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Buckeye Truck Construction Photos Page 1

Buckeye Truck
Page 1
November 2001 - June 2003

After spending nearly 2 years constructing the B&O WagonTop Boxcar, I was not intent on utilizing poor quality, "store bought" trucks made from castings that are readily available from sources in the Live Steam community. With the incredible help of Fred Bouffard, I had complete access to a Matsuura 6M Ram Master 2 CNC Milling Machine and all the equipment needed to produce a series of Buckeye Trucks for the Boxcar and any other projects I will undertake. So, we spent the better part of 2 1/2 years perfecting a program to create entirely from bar stock a 100% prototypical model of the Buckeye Trucks. No CAD or CAM programs were used at all in this venture, everything done the "old fashion way", pencil and paper. Once completed the hand-written and calculated G-Code program totaled 3000 lines for the front and 3000 lines for the rear of the sideframes alone. These trucks feature prototypical bearing construction as well (no store bought roller bearings used). The side frames are perfect representations of the prototype, cored and "3Ded". Furthermore, since this was created using a CNC machine, at any time in the future that we may need more trucks all that is needed is to load the billet, call up the program and hit the start button. The following are photos detailing the construction of the Buckeye Trucks for the B&O WagonTop Boxcar...

click on any smaller picture to view a larger picture

A photo taken of the prototype Buckeye Truck at SteamTown National Historic Site, in Scranton, PA.

A detailed view of the bearing assembly on the prototype

This long project began with creation of the wheels and axles. Here are the completed sets, constructed entirely out of bar, no castings used on the entire project. The wheels and axles feature prototypical shaping and profiling.

Machining the bronze Journal Boxes on the Bridgeport

A completed Journal Box

Many completed Journal Boxes

A photo of the Matsuura 6M Ram Master 2 CNC Milling Machine utilized in the project. All programming was done by hand, no CAD or CAM programs were utilized at all at any time. All in all, once completed, the program (G-Codes) consisted of about 3000 lines of code.

The control panel of the Matsuura 6M Ram Master 2 CNC Milling Machine

A completed test sample of the sideframe with many errors in it, a lot of work was still needed at this stage to perfect the program. These sideframes are resting on one of the 4 billets used in the construction of the sideframes alone.

Cutting the billets into smaller "blanks" of metal for the CNC machine

Squaring up the smaller billets, or "blanks" for the sideframes

Prototype "test" sideframes and the "blanks" they were machined from

The CNC Milling Machine actually roughing out a sideframe from a solid blank. Aircraft Aluminum was utilized for this project due to it's light weight and extreme strength. Ease of machining was a priority as well as many small intricate details were programmed into the sideframes.

Another view of the milling process. This stage represents finish cutting a pocket with a 1/8" bottoming end mill. I was squirting extra coolant on the area to make certain the end mill wouldn't break in such a deep pocket.


Buckeye Truck Construction Page 2
Buckeye Truck Construction Page 3
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