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Post by tjdreams on Sept 5, 2022 10:18:35 GMT -5
The Aztec Track cleaning car is Yet another item that falls under the classification of: "You Better Buy It When You See It for Tomorrow it will be GONE"The Aztec cars are no longer made and Its rare that they pop up on the 2nd hand market. When they do there selling for nearly twice their orignal list price. So with that in mind I decided to make my own track cleaning car using the Aztec car as a base model. I mean how hard could it be it's just a block of Anodized Aluminum with a hole drilled through it for the roller and a couple raised post to mount the trucks on. Easy Right? Not Quite! After pulling the shell off I quickly realized that their was a lot more to it than it first appears. I found that Aztec made 2 different versions each of which used a different chassis. One that fit under the Micro Trains "502 00 000" series 40' Plug Door Steel Box Car and the other which fit under the "515 00 000" series Double Sheathed Single Door 40' Wood Box Car. Other than the Cratex Roller the 2 chassis had several differences and were not interchangeable. Each and every, hole, notched corner, rounded off edge, raised shape and grove was there for a very specific reason. After taking a couple measurements, I ordered up some supplies. Well ok I took Lots and Lots of measurements because I'm planning to put my Aztec stile chassis under a MTL 500 00 000 series 40' Standard Box Car, with a Single Sliding Door. The measurements of the 502 00 000 series were closest to the 500 00 000 series so I went with it as a base line.
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Post by tjdreams on Sept 5, 2022 12:21:28 GMT -5
The Roller Aztec used is made from a Cratex Rubberized Abrasive Rod. They are available in a couple different grades which can be identified by there color. COARSE (Green),__MEDIUM (Dark Brown),__FINE (Reddish Brown),__EXTRA FINE (Grey Green) Judging by the reddish brown color of the rollers in my Aztec cars I ordered a 1/2" Diameter 6" long fine rod. Cutting the Rod down to size was not as easy as I thought. My plan was to chuck it up in my lathe turn it down, center drill it and part it off to the size needed. But being made of an rubberized abrasive it dulled both my HSS and Carbide turning tools in a matter of seconds. I was able to drill out the center using a cheap bit in my Dremel. Then I made a mandril out of a scrap of brass and used a couple pennies as washers. After cutting the rod off by hand with a hacksaw i mounted it on the mandril, chucked it up in the lathe and used a diamond cut-off wheel in my Foredom to turn it down to size. The rollers in both of my cars were about 0.4500 long and had a slight taper with one end being about 0.0050 larger than the other on both cars. I believe its this slight taper combined with the hole it rotates in being slightly out of square with the rails is what causes it to (Clean) sweep any dust and dirt off the rails as it rolls/drags along
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Post by tjdreams on Sept 5, 2022 12:52:03 GMT -5
This being my first project on my New to me (used) Sherline Mill I made a few mistakes here and there turning the hand wheel too far or the wrong way, I also learned that some times drilling should be done before milling and other times it should be the other way around. oops!. In any case with a few minor design & dimensional changes I was able to recover from my mistakes and continue with the build.
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Post by tjdreams on Sept 5, 2022 13:26:04 GMT -5
After Milling the chassis to the correct size. I decided to make another design change to cover up one of my oops moments. I drilled a #52 hole with the edge 0.025mm from the chamfered edge at the bottom and pressed in two 1/16 diameter x 1/4 magnets with a combined pull strength of just under 0.20lb. which should be strong enough to pick up any small metal objects that find there way onto the track yet not be so strong as to interfere with turnouts or any electronic items near by. Additionally as you can see I milled the slot on the left side at a slight angle so I will have to shim and glue the steps in place on that end. I don't have a rotary table for the mill yet so the square bolster pin mounts will have to do for now. And now that the brass rod finally got here I turned down the center axel for the Cratex roller.
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Post by tjdreams on Sept 5, 2022 13:40:08 GMT -5
Now that the first one is done and working just fine, I think maybe I'm going to change things up and try to use a different style Car body for #2,#3, & #4 For side by side comparison my build is on the left and the orignal Aztec is on the Right
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Post by BAZman on Sept 5, 2022 15:39:46 GMT -5
Good work, glad you got one to completion.
Being in close quarters to John Claudino, I have a, eh-hem, "few". And yes, the machining isn't easy. But they work great on old track, track stored in garages, smoking/painting environments. After that, treat the rail chemically so you don't have to rub the rails down (literally) every time you run.
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Post by markm on Sept 6, 2022 10:41:09 GMT -5
I had the opportunity to talk to Aztec at the Portland convention, and of course I bought another car.
He described the operation exactly as you did so it's doubtful you missed anything. As I recall they also produced an Nn3 cleaner in a 30' boxcar that probably also fits the 502 frame. I use metal wheels on the trucks. I find the plastic collects a lot of the crud we're trying to take off the tracks and metal adds a little bit of additional weight.
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