint them.
Looking up 'sponson' and 'nerf bars'...

I was doing quite well until I got to that sentence.

Sounds like a great project @Reynard , I for one can't wait to see the finished model. :hyper:
 
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