Installation Instructions

Car Body Bolster, 1-1/2" Scale, With Flat Top

Catalog Numbers 15P2A or 15P2D

Overview

This body bolster 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 of Bolster

To begin assembly of each body bolster, locate one 10-24 x 3/8 set screw, and one 3/8-16 x 3 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 the 10-24 set screw. 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. Place the 3/8-16 x 3 screw in its hole from the top side of the bolster so that the top of the head ends up flush with the top of the bolster. Pull downward on the 3/8 screw so that is tight against the bolster and tighten the set screw (do not use excessive force or damage to the aluminum part may result).

Installation on Car

The body bolster includes four or eight 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

It is recommended that you apply a coating of a waterproof, anti-corrosion, moly grease (we use Chevron Moly 2, available from our parts list) to the center pivot areas of the body bolster that will contact the truck before truck installation. You may then lower the car over the trucks, or turn the car upside down and place the trucks on the car. Next, 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

Whenever the trucks are serviced the center pivot should also be cleaned and new grease applied.

Replacement Parts List (for One Car)

Note: Do not substitute steel for stainless steel screws

_{© COPYRIGHT 1996-2010  REAL TRAINS®, INC.  ALL RIGHTS RESERVED}

Real Trains®, Inc.

_{32215-D Dunlop Boulevard • Yucaipa, Ca.92399 • phone(909)446-0600 • fax(909)795-9320 •  This e-mail address is being protected from spambots. You need JavaScript enabled to view it}