Tag Archives: Passenger

AC Baggage Cars 300-301 from Union Station Products Kit – Part 1

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With no family commitments on the Monday of the Thanksgiving weekend, I decided to make a deliberate effort to take advantage of a day off actually spent at home to do some work on various model projects. One project I’ve been working on today is a model of one of the Algoma Central’s two ex-Denver & Rio Grande Western baggage-express cars.

These two cars are a little unusual in that the lower portion is clad in stainless steel fluting, but the upper part of the car is smooth. Built as baggage/RPO (railway post office) cars by Pullman-Standard, these cars were originally ordered by the Chessapeak & Ohio Railroad, but ended up being delivered instead to the D&RGW in 1950. The Algoma Central acquired two of the three D&RGW cars in 1973, numbering them 209-210. In 1981 when the 200 series GP38-2s were delivered, all of the AC baggage cars were renumbered into the 300 series, and these became AC 300-301.

Here’s the 301 at the Steelton yard shop tracks in 2004:

SAMSUNG DIGIMAX 360

The basis for this model is a car side kit from Union Station Products. It’s one of a group of such kits I acquired back in July. (Actually I got two copies of this particular kit, so I will be able to model both car numbers 300 and 301.) The kit consists of a .020″ white styrene side and a .040″ clear plastic (acrylic?) core that are meant to be laminated together. The core has cut out sections for the windows, these to be applied later, after painting. The side kits are then meant to be used with passenger car core and detail kits from Train Station Products (which USP also resells) to provide the roof ends and underframe for the car.

The Algoma Central removed the skirting from these cars when they acquired them, so the first stop was to perform some minor surgery on the car sides to cut away the skirting between the trucks:

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This was easily accomplished with a straightedge and many light passes with a sharp X-acto knife to cut away the unwanted material. Following that, it was essentially a matter of cleaning up the various pieces before assembly.

The skirting area on the clear core has a bunch of horizontally scored lines in it so that the skirts can be curved inward using pliers. (The smooth side is the outside, the cut side curves inwards.) I used a a pair of flat (not needle-nose) pliers to gently curve the remaining skirting at the car ends. Just work gently and slowly and evenly along the skirt you’re bending.

The kit instructions suggest you start with the skirting when you glue the side and core together. I started with the skirt at one corner of the car and careful to keep the whole side square and lined up, glued it to the clear core with CA glue, applied with a toothpick. After holding that in place and allowing it to set for a few moments, I proceeded out from that corner along the side of the car, applying glue to a section up to a door opening, and laminating that portion of the side. I did not go ahead and glue the skirt at the other end right away – you want to start at one end and work your way down; if you’re off by even a fraction of a millimeter you can end up with a major ripple in the side.

Once the side and core were laminated together, I spent some time going over the outer edges and also the edges of the door frames with a small flat file to clean up all the edges and remove burrs from the manufacturing process. (The sides and cores are CNC milled.)

For their fluted side cars, Union Station provides a separate strip of fluting that is laminated onto the surface of the car side. This was easy to cut to length with my Chopper and apply to the side. I attached these using Testor’s liquid cement. I applied a small amount to the back of the fluting strip to tack it in place, and once properly aligned, applied cement sparingly around the edges of the strip with a very fine point brush. This wicks into the joint and makes a very clean and permanent joint.

Here’s how the one side looks so far:

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Just need to finish the other side (actually x3 because I’m doing two of this car) and then work on the roof and underframe, which require a certain amount of cutting and splicing because the baggage cars are shorter than a typical 85′ coach which the core kits are designed for.

ex-Troop Sleeper Baggage Cars – Part 3: Plugging windows

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The next step with these cars involves plating over the carbody vents and the unwanted windows. The upper vents were all plated over on these cars, but the windows varied from car to car, and were done later. Up until the late 1960s and probably into the early 1970s, the cars all would have had their original windows still. In the 1970s however, some of the cars started to have windows blanked out and plated over when they received a full shopping.

The car I’m currently working on represents AC 306 (ex-AC 205, ex-US Army 7883). Photos I’ve collected from various sources online show that on one side of the car, 3 windows (2 to the right and 1 to the left of the baggage door) were plated over, while on the opposite side, only one window to the right of the door was plated.

Note that the windows I’m referring to here are all in the first double pair of windows; the original troop sleepers have a single window on either side of the original entry door, but both of these windows and the original man door are overlapping with the space where the baggage car door will go. Those windows will need to be completely gone, not just plated over with the frame still in place. That’s a little bit more involved, so I’m leaving that until later.

I plated the required windows quite simply by cutting rectangles of .010″ styrene sheet to fit the window openings. (Actually I cut this just slightly oversize and then carefully file down the edges so that it fits in perfectly.) When you look at the windows on the model, you can see the riveted frame around the window, and then an inset window sash, which on the rear car would have been the moveable part of the window. To plate over the window, I just cut the plate to fit just inside the outer frame, and lay down on top of the recessed sash. The .010″ thickness of the styrene sheet set on top of the recessed sash perfectly represents the plated over opening.

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Car with upper vents and two windows at left plated over. The two windows at right will remain open and receive the original kit window glass pieces when the car is fully completed.

Similarly the vents along the top of the car body were also plugged with .010″ material but in this case their narrow width meant a 010″x.080″ strip cut to length will fit perfectly in the vent opening. Again the recessed depth is such that a .010″ strip is almost perfectly flush.

That takes care of the easy part of the car side modifications; cutting out the door, removing the single windows and smoothing everything up again will be considerably more invasive surgery.

ex-Troop Sleeper Baggage Cars – Part 2: Doors

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The doors for these cars was an interesting scratchbuild project. It’s been a while since I worked out the measurements, but I was able to come up with something that looks pretty good. Here’s my drawing from my notes:

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Measured construction drawing of the baggage car door.

The scratchbuilt door master consists of a .020″ styrene door blank with the trimming made from scale 1″x6″ strip (except for the centre vertical that divides the lower part of the door into 2 panels with is a little wider – 1″x8″. Working carefully and measuring with my dial calipers, the trim was fixed by applying liquid styrene cement with a fine brush. My favourite here is the Testors liquid plastic cement. I highly recommend against Plastruct’s Plastic Weld in this application as I’ve found it to leave a nasty surface residue when used on styrene.

To get a nice clean upper window, I applied the trimming to the door blank before cutting out the opening. I don’t remember doing the cutting anymore, but the best approach would be to drill out the corners and then play “connect-the-dots” to cut out the rough opening. What I definitely do remember is carefully opening up the window opening with a series of fine needle files, filing the opening even with the 1×6 trim strips.

Since I knew I wanted to probably make more than one of these cars, I planned on making one door master which I could then make molds from to cast several copies in resin. The door blank was therefore cemented to a piece of .060″ styrene backing.

The window mullins were added after the door was cemented to the backing plate. This ensured that they were nice and flush. The mullins are .030x.040″ strips, laying on their wide side to match the ~.030 thickness of the .020″ door + 1×6 (.011″x.066″) trimming. These should be evenly spaced. (I didn’t keep notes for this spacing, but measuring the door master shows each window pane to be an average of .145″ wide (within a variance of .005″, well within a margin of error and not detectable by the eye).

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Finished door master.

Following the completion of the master, I was able to create the rubber mold from the master and use it to cast several copies of the door. I now have more than enough doors to do several cars.

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Rubber mold and scratchbuilt door master.

ex-Troop Sleeper Baggage Cars – Part 1: Background

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In 1949, the Algoma Central began to replace their older 1914-built wooden passenger coaches with “new” secondhand steel cars acquired from the United States. (Ironically the coaches acquired from the D&RGW were actually older than the wood cars they were replacing!) Included in the AC’s acquisitions were five surplus troop sleeper cars from the US Army.

These cars were built during World War II by Pullman-Standard, and following the end of the war, many of them ended up on railways all over the continent as they became surplus, many of them rebuilt as baggage or express cars or work service bunk cars. (The Alaska Railroad had perhaps the most interesting conversions, chopping up pairs of old troop sleepers and turning them into 50′ high-cube boxcars!) The five acquired by the ACR were rebuilt as baggage cars, initially numbered AC 201-205 and painted in the ACR’s then-current dark green scheme.

These cars were rebuilt with a sliding baggage door and remained in baggage service for many years. One car, AC 204, was later rebuilt to steam generator car AC 76 in 1952 following the dieselization of the railway. The ACR also built 4 more home-built steam generator cars on the frames of old 3100 series boxcars. (No original ACR locomotives were ever equipped with steam generators. The ACR preferred the flexibility of multi-service locomotives and stand-alone steam generator cars were built to heat the passenger trains.)

In 1981 the ACR’s baggage cars were all renumbered into the 300 series to make room in the numbering for the new AC 200-205 series GP38-2 locomotives. The remaining troop sleeper cars became AC 303-306. Since my modeling time frame is 1985, this is the series my cars will be numbered within.

Over the years, windows on several of the cars were plated over. This seemed to vary a bit between the different cars, so working from photos is essential.

Most of these cars were still painted in the ACR’s handsome 1955 maroon and grey colour scheme in the 1980s. One exception was AC 306, which got painted into the 1974 silver scheme with maroon name band, but never actually received the Algoma Central lettering along the top, just the road numbers on the corners of the car. That’s just so silly, it needs to be modeled.

Here’s a link to a Ted Ellis photo of AC 205 (later AC 306) in 1979 in the silver colours:

http://algomacentral.railfan.net/images/AlgoCenRy/AC_205_Hawk_12-26-1979.jpg

And AC 303, looking a little the worse for wear, in the late 1980s still in the 1960s maroon and grey colours:

http://algomacentral.railfan.net/images/AlgoCenRy/AC_303_Hawk_Jct_6-19-1987.jpg

And lastly, a 1979 shot of steam generator AC 76, coupled to AC 74, one of the home-built generator cars just out of frame:

http://algomacentral.railfan.net/images/AlgoCenRy/AC_76_Steelton_12-30-1979.jpg

In HO scale, Walthers has produced a model of the Pullman-Standard troop sleeper car, which can be modified in much the similar fashion to the prototype in order to model these AC cars. Windows and vents will need to be plugged, enlarged door openings cut out and the doors scratchbuilt.

I’ve completed the doors and I’ve been working away on one of the Walthers cars to convert it into baggage car #306; ultimately I’d like to do the steam generator car 76 and possibly one more baggage car for a nicely rounded fleet.

Next: Scratchbuilding the baggage doors.

Passenger Train in a Box!

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Just before I left on vacation a couple weeks ago I got a package of goodies from Union Station Products in the mail. A bunch of car side and core kits:

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The core kits are made by Train Station Products, and the sides are either laser cut or CNC machined for specific prototype equipment. Since all of the AC passenger equipment is secondhand from various sources, there’s a number of side kits that are appropriate for AC equipment.

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The top kit in this photo is a Central of Georgia coach (AC 440) and the bottom a DRGW Baggage/RPO (AC 300-301).

A few of the car kits acquired (and the AC cars they will represent) are:

2x #7603 – DRGW P-S RPO – AC 300-301
1x #2866 – CofG ACF Coach – AC 440
1x #9636-023 – NYC Budd Observation – AC Canyon View
2x #7423-R – SP Articulated Coach (Modernized) – AC 450-462

This should be an interesting series of projects when I get a chance to work on these!