| Catalog Number 15P2H - Car Body Bolster, Roller Type, 1-1/2" Scale, For 1" by 2" Tube Frame |
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Installation InstructionsCar Body Bolster, Roller Type, 1-1/2" Scale,For 1" by 2" Tube FrameCatalog Number 15P2H
Overview This body bolster provides roller bearings to both carry the weight of the car, and to provide a central pivot point about which the truck will rotate. These bearings replace the normal sliding surfaces and provide much easier movement of the truck. It has been designed to provide a simple, well proven method of mounting trucks to your car. It is important to realize, however, that this part is only one component of a well designed car. The reliability and safety of your car, and your enjoyment of it will depend on how well you design the overall car. These instructions are provided to give the basic details of mounting the body bolster. They are not intended in any way to be design guidance for the entire car. If you do not feel comfortable doing the design yourself we strongly advise you to seek out more experienced modelers for help. If you are unsure of anything, please contact us.
Assembly to Frame The top of the body bolster contains a recess that the frame fits into. When properly installed the top of the frame will be flush with the top of the body bolster. To begin assembly of each body bolster, locate two 10-24 x 5/8 stainless steel socket head cap screws, one 10-24 x 3/8 set screw, and one 3/8-16 x 2 1/2 socket head cap screw (all are packed with body bolster). Make sure that you have the correct size hex keys for each of these. It is also recommended that you use a retaining compound of the small screw (low strength) type on all three of the 10-24 screws. The same, or a high strength compound can be used on the shank (the part within the body bolster) of the 3/8-16 cap screw. You may also grind a small flat on the cap screw where the set screw will contact it.
The three-eighths inch cap screw is the center pivot bolt for the truck. It is commonly used because it allows the car to be lifted with the truck remaining attached. If this is not a concern to you it may be omitted. There is also an additional choice as to how this bolt is installed. If the car design allows access to the head of this bolt after assembly (of the entire car) it can be installed loosely in the body bolster. This allows easy replacement if damaged or worn. If access to the head is not possible it will be necessary to secure the bolt to the body bolster so that it will not turn when the lock nut is installed below the trucks. This may be done through the use of a set screw that is provided, or by securing the bolt using a coating of a high strength retaining compound (bearing mount type) between it and the hole for it in the body bolster. Based on your choice you should modify the instructions that follow as appropriate.
Install the set screw into the hole in the side of the body bolster (the outer portion of the hole is larger than the screw, the inner end only is threaded). Carefully thread the set screw inwards so that it stops slightly outside of the center hole. Note that the set screw hole and the mounting screw hole intersect. The body bolster attaches to the frame using the holes indicated on the frame installation instructions. All three holes are much larger on the top of the frame than on the bottom where the body bolster goes. With the frame and body bolster oriented correctly, install the two 10-24 x 5/8 cap screws so that the head is inside of the frame and the threaded portion extends below the bottom of the frame. Thread each of these screws a short distance into the body bolster (two turns). Place the 3/8-16 x 2 1/2 screw in its hole. Tighten the 10-24 cap screw that is on the side opposite the set screw (do not use excessive force or damage to the aluminum part may result). Pull downward on the 3/8 screw so that is tight against the frame while pushing the body bolster up against the frame and tighten the set screw (carefully). Now thread the remaining 10-24 cap screw in fully and tighten it.
Installation on Car The body bolster includes four 3/16" (4.78mm) diameter holes for bolting to the car. We recommend that they all be used. Do not attempt to weld to the body bolster. Do not enlarge these holes to use larger bolts. Use #10 machine or wood screws only. We cannot over stress how important a correct attachment is to both the safety and enjoyment of your car. Please consider that a common industrial standard is that any part should be able to withstand three times the total load it normally carries. If you feel your mounting is this strong, you will be much more comfortable when enjoying your trains operation.
Installation of Trucks Do not apply any type of grease to the surfaces of this bolster. To install the trucks you may either lower the car over the trucks, or turn the car upside down and place the trucks on the car. Then, locate the flat washers and nylon insert lock nuts. Use one washer and one nut to secure each truck. Tighten the nut with the correct size wrench until approximately 1/16" (1.6mm) of space remains below the nut. Do not fully tighten these nuts because the truck must be free to turn and to rock slightly under load.
Maintenance Finish Care The anodized finish on the aluminum parts is very hard. Do not try to sand, file or machine these surfaces. If the finish is damaged it may be touched up with aluminum blackening solution available at sporting goods, firearms and large hardware stores.
Lubrication The bearings used are filled with enough grease for life under typical use. If used commercially or if exposed to conditions that call for re-greasing use the following steps. To grease the four central rollers remove the truck from the body bolster. Then, using a needle adapter and grease gun, add a small amount of grease to the center hole in each bearing. To grease the two outer rollers use standard grease gun attached to the fitting on the end of each bearing.
Use a high quality bearing grease. Shell Alvania number 2 grease is what is originally provided and is available from our parts list. Only a small amount of grease is required and too much pressure can damage the bearings.
Bearing Replacement To replace the two outer rollers, first remove the grease fitting by unscrewing it from the bearing assembly. To replace any of the bearings use the correct size hex key to unscrew them. When installing the new bearing we recommend the use of a small screw (low strength) retaining compound. Do not over-tighten the bearings in the aluminum bolster. When replacing the outer two rollers drive the grease fitting removed from the old bearing (or a new replacement) into the hex opening of the bearing after screwing it in to place.
Replacement Parts List (for One Car)
Note: Do not substitute steel for stainless steel screws
There are certain parts that we do not manufacture. The suppliers of these parts often change their specifications, delete models, and change part numbers without notice. The only way to be sure that you are getting exactly the correct replacement part is to order it by our part number. We do, however, understand that some people will want to know the current manufacturers name and part number. We provide this without warranty for information only. The outer roller bearings are Torrington CSRB-14. The central roller bearings are Torrington CSRB-8.
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