Plaster was still a little damp... Sculptamold dries in two-stages. The plaster part sets in about 30 minutes, but the paper fiber part takes several days to dry out depending on humidity and how thick a layer is drying. You can't sand it when it's still damp.
So I finished up the bumpers. Since these were all hand-measured and hand cut, there was a lot of variation between pieces. It's the reason that mass production always used jigs, fixtures or computer control to ensure part to part uniformity. What I had was the opposite of that.
Case in point. While the angled end of the back brace was measured as carefully as I could (I didn't make one of my detailed drawings) the notch the brace sets into was not at the correct angle, so the angled brace in about have the cases stuck out past the datum line which mated with the front frame. I glued all the angle braces up using medium CA and then marked a line that represented a true vertical.
When the difference was large like this one, I first trimmed it off with the scroll saw and then sanded both with the horizontal part against the fence on the True Sander so the angle and straight pieces were in line.
I glued everything up with Aleen's Tacky glue. The frames were clamped when they dried, but I found that clamping the total assembly tended to knock everything out line, so I just applied glued and let them sit until they dried. I then went over the joints with some thin CA to fill in any slight mismatches.
Here's one bumper in position on the shelf. I am going to glue and possible screw them down onto the shelves. I will drill through the angle brace into and through the horizontal brace right at the notch joint, and then screw them onto the shelves. This should stop the casual bump from having a car end up on the floor. If the car is shoved against the bumper with some force, it would probably break the bumper.
Note: the glue is still wet in this picture.
Tomorrow, back to the plastering and crossings, and then work on the station itself.
