Detailing Timber Bolsters

Last month I received 4 bogie timber bolsters in 3D print ready to roll. As usual with 3D printed models I feel I have to remove the most visible traces of the printing proces - the thin lines of layered resin or plastic material. A lot of work with sanding sticks and sand paper will usually take care of most of it. I also wanted to add a little extra detail. I'm still working on the bogies and below is a status of the progress.

One rusty timber bolster bogie, a horse without harness and a bewildered workshop manager drinking coffee. Weekend approaching at Nystrup Gravel?

As I took a closer look on the timber bolsters I decided to limit my work on them to the following tasks:

• remove most of the 3D printing layering lines by sanding (the paint I use help to hide the rest)
• fill holes in the bogies' top plates (don't know why they are there?)
• replace printed on footsteps with scratchbuilt metal items
• add bolt detail
• remove brake gear
• add hand rails

Filling holes with putty and sanding (particularly the upper surfaces) was done on all 4 bogies in assembly line-style. After testbuilding the first footstep and fitting it on one side of a single bogie, I built and fitted the remaining three steps. I intentionally made two of the steps crooked as the steps were prone to be damaged by occasional derailments. From there I concentrated my efforts on a single braked bogie. The rest will hopefully follow in quick succession.

New footstep made from nickle silver sheet and brass wire next to the item to be replaced. The 3D printed part was too clumsy in my opinion and easy to replace.

'Pretty decent work', the Nystrup Gravel chief mechanic seem to think, 'Now three more steps needs replacing'.

From the beginning I had been a little disappointed with the look of the brake installation printed integral to the platform railing. As Nystrup Gravel's lines were without steep gradients braking, besides what could be accomplished by the locomotives, weren't necesarry during a train's movement. To keep wagons stationary on sidings a branch or a stone placed on the railhead would usually suffice. Only a few braked skips are documented on photos from Nystrup and consequently I decided to discard the brake installation. I presume it was removed on the real version of Nystrup Gravel to cut down on maintenance and to avoid complicating the operational environment for the workers who seldom were among the most mechanically experienced. 

Having cut away the brake installation from the platform railing I added handrails and corresponding bolt imitations. The railing was then glued to the bogie with AC-glue. More bolt heads from sliced octagonal plastic strip were added to bogie ends and under the axle box guides. Total sum of new parts added to the bogie reached 36. In addition I glued two pieces of lead under the bogie to increase its weight. 

The first 1/19 scale timber bolster bogie in rusty condition. Hardly anyone will notice my work adding bolt heads, handrails and replacing footsteps. But I know it's been done.

The bolster works as the real thing: lift the side support and it falls down to allow loading or unloading.

I separated bogie and timber bolster before painting to avoid everything being 'welded' solidly together by dried paint. I used a rust colour in a rattle can. The paint has a slight texture to it. I used a German made product 'Rosteffekt' from the brand Belton in a standard 400 ml spray can. The paint does smell quite a bit and it's probably best to use it outside the house - I did.  

The bogie will have a partly covering layer of dark grey paint over a covering of chipping fluid from Vallejo. That will allow me to create an impression of flaking and worn paint with rust showing through. But first I will finish the other three bogies.