HOn2½ Box Cabs - "The Twins"

construction sign

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These engines were built as a tribute challenge to a forum member of the Railroad Line Forum back in 9-16-2016, over 5 years ago.
I've decided to finally put up the construction build on my website of these two boxcabs for wider information distribution
amongst the model railroading community. The idea of building a four axle boxcab in HOn2½ the fact I was interested in On2½.
I built two On2½ boxcabs using a set of DD40 trucks. After I decided to just stick with HO and start building a layout that contained
three gauges, Standard gauge, HOn3, and HOn2½. The HOn2½ will be the quarry line that I have started to build the quarry line.
Needing something to power those dump cars brought up this design for motive power.

I started by purchasing an "N" sale DD40 from E-bay.


Once I got the engine I disassembled it to see what parts I
could use. I was going to use the original motors but
decided not to once I got to that point.


The first part to be made was a platform
to mount to the truck to hold the shell.


Using a CAD program I came up with a design. I printed
it out and using spray adhesive I glued the print out to some cardboard, also known was "chipboard".
Chipboard can be purchased from your local art
supply store.


Once I had the design I liked I used my CNC Sherline
to cut out the sides from .0312" thick brass sheet.


Once the sides and ends were cut out they were cleaned up
with a file to get rid of all the burrs. A piece of wood cut
square is used to make sure the sides are perpendicular
when soldering. This first shell was soldered together
twice. I soldered the ends to the sides and then soldered that assembly together. Took two tries to get it square.


End result of the first assembled shell.


I got smarter on the second shell assembly. I made two
wooden jigs using my Grizzly milling machine. The light
colored wood is rock maple and the dark colored wood is
MDF and is used to solder the front or back to one of the
sides.


Here's the set up. I used my home made soldering rig to
do all the soldering.


First a side and one end is soldered
together on the MDF wooden jig.


Then those sides are soldered
together on the rock maple jig.


The finished soldered shell.


The finished soldered shell on
the sitting on the power chassis'.