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PenBits BACHMANN CLASS 24 Assembly Instructions Manual

Sprung bogie kit
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ASSEMBLY INSTRUCTIONS
PK006
SPRUNG BOGIE KIT
BACHMANN
CLASS 24/25
PenBits Model Railways
www.penbits.co.uk
c/o 12 Fieldside, Long Wittenham, ABINGDON, Oxon, OX14 4QB

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  • Page 1 ASSEMBLY INSTRUCTIONS PK006 SPRUNG BOGIE KIT BACHMANN CLASS 24/25 PenBits Model Railways www.penbits.co.uk c/o 12 Fieldside, Long Wittenham, ABINGDON, Oxon, OX14 4QB...

  • Page 3: Table Of Contents

    Class 24/25 Bogie Bolster Bachmann 24/25: Preparing the Locomotive Modifying the Bogie Drive Fitting Wheelsets Springs, Bogie Assembly and Rolling Test Bachmann Class 24/25 Cosmetic Bogie Frames Pickups and Power Class 24/25 Final Assembly (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 4: General Notes

    The instructions are available on line in both HTML and pdf formats. The HTML versions have one page for each major section, whilst the pdf versions have a single file for each kit. Structure (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 5: Printing

    Any remnants of the tag may be cleaned up using a flat file. We have tried to avoid putting tags on mating faces, but there are some instances where they need to be removed (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 6: Slots

    In places which can't be reached by a file, e.g. in acute corners of the etch, the cusp may be pared away with a sharp knife. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 7: Folds

    Green Label flux may be rinsed away with water; a little added citric acid will neutralize it. Liquid or paste fluxes can be washed away either with a proprietary flux cleaner or a 50/50 mix of methylated spirits and water. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 8: Spring Winding

    Keeping the coil on the armature, you can stretch or compress the spring axially to get the coil spacing you need. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 9 Trim off the waste at the ends of the spring. File the ends of the spring flat, using the free end of the armature to support it. Reset the armature in the chuck to the desired length of the spring. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 10: Warranties

    However, as the fitting of the kit by the user is out of our direct control, we can make no warranty, expressed or implied, as to the performance and continued serviceability of the locomotive following modification. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 11: Bearing Carriers

    Put the subframes in their containers safely to one side for now. Test fit the axle bearings on the 2mm replacement axles. They should be a free running fit. Remove any burrs or swarf from the front and rear faces of the bearings. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 12 This will help minimise any unwanted distortion in the fret. Note that Fold 3 is a jig fold, made along the tags at the base of the carriers. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 13 Make Fold 3, to approximately 45°. Note that this fold is along the line of the tags at the base of each carrier, forming part of the frame assembly jig, and is not a part of the finished carriers. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 14 This will ensure that the area is kept free of solder when the bearings are fixed into the carriers. An alternative is to use a permanent marker: the ink should resist the flow of solder. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 15 Take care, as the top parts of the carriers are quite fragile at this stage: it may be best to leave cleaning up the tags until after the folding and soldering stages below. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 16 0.5mm running clearance for the primary spring wire. Here are some images of the carriers with all the folds having been made. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 17 This should set the correct alignment. That completes the bearing carrier assemblies. To finish off, clean them up to remove any flux residues, and return them to their respective containers. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 18: Subframes

    Fold in the end plates. Pay attention to the fit; remove etching cusps on the edges of the end plates as necessary to avoid forcing the sides of the mainframes apart. End stretchers (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 19 Make the two outer vertical folds. Care is needed to make the folds true to the direction of the half-etched lines, as they are quite short. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 20 Do not apply too much solder; the holes for the spring (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 21: Traction Ears

    Traction Ears Remove two of the traction ears from the fret. There is one of each hand for each bogie. Make the single fold on each ear. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 22: Undertray And Secondary Spring Seats

    Ensuring that the seats and undertray are correctly aligned, solder the two together. Fit the undertray into the subframe and solder up. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 23 Bachmann Class 24/25 Subframes 23/51 That concludes the bogie subframe assembly. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 24: Class 24/25 Bogie Bolster

    Run a generous fillet of solder around the nut, but avoid getting any into the etched fold lines or slots. Remove the screw from the nut (it should have been prevented from being soldered in place by the grease). Make the two folds in the etch (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 25 Make fold 2, check it is at 90° and reinforce it with a small amount of solder applied to the slots on the outside of the fold. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 26 Fold up the restraints as shown. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 27 Solder the legs of the bolster centre to the side. Turn the assembly over and repeat for the other bolster side. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 28 Note that the bolster is asymmetric; the face of the bolster tower which is set back a little from the lower part of the bolster sides should face the outer end of the bogie. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 29 The following instructions describe how to fit these parts. Clean any stray solder from the outer surface towards the top of the lower bolster sides where the detail etches will be fitted. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 30 Make the 90° fold at the back of the detail, then unfold it slightly. Fold in the sides of the detail, then remake the back fold. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 31 'box' assembly. Hold the parts firmly together and flash in some solder through the slot and around the back. Remove the assembly from the surface and clean up any excess solder. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 32 Clean up the bolster assembly to remove all flux residues. If you wish to apply c hemic al blackening, this is a good point at which to do the bolsters and bogie subframes together. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 33: Bachmann 24/25: Preparing The Locomotive

    If there is any misalignment, check for obstructions, such as swarf, preventing the plastic undertray from fitting snugly up against the cast chassis block. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 34 Remove the bolsters from the chassis and leave the glue to harden to full strength. Trim the M2 screws so that they protrude no more than a thread or two below the nuts in the tops of the bolsters. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 35: Modifying The Bogie Drive

    Remove the strips and, with a sharp knife, the moulded pips which locate them. Put the pickup wires and strips to one side for reuse. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 36 'soft' and 'soapy', the plastic can crack in a brittle manner if overstressed. Take great care at all stages not to damage the retaining lugs for the main axle bearings. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 37 Fold in the side ears of the retainer. Returning to the drive unit, cut off the triangular lugs from the top parts of the plastic pillars which rise either side of the inner worm shaft bearing. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 38 Give the drive unit assembly a thorough wash and degrease to remove all traces of swarf and dust. Refit the worm gear retainer and secure it in place with one of the 14BA screws and nuts supplied. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 39 The holes are drilled such that the shaft of the bolt is in contact with the top of the bearing. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 40: Fitting Wheelsets

    If there is binding when one axle is raised, open out the Bachmann axle bearings just a fraction more, up to a maximum of 2.3mm. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 41 Test fit each axle in its slot to confirm that it moves freely up and down and has a suitable amount of lateral play. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 42 Lubricate the bearings with a light machine oil and ensure that the oil is taken in to all the axle-bearing interfaces. That completes the assembly of the wheelsets. The photo here shows a similar completed wheelset in place in a bogie subframe. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 43: Springs, Bogie Assembly And Rolling Test

    Thread the wire through the holes in the two secondary spring seats (mounted on the undertray of the subframe) and then through the corresponding hole in the opposite (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 44 Primary Suspension: at 0.5mm deflection, the tops of the bearing carriers are level with the tops of the bogie subframe immediately adjacent. Secondary Suspension: at 0.5mm deflection, the base of the bolster is level with the lower surface of the subframe and undertray. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 45: Bachmann Class 24/25 Cosmetic Bogie Frames

    The second pair of cuts is made through the inner stretchers. The outer faces of the cuts are spaced 14.2mm apart, symmetrically about the centre line. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 46 Make a notch on the inside of the moulded equalizing beam, to provide clearance for the secondary spring retaining hook on the bolster. On the outer stretcher, cut away the material above the top flange of the moulded detail. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 47 A fixing hole is etched in the outrigger. A spare inner stretcher, included on the fret, can be folded up and used as a drilling guide to make a matching hole in the stretcher stub. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 48 There is no need to do this, however, if you intend to remove the solebars as part of your detailing project. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 49: Pickups And Power

    We use quick set epoxy, thoroughly degrease the mating surfaces on the drive unit and copper, and score the surface of the drive unit to provide a key for the adhesive. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 50 (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

  • Page 51: Class 24/25 Final Assembly

    Place the bolster over the subframe's traction ears and fit the secondary springs. Route the pickup wires through the holes at the top of the bolster. Fit the bogie sideframes. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...
  • Page 52 Finally, replace the body of the locomotive according manufacturers' instructions. IMPORTANT NOTE: If you need to remove the body subsequently, it is best to avoid pulling on the bogies when separating the body from the chassis. (c) PenBits Model Railways, All Rights Reserved 27/09/2021...

This manual is also suitable for:

Bachmann class 25Pk006

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