removable building a Λ signal presented by bob van cleef of the north river railway
TRANSCRIPT
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REMOVABLE BUILDING A Λ SIGNAL
Presented by BOB VAN CLEEFof the North River Railway
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A BASIC DESIGN
• Almost any layout can use signals.
• This presentation shows how to build a simple 2-aspect signal.
• Mass production techniques make construction fast, easy and reasonably good looking.
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SIGNAL HEAD SHIELD
• We will start by making the shield• It can be fabricated from any thin
material including .020 brass shim stock.• I used unclad glass epoxy printed circuit
board.• These heads were about ½” (HO 3’-6”)
wide by 7/16” (HO 6’-9”) high.• Railroads used a greatly varied sizes.
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• A simple tool can be made from scrap materials to shape multiple the shields to a uniform size easily and quickly.
• Drill 1/8 holes (.125) for 3mm LEDs.
• Glue or solder a bit of 1/8” OD tubing in top hole to hold shield in place while sanding or filing to size.
TOOL FOR MAKING SHIELDS
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SHIELDS BEFORE AND AFTER
• Simply cut shields to rough size then use this to sand or file shields to shape.
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MAKING THE FINALE
• The Finale at the top of the mast is made by soldering a short length of telescopic tubing inside the mast.
• Overfill the center then file to shape.
• The mast can be placed in a hand drill and filed if a lath is not available.
• This technique can also be used to make flagpoles and other decorative details.
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Close-up of Finished Finale
• This is what the finale looks like before painting.
• Note that the (2) sizes of tubing are plainly visible.
• Be careful not to dull the tip as solder is very soft and easily dented.
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About the LEDs
• LEDs are used for the signal lights.• LEDs vary in color and size.• Note that the long lead (side opposite
flat on rim) is the anode (+). • Different Colors will draw slightly
different currents due to their chemical makeup.
• Slightly different resistance values might therefore be required for even brightness.
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LEDs Used for signal lights
NOTE: make sure to observe the polarity or else the LED will not work as expected.
• T-1 (3mm) LEDs were used for this project.
• This size will fit a .125” hole• Cut and bend leads as shown.• First bend the anode (+) lead.
This is the longer lead opposite the flat on the outer rim.
• Then bend and cut the cathode (-) lead.
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A SIMPLE SOLDERING FIXTURE• A simple fixture is used to hold
parts in place as the signal is assembled.
• Standard height signals will use the (2) upper holes for an offset signal head.
• Dwarf signals will use the (2) lower holes for shields centered with the mast.
• This technique can be used to build a multitude of signal configurations.
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HOLDING PARTS IN PLACE
• Note the (3) pins that will hold the mast in the proper position.
• The aluminum clamp swivels to hold parts in place.
• Make sure to include clearance for the shield.
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SOLDERING the LEDs
• The next step is to file the groove in the mast.
• Re-install the shield with the LEDs in place.
• Solder the anode lead of the LEDs to the mast.
• CAUTION – use as little heat as possible. Consider using a low melting point solder.
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COMPLETING SIGNAL HEAD
• This drawing represents the completed signal head.
• Notice the notches for the LEDs at the top and for mounting to the base at the bottom.
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“WIRING” the signal head
• Phonograph pickup wire (7 x #36) makes a nice “cable” for signal lights.
• Again, use as little heat as possible when attaching to Cathode (-) lead of the LED.
• Bend and thread the wire through the mast to the base.
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REMOVEABLE SIGNALS
• Signals near tracks can cause problems.
• Signals can easily be damaged during track cleaning.
• It is also hard to clean tracks near signals.
• Making signals removable remedies these problems.
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DETAIL OF SIGNAL BASE
• Here is how headers can be used to make signals removable.
• A male connector can be seen in the base of the signal.
• A female connector is buried in scenery can bee seen in the lower left.
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HEADERS
Male and Female Headers cut to shorter lengths for use in signals.
• Headers , a type of electronic connector, can be purchased in various lengths.
• Most are scored for easy cutting to shorter lengths.
• The male (upper) half will be soldered to the base of the signal mast.
• The female half (lower) will be embedded in the scenery / table top with wires extending below table level.
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ASSEMBLING BASE
• This schematic shows the connection between the mast and the header.
• Note that the mast is soldered directly to (2) pins of the header.
• The (2)wires from the LEDs exit the base of the mast through a short notch and are each soldered to one of the remaining pins of the header.
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NOTCHING THE MAST BASE
The exact dimensions of the notch is not critical. Either putty or a signal box will
hide the actual connections.
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The SIGNAL BOXThis can be made from a simple block of wood. Drill a hole through the center from the top, then hollow out the base from the bottom.
Signal box on mast.
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VIEWS OF FINISHED BASE
Wires soldered to pins on header.
Mast soldered to header.
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FORMING PLATFORM RAILS
• A simple forming tool is used to form both the signal railings and the platform base.
• (5) pins and the edge of a block are used to bend #22 brass wire for best results.
• Copper wire that has been stripped of all insulation can also be used.
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WIRE IN FIXTURE BEING FORMED
• This shows a handrail being formed.
• Note the extended wire at the top is bent sharply down at a right angle over the top of the forming tool.
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FORMED SHAPES
• Here are the handrails and platform base.
• The finished platform is at the bottom.
• Dozens of railings can be made in just a few minutes.
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FORMING THE PLATFORM
• The “floor” of the platform is constructed using several parallel wires.
• These wires are held properly spaced with a fixture.
• Solder the platform base in place and trim wires.
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FINISHING THE PLATFORM
• Note that the shorter fixture is made by drilling through the longer piece and insures that the wires are held exactly parallel.
• Use regular (higher temp) solder for the platform.
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PLATFORM ASSEMBLY
• The handrails, platform and ladder can now be soldered in place.
• Use a low-temp solder to avoid problems with solder on platform melting while doing this work.
• File and clean all joints.
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TWO SLIGHTLY DIFFERENT VIEWS
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TWO MORE VIEWS OF SIGNAL HEAD
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Side VIEW OF SIGNAL
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A DWARF SIGNAL
• A dwarf signal is a bit different.
• There is no platform or ladder, or finale.
• Also, the head sits on top of the “mast”.
• The signal box is built up from wood-filler and sanded square.
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SIDE VIEW OF DWARF
• The LED connections are the same as on a standard signal.
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FINISHED SIGNALS
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For More Information…
Digikey http://www.digikey.com/
Source for wide variety of electronic related parts and hardware including LEDs, Wire, Solder, Copper wire, printed circuit board and headers.
Walters http://www.walthers.com/
Largest single supplier of model railroad supplies including stripwood, brass telescopic tubing, ladder stock, brass wire and paint.
Also, see clinic on STALL MOTOR CONTROL for more information on LEDs.
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This presentation has been brought to you by the North River Railway
Bob Van Cleef46 BroadwayCoventry, CT 06238http://www.northriverrailway.net
THE END