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... topic: 492 Making precise bends in bullhead rail posted: 14 Jul 2008 20:59 from: Martin Wynne Here's a simple idea which costs nothing and is a good way to make precise symmetrical bends in bullhead rail. It needs a bit of practice to know how hard to tap! 2_041840_270000000.png 2_041828_140000000.png Hopefully the diagrams are self-explanatory. Just two bits of rail about an inch long laid side by side with a gap between. The smaller the gap, so the harder you need to press/hit, but the more precisely located will be the bend. Make sure the rail is exactly square across them before making the bend -- a sheet of graph paper underneath helps. regards, Martin. posted: 14 Jul 2008 21:05 from: davelong Worked perfectly for me. Thanks Dave Last edited on 14 Jul 2008 21:23 by davelong posted: 15 Jul 2008 01:04 from: donald peters I feel the great hazard with this device is precisely the 'practice' element that is always inconsistent after long absence or lack ...
... straight-cut switch planing). That's not just for pre-grouping, it's for all bullhead. GWR and BR(W) used joggles throughout. Other companies used the REA designs with joggles in running-line facing turnouts only, and a plain set in other turnouts. This shows a plain set, thanks to Rod Cameron for the photo: stock_rail_rea.jpg It's very difficult to make an accurate prototypical joggle. A set in one side only is much easier to model, and the easiest way to make it is: 2_041840_270000000.png 2_041828_140000000.png Hopefully the diagrams are self-explanatory. Just two bits of rail about an inch long laid side by side with a gap between. The smaller the gap, so the harder you need to press/hit, but the more precisely located will be the bend. Make sure the rail is exactly square across them before making the bend -- a sheet of graph paper underneath helps. For details of how to do this and get the correct angle, see this topic on here: topic 491 and this post ...
... of the spring in the rail. Perhaps also add some packing below the rail as a depth stop. I don't believe the knuckle radius is too critical in terms of running, provided the wing rail front aligns properly with the vee rails and the check rails are correctly positioned. But now that Templot templates show the extent of the knuckle bend, you have something to aim for in making a prototype pattern knuckle. For sharply defined bends, such as the set in the switch stock rail, practice with a small hammer: 2_041840_270000000.png regards, Martin. posted: 5 Sep 2017 03:51 from: Andrew Duncan Hello HowardThanks for your reply (swipes at us poor souls who don't/can't model to the ultimate gauge, aside) and clear explanation of the radii required. I'll give your solution a try and if or when it fails I'll try Martins somewhat more scientific approach! I trust everything's going well in your preparations for Scaleforum and hope to see you then. Kind regards Andrew posted: 5 Sep 2017 04:15 from: Andrew Duncan ...
... have unlimited possibilities and I cannot believe they had limitless options for presses in the factories. Yes, I know the 'big blokes with big hammers' but I'm not sure that would work here. Does anyone know how they overcame this, please? I would like to design a simple jig that anyone can build from easy to get components. Thanks Derek posted: 22 Oct 2020 00:36 from: Martin Wynne Hi Derek, I've posted these diagrams before, including in your previous topic on this subject: topic 2788 2_041828_140000000.png 2_041840_270000000.png They could be worked up into a proper press tool with a depth stop to set the bend angle, etc., or as an attachment to a drill press. Note the above is for vertical rail. If you want to make horizontal bends in inclined rail you need a conical mandrel, the rail must be held firmly at the inclination angle (1 :20), and a lot more force. It may require the rail to be annealed at red heat first. It might be possible to twist the rail ...
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