I just blew 20 minutes of writing a thread when switched to another site, but forgot to open another window. DOH!
This thread was about a nice Saturday session. I finished the right side wall, built more windows, downloaded some machine tool drawings from the SketchUp 3D Warehouse, and fixed some more problems.
I decided to fit the ends to the left side to see how square they came out to be. They were nicely square.
Then I tried the newly completed right side wall. Oh no! I got the offset wrong again! What happened this time? My wife always wants to know what I was thinking when I have these lapses. I explained that I had reversed the order in building the second wall. I did all the outside pilasters first and then did the inside. I had already offset the corner pilaster to overlap the end's corner. That offset confused me so when I placed the inside corner pilaster I already thought it was offset for the end wall, but I was mistaken. I needed to offset it one more time. The glue was cured. I needed to remove the parts using the plane blade. Titebond is stronger than the substrate and when you try and separate it, the MDF fails. Luckily most of the failure was on the pilaster and not the wall itself. I have many, many extra pilasters.
While this was drying I was making more windows… lots of windows.
Having so many windows to produce gave me ample opportunity to find the best way to assemble. I found out that holding the window and bringing it in contact with the adhesive frame was easier to align than how I first was doing it; holding the acetate and bringing it to the frame.
I still have a few more big windows to build. I then had another faux panic! I have 29 small windows (13 for each side and 3 on the back), but I only had 24 big windows on the frets. I started writing an eMail to Rail Scale. During the typing it hit me. The left side only has 5 big windows due to the machine shop, so that adds up to 21 (13 + 5+ 3 = 21). Instead of being short, I have 3 extra. I deleted the half-written eMail.
Then I found another problem. My window arrangement on the right side was not symmetrical…it was supposed to be, but wasn't. Not enough space on one end to clear the wide inner window frame. The result was trimming the pilaster and then the buttress.
I trimmed the pilaster on the scroll saw, but the buttress, at 3/4" thick, was too thick for that machine, so I sawed the relief cut with a hand jig saw. I smoothed out the cut with the 1" belt sander.
I removed the foam under the machine shop and prepared the site for that part of the building. It's being supported by the foundation blocks as I did on the main floor. I'm still deciding if I should fasten this floor to the main, or leave it just connected to the machine shop walls.
The other thing I was doing while stuff was drying was download a bunch of great machine tool drawings. These are all drawn 1:1 scale and needed to be shrunk to 1:48. Then they all need to be modified for 3D printing. That will take some time since all aspects must be read as "solids" by the slicing software. A "solid" in this instance is a shape that has all edges and faces as a contiguous thing. Any non-connection renders the object "not solid" and not printable. Then I have to evaluate them based on how small of a feature size is capable of printing. I'll do that experimentally. The printer arrives tomorrow and I'll have a pretty steep learning curve, but it's going to be fun.
I looked for larger machines like vertical turret lathes or Wheel Lathes, but came up empty. If I want to include those, I will have to draw them myself. I will also need a crane system for the machine shop. The parts are heavy.
I'm going to do the same thing on the HVAC units.
My special Kalmbach book on the 4014 came and was great. It really showed the beautiful work that was done on that remarkable engine. The drivers were turned at Strassburg RR's Steam Shop. Funny that this little railroad with only small 1900s small-drivered steam engines in their stable, has the only capability in the country to turn monster drivers. They chose 4014 out of the eight extant Big Boys since it was in the best condition and the group that owned it was amenable to make a trade for it. Being in Southern Cal for the past 60 years kept it from rusting away. The pressure vessel was in very good shape, and required little in the way of rebuilding to make it functional, mostly around changing out staybolts.
I will fully document the learning curve on the 3D project so the rest of you can decide on whether it's for you.
