Building the BC&G Railbus A
text, drawings and photo by Phil Bonzon, MMR |
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The Railbus was a 1921-built Mack Model AC Railbus that
the BC&G acquired in 1941 to provided passenger and mail
service between Dundon and Widen, WV, just 18.6 miles away.
Twice a day it made the round trip between these two towns
and in the late 50s with Kenneth Brady as the engineer.
Originally built with a 64 hp 4-cylinder engine, the BC&G
replaced it with a “more modern” Chevrolet engine and opened
up the front of the hood for additional cooling.
Construction
Styrene sheet is the principle material used in the model
construction. Brass was used for some chassis members, body
moldings, pilot, fenders, handrails and horn.
The Chassis was made from brass channel shapes that are
soldered together and then bonded to the 0.100-styrene floor
with CA adhesive.
 The Hood was carved from a solid block of styrene to the
required shape. The louvers were made from 0.030-styrene
quarter round shapes bonded to the hood with plastic solvent
adhesive. The hood hinges are 0.010-styrene.
The Body was made from three layers of styrene. The inner
layer, which has the individual window sash cut into it, is
0.010-styrene; the middle layer, which has the paired
windows and doors cut into it, is 0.030-styrene; and the
overlays, which includes the embossed rivets, is
0.010-styrene. The horizontal and vertical window muntins
are scale 1"x2" styrene strips. All of the styrene was
bonded together with plastic solvent adhesive. The molding
above and below the windows was made from 0.020-brass rod
bonded to the body with CA adhesive. The rivets were hand
embossed using a NMSL rivet tool.
The Roof was made from a layer of 0.090-styrene bonded to an
interior layer of 0.030-styrene. Lead weights were adhered
to the underside of the roof to increase the weight for
better electrical pickup. The canvas covering was simulated
by applying a single layer of facial tissue to the roof that
is coated with ‘Grimy Black’ enamel and then given an
overcoat of the same enamel. The roof is removable to allow
access to the interior and is retained by a screw from the
underside of the chassis.
The front Fenders were made from 0.015-brass sheet cut and
formed to shape and then bonded to the body with CA
adhesive.
The Pilot was made from brass angles with holes drilled to
locate the brass rods; the assembly was soldered together;
the projecting ends filed off and pilot was bonded to the
body with CA adhesive.
The Handrails, Grab Irons and Door Handles were formed from
0.010-brass wire and applied to the body with CA adhesive.
Glazing was made from “overhead projector” film and bonded
to the body, after painting and weathering, with CA
adhesive.
Front and rear Headlights were made from aluminum tubes with
14-volt light bulbs wired to the decoder to provide
directional lighting. The nonfunctioning headlights were
made from styrene rod and brass wire.
The front Steps were made from styrene while the rear was
made from brass wire.
The Grille was made from 0.010-brass wire soldered together.
The Motor/Gear unit is a NWSL “Flea III” assembly, supplied
by custom order, with 36" nine spoke wheels. It is built
into a styrene subassembly that includes the brakes,
simulated leaf springs and supports, brass sand pipes,
simulated drive staff and continuation of the brass chassis
channels in styrene. The motor was hard-wired for DCC. The
sub assembly fastens into the body assembly with two brass
screws.
A LokSound’s decoder and sound system was hard-wired into
the model to replicate the sounds of the Railbus.
 The front truck was made resemble the BC&G prototype from
styrene sections that were bonded together with plastic
solvent adhesive. The three major components, truck sides
and cross member, were fastened together using brass pins
and CA adhesive. The 26" NWSL wheels provide electrical
power pickup through 0.008-phosphorus bronze ‘wiper’ wires
to the decoder. Simulated brake shoes and journal boxes were
made from styrene.
Interior: An interior was made for the passenger compartment
from styrene with a raised floor, to clear the decoder and
speaker located below. Lead sheet was bonded to the
underside of the raised floor for additional weight. Because
of the raised floor, the bench seats had to be abbreviated,
as did the five passenger figures, plus the engineer and a
coal stove. In the baggage compartment, wood crates made
from scale lumber, cover the motor.
Exterior: There are many details included on the exterior;
the brass horn, the roof ventilators and the brass radiator
cap, the headlights on the pilot (all turned using a Dremel
tool and a file as a lathe); the grille; the battery box
located on the left front fender; the square gas tanks with
their filler spouts; the underbody storage shelves; the
smoke stack; and all the details at the rear axle, i.e.,
springs, brakes and sanding pipes, just like the BC&G
prototype.
Finish
The model is finished in Floquil’s enamels in colors
corresponding to the BC&G prototype for the period.
Custom-made decals were applied and the model was given a
light weathering using Floquil’s ‘mud’ and ‘dust’ and a
light wash of India ink.
Scratchbuilt
The model is entirely scratchbuilt except for the following
allowable items: Motor/Gear unit – Wheels - Light Bulbs -
DCC Decoder and Sound system.
Footnote
Phil's Railbus model won Honorable Mention in the
“Scratch Built Locomotive Other” category at the NMRA 75th
National Convention in July 2010. His scratch building
article on the BC&G Railbus A will appeared in the December
2009 issue of Railroad Model Craftsman.
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