Our caboose was constructed using "End Cupola Caboose" plans purchased from Titan Trains. (titantrains.net)
Here are some photos of the construction.
|
Parts laid out on graph paper to maximize use of a 4' x 8' sheet of plywood.
|
Sides cut from 4' x 8' sheet of 1/2" AC plywood.
Note the dissimilar sides (number of windows).
|
Additional parts. The roof sections were cut from 4' x 8' sheet of luan plywood.
|
Additional parts made from 3/4" select pine.
|
Bettendorf trucks were purchased from Titan Trains.
|
Floor, endsills and couplers assembled.
Assembly was then tested for proper tracking on the railroad.
|
Another view of the floor, endsill and coupler assembly.
|
Right side view. Parts were joined with finishing nails and epoxy.
The siding grooves are 1/16" deep and 3/32" wide, cut every 1/2" along the sides using a radial arm saw.
|
Another view of the right side showing the cupola ends and one of the end doors.
|
Partial completion showing window moldings.
|
We painted the caboose with Benjamin Moore interior eggshell-luster acrylic paint & primer purchased at Belletetes in Peterborough, NH.
The caboose will not be subject to the weather, so interior paint is suitable.
The color is 'Neon Red' to closely match the prototype.
|
Catwalks and chimney added and painted.
The catwalks and catwalk supports were constructed from 3/4" select pine
and painted using Benjamin Moore interior 'Buttercup' (2154-30) color.
The chimney was constructed from 1/2" copper tube size CPVC,
painted with Rustoleum oil-based gloss black. The endsills are also gloss black.
The roofs are removable and were painted with Rustoleum oil-based flat black paint.
|
Another view after painting.
|
Handrails were constructed from 1/8" brass rods, bent to shape using wood forms and press-fit into the caboose body. Steps were added using 1/4" luan plywood. The step backs were painted to match the catwalks.
|
Front and right-side view.
|
The trucks were painted gloss black, moved to the track
and the caboose mounted on the trucks.
Decals still need to be added. See photos near the bottom of this page for a description of how decals were affixed to the sides of the caboose.
|
The caboose is finally part of the train!
|
To view a short video of the caboose's first run
click on the red "Play" icon in the center of the video above.
|
Decals would not adhere to the plywood sides of the caboose, so aluminum strips were cut from a thin (0.025) sheet of aluminum on which to apply the decals. After cutting the strips to size just slightly larger than the decals, they were painted with gray #8781502 Rust-Oleum Latex Primer. Then the strips were given two coats of the red paint used for the sides of the caboose. See the photo above for a picture of the strips after the primer was applied and prior to adding the red paint.
|
The decals were affixed to the thin aluminum strips and the strips then affixed to the caboose using a small amount of Permatex Silicone RTV, a clear adhesive sealant.
|
The RTV should be clamped or othewise secured for about one hour (24 hours to completely cure), so we turned the caboose on its side and placed heavy cans on the decal strips protecting the decals with paper toweling.
|
The caboose was moved to the track and reunited with its trucks.
|
...and became part of the train
|
|
