Alexander Chapter- NRHS
Alexander Chapter- NRHS
Casting Hardware for Boxcar #401

     Jim first started by making rubber molds of the original parts. On the left, encapsulated in rubber, are a boxcar door stop, and a spacer used in on one of the long metal door guides.
     On the right is the mold for one of the pole pockets. 

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     Out of the cardboard forms  is the rubber mold with the original sand cast parts of the stop and spacer inside (below) and out (right).


The first parts are made from the mold. It sure seems like magic to many of us!

     Is it live, or is it Memorex??

This is a close-up of the resin part. Note that rust from the original part transferred to the rubber mold and THEN transferred back to plastic part.  Even the foundry marks are duplicated and appear to be a C&O pattern !

On the left- the original door stop.

Left to right- three castings.

Below, left and right, are the molds of the pole pocket, before and after being filled with resin.

And voila! We have a pole-pocket.

The original is on the left, the empty mold, above, and the casting on the right.

Thanks again to Jim King and Smoky Mountain Model Works for all his hard work and dedication!

     This page provides a sampling of photos that detail the process of casting plastic resin parts to use in place of some metal hardware that is missing from the boxcar. This process is used only on parts that will not see stress as the car would on the life of a railroad, and in cases of missing grab irons, steps, etc, we will go back with steel parts. However, for the more "ornamental" metal parts of the car, as it relates to the car as a museum display, the resin is perfectly acceptable and will save hundreds, if not thousands of dollars in the restoration of the car. So enjoy the photos (all by Jim King), and admire the work of Smoky Mountain Model Works.