Buffer lights 2017 comp

Have any questions or tips and advice on how to build those bits that don't come ready made.
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TimberSurf
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Buffer lights 2017 comp

Postby TimberSurf » Sat Dec 24, 2016 11:02 am

Never tried a competition before, but I will bite and have a go. The 2017 Forum Competition
I have been collecting for many years and only recently had the time to start construction. In the process, I have in stock, dozens of buffers and buffer kits. The current construction phase will need some 20 and future plans will need the same again.
I want each to have a working lamp.
I want them to be to a very high standard of detail.
I recently bought 500 LED's (I think that may cover future endeavours)
I have all the paints, airbrush, glues, static grass, static grass applicator, gravel & time I need

There will be the following mixture of types:-
Peco SL-41 00/H0 Buffer Stop Sleeper Built Type
Peco ST-270 00/H0 Buffer Stop, Sleeper Built Type
Peco SL-340 Buffer Stop Rail Built Type
HORNBY R083

Possible:-
Matchstick scratch build
PARKSIDE DUNDAS metal

Let mass production start!
Last edited by TimberSurf on Sat Dec 24, 2016 11:38 am, edited 1 time in total.
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Principles

Postby TimberSurf » Sat Dec 24, 2016 11:29 am

I would love to use DCC Concepts buffer lights, but as I need 40+, cost would be prohibitive!
I have seen some have used 3mm or 5mm red LED's, but that looks terrible!
I had a bash with this about 10 years ago on a ST-270 and the result was good, so will stick with the principle.
I have chosen red SMT 3528 LED's as a near representation of size
This will require some very fiddly soldering!
I will drive them from my Computer controlled (timed cycle) layout lighting @ 12VDC, so each will require a suitable resistor
Sleeper types will have the resistor built in underneath, with just leads poking out the bottom to go through the board. The rail type will have to have 0.2mm wires, not sure how they will make it under the board to the resistor and power?
All will be painted, sleeper type with grimy brown and rail type as rust.
Sleeper type will be topped with real ballast and greenery up the sides
Should the wooden buffer bar be red? Some of the kits are white plastic! or were some they unpainted?
Were the lamps red or white or black casing?
Last edited by TimberSurf on Wed Dec 28, 2016 11:21 am, edited 1 time in total.
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Step one

Postby TimberSurf » Sat Dec 24, 2016 2:44 pm

First step complete
Sleeper type constructed, with some variants to a flat top created by heating waves into top plastic square.
Next, a base coat of grey, using my new airbrush kit and home grown Spray Booth.
Grey buffers.jpg
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Sleeper Type Step 2

Postby TimberSurf » Mon Dec 26, 2016 9:38 pm

Second coat of spray paint with brown, then dry brush with different shade to make "non-uniform"
Hand paint red buffer in matt red
Last edited by TimberSurf on Mon Dec 26, 2016 10:18 pm, edited 1 time in total.
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Sleeper Type Step 3

Postby TimberSurf » Mon Dec 26, 2016 9:50 pm

Solder 0.2mm wires to each LED
Drill two 0.8mm holes above buffer beam.
Thread wires through hole and glue back of LED to buffer
Sleeper LED.jpg
Sleeper LED.jpg (83.86 KiB) Viewed 143 times

(tried several glues, but the Peco ST-270 00/H0 Buffer Stop and Sleeper Built Type Peco SL-340 Buffer Stop Rail Built Type are both made of polyethylene and most glues will not stick! Some research lead me to a special epoxy called JB Plastic Weld 25ML Quick Setting 5min Epoxy Syringe, which after a quick purchase and test proved suitable)
Terminate a short insulated 7/0.2 wire to 10K resistor and then wrap and solder 0.2 wire to other end of resistor (twice)
Glue wire to side of buffer internally to secure.
Sleeper resistor.jpg
Sleeper resistor.jpg (87.96 KiB) Viewed 143 times


The sleeper type production line
Sleepers wired.jpg
Sleepers wired.jpg (96.06 KiB) Viewed 143 times
Last edited by TimberSurf on Mon Dec 26, 2016 10:18 pm, edited 1 time in total.
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DCC vs DC

Postby TimberSurf » Mon Dec 26, 2016 10:15 pm

My original idea and prototype 5 years ago was to have a resistor one side and a 1N418 on the other side, this ensures that the high voltage of the DCC does not overpower the reverse current on the LED, it also stops connecting the wrong way round on DC, from blowing the LED. I have decided this is not necessary and omitted, as I will be using DC and should be shot, if I reverse connect! I now have a resistor both sides, it just keeps it uniform and a good anchor point for gluing both sides. I am using two 10K ohm resistors, as I want very dim lights, like oil lamps. Future night shots will prove the point (hopefully)
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Rail type Step 1

Postby TimberSurf » Mon Dec 26, 2016 10:21 pm

Hornby R083 type, first coat of paint
Pre washed in IPA, then airbrushed with two coats of rusty brown, then rusty orange.

Rail base coat.jpg
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nickbrad
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Re: Buffer lights 2017 comp

Postby nickbrad » Mon Dec 26, 2016 10:36 pm

Looks like you've made a good start already, I'd say you can complete enough for your full layout at this rate, rather than just the 20 for phase 1 :D

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Re: Buffer lights 2017 comp

Postby carnehan » Tue Dec 27, 2016 9:16 am

Wow, now that is what I call a production line. The idea of putting together a lot of these at once is a good one if a little repetitive I imagine.

I'm enjoying the thread though, it gives me thoughts for adding LEDS to buffers st some point I need the future.

Paul

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Hornby alternate

Postby TimberSurf » Wed Dec 28, 2016 11:53 am

I am just doing everything I have in stock, pointless not to get production line and complete them while I am in the mode! This will cover my immediate needs and give me a range of choices, each time I come to fit one in a particular location. I actually have a massive stock of Peco and Hornby Hydraulic buffers, but as I have no need of them in this phase, I will leave that project for another year. I may well sell the greater surplus, that was always the intent for the hydraulic ones (just thought it may be a very saleable item, once painted, weathered and lighted) and I have picked up lots of second hand ones cheap, every time I had the opportunity. I am not even sure I will be satisfied with the result of the Hornby R083 type, they aren't very prototypical. To that effect, I have ordered some white metal ones this morning , so I can produce a few sample metal ones. They are not cheap (albeit only slightly dearer than new plastic proprietary ones), but compared to the peanuts I have paid for second hand ones over the years, a purchase now of the numbers I will require will run to over £100! (20ish x £5.95)
P.S. PARKSIDE DUNDAS sell them, but they are only a reseller of the manufacturer LANARKSHIRE MODELS & SUPPLIES, same price but OEM postage is cheaper :D
Last edited by TimberSurf on Wed Dec 28, 2016 10:59 pm, edited 1 time in total.
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Sleeper type step 4

Postby TimberSurf » Wed Dec 28, 2016 10:47 pm

Added real stone gravel ballast to top today.
You might just make out the undulations I put into the plastic plate underneath on some, will need a second layer of "bumps" just to make it even more 'random'
Five back.jpg
Five back.jpg (99.6 KiB) Viewed 100 times
Eight front.jpg
Eight front.jpg (114.74 KiB) Viewed 100 times
Eight back.jpg
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Sleeper type step 5

Postby TimberSurf » Wed Dec 28, 2016 10:58 pm

Last step will be to add random grass tufts to top gravel. I tried some on the side of a sample, but looks a bit weird. I think I will leave the sides on all the others till I site them on layout.

So sample is done, I set up a photo shoot, the wood on that one is not so good, needs some better dry brush weathering. The white needs painting on the lamp to loose the solder bars. This sleeper type were quite easy, the rail type are going to be much harder!
Photo's of sample photo shoot below

Quartered.jpg
Quartered.jpg (170.91 KiB) Viewed 100 times


Low light shot with lamp on (looks white, but camera lies), tried in the dark, but camera just catches a blurry red dot on black!
Lit front.jpg
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Lit side.jpg
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Sleeper step 5 mass production

Postby TimberSurf » Tue Jan 03, 2017 12:26 am

Mass production of the Sleeper type continues, 2mm green grass just been added, 4mm yellow to go!
P.S. pic shows after just adding static grass, no they will not look like green carpets! Once they were dry, a lot came off!
Sleeper grassination.jpg
Sleeper grassination.jpg (73.36 KiB) Viewed 74 times
Last edited by TimberSurf on Tue Jan 03, 2017 12:41 am, edited 3 times in total.
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Re: Buffer lights 2017 comp

Postby TimberSurf » Tue Jan 03, 2017 12:31 am

The white metal kits arrived promptly, paint to inside edges first, then sub assembly of side frames.

Rail flat.jpg
Rail flat.jpg (86.66 KiB) Viewed 74 times


Then adding the LED and building up.
The long version has to be assembled on a certain sleeper arrangement, the short type sits outside of the track rails, so can be fully assembled as a standalone

Rail clamp.jpg
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Re: Buffer lights 2017 comp

Postby TimberSurf » Tue Jan 03, 2017 12:35 am

Yes, yes, I know I said I don't need them, but I couldn't resist doing a hydraulic to complete the competition set! :D
First stages of multiple paint colours, to build up the weathered look, pistons will be red, more features may be added and of course the led mounted in the original Hornby red lamp piece.

Hydraulic paint.jpg
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