Caley Coaches CL02/2a Petunjuk Bangunan - Halaman 4

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Caley Coaches

CL02/2a Building Instructions

bearing that is able to slide back and forth in its block is not conducive to good running. It is a

good idea to pair bearings and hornblocks as small manufacturing differences can be present in

either.

4.3

Select the frame spacers appropriate to your gauge. Bend spacers S1 and S4 to "L" forms. Working

from front to rear, locate the spacers S1, S2 and S4 in the slots on one side frame and solder. Now

solder the other sideframe to the spacers. The ﬂat plate spacer S3 is effectively spare but may

be located anywhere between the frames as allowed by your motor/gear/compensation beam

arrangement for additional strength.

4.4

Locate the top-hat bearings in place for the driven axle, opening up the holes slightly if necessary.

Take care to keep the holes circular. Use the axle/hornblock alignment jig to check the alignment

of the bearings and when satisﬁed solder the bearings to the sideframes. Leave the jig in place.

4.5

Using the previously assembled coupling rods and the set of axle/hornblock alignment jigs ﬁt

the hornblocks and bearings as follows :-

Locate the hornblocks and bearings for the centre axle, using the spring of the jig to hold

them in place,

For each side, slip the appropriate section of the coupling rod over the spigot of the jig in

the ﬁxed axle bearings and over the spigot of the jig in the centre axle bearings adjusting

as required,

Once happy with the alignment of both sides, solder the hornblocks to the sideframes,

Repeat from a) using the other sections of the coupling rods and the centre axle as the

reference point for the other axle.

4.6

Remove the coupling rods and jigs and solder a keeper wire across the bottom of the slot in each

sub-hornblock if the representation of the spring on the frame isn't doing the job adequately.

4.7

On the class 812, solder the coil springs in place below the central axles.

4.8

The pivot of the compensation beam locates in the holes in the sideframes above spacer S2 which

should be drilled out to suit the diameter of the supplied brass rod. Cut a length of this rod to the

dimension over the outside of the frames and a length of the slide-ﬁt tube to be a neat ﬁt inside

the frames. Locate the tube in position between the frames and insert the rod through it. Solder

the rod to the outside of the frames taking great care that the tube is still able to pivot around

the rod. Some Carr's solder mask smeared onto the ends of the 1mm bore tube prior to assembly

should ensure that it doesn't get soldered solid. Use a length of the brass rod as the compensation

beam and solder it at right angles such that it is able to bear onto the centre of the rear and middle

axles.

Section 5 Motion and Brakes

5.1

Open out the crankpin holes on the coupling rods to be generously oversize on the crankpin bush.

Use a 5-sided tapered broach to ensure you keep the holes circular.

5.2

Solder 0.45mm locating wires for the brake hangers to the sideframes.

5.3

Clean the chassis thoroughly at this point and paint. Ream any paint out of the axle bearings

afterwards.

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