The purpose of this little project was to see if I could apply the lessons learned from building the original kit, as well as to test a few techniques using... junk.
Well, maybe not junk per se. The ends, roof, and floor are made from sections of yardsticks (Ace yardsticks are 1/8" thick by 1 1/8" wide, Home Depot ones a shade over 3/16" thick by 1 7/16" wide, and of course both are 36" in length, but you knew that already, I hope). They are fairly soft wood, and make great material.
Oh, and how exactly did the notion of using yardsticks as material enter into my mind in the first place? The blame falls squarely on the classic Kalmbach/Model Railroader book "Easy-To-Build Model Railroad Freight Cars" and the last project in the book. But I seriously digressed, though I do recommend the old book.
I laminated a copy of the printed parts onto a sheet of a favorite material of mine - cereal box cardboard. The adhesive for this was E6000 Latex based spray adhesive. Be easy with this stuff, as it's water based. The color print was applied to the smooth outer surface of the cardboard. I put the laminated parts under a weight and let it dry.
Using the measurements from the StromBecker parts I built up the core, knowing that the roof and floor would need to be shimmed up, as they used the narrower Ace yardstick. The ends from the Home Depot yardstick simply needed to be trimmed down.
After these pieces dried, I cut notches into the roof and floor shims where the ends and center support were to go and glued the pieces down to the floor, and added the roof. I used a rubber band to hold it all together. I also put together the center beam for the roof from coffee stirrers (3/16" wide, about 1/24" of an inch thick).
After the main assembly dried, I added the roof's center beam.
The roof was made from more cereal box cardboard. This time, it was important to check the grain of the material. I wanted the grain to cross the roof to add some rigidity. After double checking the measurements, I cut the piece out and drew on the marks for the roof "ribs", scribed the folding lines using a dead ballpoint pen, shaped the roof, and glued it down. Note that the center line is not peaked but flat. Not prototypical, but it would make adding the roofwalk easier to "fake" a milled roof. The roofwalk was cut from "craft stick" wood, about 1/16" thick, with scribed "planks". The cross roof ribs were made from flat wooden toothpicks. Oversized, perhaps, but the look the part (also, for the rivet counters out there, yes, I know, wrong number of ribs). I also added fishing weights, just four in the end corners, using E6000.
And another problem.
The scanned copy I made of the sides did not translate well in dimensions. I am unsure why this happens in the translation from Gimp 2.8 for Macintosh to Windows, but it has been a consistent problem. The size difference is normally small, but it is enough to throw everything off.
To solve the length problem, I used the thickest cardboard I had to add pieces to both ends. I also needed to make new end fascia.
I made end fascia, and this is where I discovered a mistake - the pitch of the roof was far too steep. I mis-measured the height.
Sigh.
The next morning, after allowing this to dry overnight, I carefully cut along the glued edges of the roof, removed the fascia, and carefully lifted both side. When this was done, I used two coffee stirrers on both sides the shim the edges up. I then trimmed the fascia and added them once more.
After my nerves settled and the glue dried it was time to paint the roof, once more using the Apple Barrel Kelly Green, with the new end fascia painted black.
Now it was time to add the printed sides and ends. Fortunately, the sides only needed marginal trimming, and raising the edges of the roof helped the fit. The ends were perfect, or as close as I was going to get.
One of the other things I did on this model was to cut the roof hatches out from those platforms that they are printed with. Once I had, I blacked their edges and glued them into place.
The finished body compares well enough with the original, though it is a little bit darker in color, an artifact of correcting the image no doubt.
Anyway, now we wait on the trucks and couplers.