Ginnerbeck viaduct for Rylston Light

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Re: Ginnerbeck viaduct for Rylston Light

Post by philipy » Thu Jul 09, 2020 1:34 pm

RylstonLight wrote: Thu Jul 09, 2020 12:13 pm I read them, honest. I followed them, initially.

However, after a few minutes nothing seemed to be happening so I topped them up to three-quarters full. This resulted in the foam expanding first to the top of the pier - success. Then it continued to form a loaf-like mass above the opening - mild failure. I cut off the forming loaf contaminating my saw and hands (thankfully gloved) with sticky toffee-like goop. It kept coming falling down the sides of the up-ended piers in torrents of waterfalls - major failure.
Been there, done all of that!! :oops:

Let it fully harden and then use a screwdriver to re-scribe any filled in mortar joints. It's a pain but doable.
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Re: Ginnerbeck viaduct for Rylston Light

Post by RylstonLight » Thu Jul 09, 2020 1:40 pm

ge_rik wrote: Thu Jul 09, 2020 1:22 pm
Incidentally, how did you stop air bubbles forming in the resin? I recently saw a YouTube video where someone vibrated the table with a blade-less jigsaw to make the bubbles rise to the surface.

Rik
My technique in avoiding air bubbles is highly technical and laborious to describe so only read on if you are an expert modeller. . .

The simplest way to describe it is that I didn’t know it was a potential problem :lol: :lol: :lol:

Now I’m going back to the viaduct to look.
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Everyone knows that Rylstondale stone is very friable and prone to pitting (new addition to background folklore).

Andy
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Re: Ginnerbeck viaduct for Rylston Light

Post by Jimmyb » Thu Jul 09, 2020 1:41 pm

RylstonLight wrote: Thu Jul 09, 2020 8:31 am
Jimmyb wrote: Wed Jul 08, 2020 10:42 pm. . . but which silicon do you use for the moulds.
I have used a variety. For small moulds I used Siligum; a two-part solid material. Advantages is that small volumes are easy, no mess and it cures for use within 20minutes. The disadvantages it is relatively costly and it is vey easy to have hidden voids that can result in either a lot of cleaning of the casting or a frankly useless mould. The cost and the fact you have to work the Siligum around the master mean large moulds are not practical.

For larger moulds I use CS25 Condensation Cure Silicon Rubber from Easy Composites (pictured in OP). This is a two-part liquid. Advantages is that it is easy and takes the imprint of the master well. Disadvantages is it is messy, hard to measure small amounts, requires building a dam around the master, and takes 24h (sometimes longer). Advantages are the final mould is very pliable compared to Siligum, larger moulds are a doddle and the detail is better. Also there is no trepidation when demoulding for the first time: you know the cast will be true to the master.

The example of the above points are the viaduct sides mould cast in CS25, and the triangular stones cast in Siligum.

I can’t comment on the resilience of the two methods as my cast runs are low. I know from more well used moulds that Siligum tends to tear with time (more pronounced with deeper moulding). I know that the standard wall-sheet mould has lasted well but that was an earlier version of the CS25 that was superseded.

Along the way I have tried a re-meltable rubber from Hobbies (messy, smelly and stiffer than CS25), and a seaweed based material which was also re-usable or would be if it was usable!

I stress that I did Iittle research and just launched in, other posters may have more informed experiences.

Andy
Andy, many thanks, must admit I missed the silicon in the OP, I have used the meltable rubber, but it need a robust pattern, and didn't hold up to my plastic pattern.

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Re: Ginnerbeck viaduct for Rylston Light

Post by ge_rik » Thu Jul 09, 2020 2:00 pm

RylstonLight wrote: Thu Jul 09, 2020 1:40 pm My technique in avoiding air bubbles is highly technical and laborious to describe so only read on if you are an expert modeller. . .
The simplest way to describe it is that I didn’t know it was a potential problem :lol: :lol: :lol:
Now I’m going back to the viaduct to look.
Everyone knows that Rylstondale stone is very friable and prone to pitting (new addition to background folklore).
Andy
Those bubble pockets are hardly noticeable, no wonder you didn't see it as a problem. I think they become more prevalent when there are overhangs and/or the parts are thicker.

Rik
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Re: Ginnerbeck viaduct for Rylston Light

Post by RylstonLight » Thu Jul 09, 2020 2:30 pm

Building Ginnerbeck viaduct for the Rylston Light Final Part.

The last instalment opened with the reveal of whether the newly assembled viaduct would fall apart on its first lift. Spoiler: It didn’t.

This instalment opens with whether I survived after the debacle of the expanding foam in the dining room. Spoiler: I did :shock:

At this stage the major part of the build was complete. The final result of the expanding foam was disappointing in terms noise abatement but there was a separate benefit of doing it. The overall rigidity of the piers was improved and I would do this again.

The joins between the arch-side panels were adequately hidden by the triangular block strips, but that portion of the wall above track level was still visible as a plain butt joint with non-continuous stone courses. These needed to be blended in with forming stone courses across the joints using U-pol filler. The following (poor) photo shows the effect achieved.
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I felt that the triangular strips were a little too visually prominent. I had an old Siligum mould for a tie-rod anchor-plate that I had made for the buttresses of Lygibeck viaduct some time ago. I cast 16 anchor plates figuring that they would shrink the impact of the triangular strips.
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These were fitted to each side panel with dollops of U-pol. I filled any remaining gaps with U-pol.
Side note: over half a 3L tin of U-pol was used just in assembling and filling the viaduct.

Still another hour before the local forecast predicted rain, so into the garden for some undercoat. I’m always amazed how a unifying coat of one colour dramatically pulls a project together on a new level. It took 3 large rattle cans of plastic primer, and then a light spritz with the very little flat khaki I had in stock before the final photos for this opus.
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Now if you have followed this somewhat detailed account to the end then I thank you. Obviously I need to paint the viaduct properly and weather it, then there is the no small matter of building the miniscape into which it sits. I will post a final picture when it is weathered but there will be some delay before I can finish the paint job . . .

I have to de-goop the dining room first.

Hope you all enjoyed the ride. Andy
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Re: Ginnerbeck viaduct for Rylston Light

Post by philipy » Thu Jul 09, 2020 3:34 pm

What a superb job!!

Can't wait to see it in the 'miniscape'... leave the de-gooping, she'll never notice (much!)
Philip

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Re: Ginnerbeck viaduct for Rylston Light

Post by Peter Butler » Thu Jul 09, 2020 4:18 pm

Just a stunning piece of craftsmanship, if all your structures are going to be of this standard we are in for a treat.
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Re: Ginnerbeck viaduct for Rylston Light

Post by ge_rik » Thu Jul 09, 2020 6:35 pm

Looks wonderful already. Can't wait to here it finished and installed in its final location.

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Re: Ginnerbeck viaduct for Rylston Light

Post by Lonsdaler » Thu Jul 09, 2020 9:40 pm

Well there you go, I leave the forum alone for a couple of days and a magnum opus appears! Absolutely tremendous work Andy. I was struck by how the relief on the stonework really stood out with the paint job you have done already, so any further paintwork will be interesting to see.
A wonderful project, that well deserves the photo opportunity with your masterpiece. :thumbup:

I tried that meltable mould material - absolutely vile stuff, and after a short period of time the mould started to ooze an oily residue. :dontknow: Now consigned to history.
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Re: Ginnerbeck viaduct for Rylston Light

Post by Jimmyb » Thu Jul 09, 2020 10:15 pm

Absolutely loved the “ride” a real skill and imagination.

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Re: Ginnerbeck viaduct for Rylston Light

Post by LNR » Fri Jul 10, 2020 2:20 am

Spectacular job Andy, and the scene it is to fit into I'm sure will be done with as much thought. Can't wait (impatient lot aren't we!)
Grant.
PS a little concerned as to how your crew are going to get off the structure, a case of "watch the first step, it's a doozy!!!"

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Re: Ginnerbeck viaduct for Rylston Light

Post by gregh » Fri Jul 10, 2020 6:24 am

ABSOLUTELY FANTASTIC. That must be the most detailed stonework I have seen.

Just a slight warning. When I finished my viaduct and before I laid track, I discovered I had built a perfect AQUAduct. I had to drill some 'weep' holes to let the water out.
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Re: Ginnerbeck viaduct for Rylston Light

Post by RylstonLight » Fri Jul 10, 2020 8:14 am

gregh wrote: Fri Jul 10, 2020 6:24 am
Just a slight warning. When I finished my viaduct and before I laid track, I discovered I had built a perfect AQUAduct. I had to drill some 'weep' holes to let the water out.
Mmmm . . .

I did consider that. I was going to run some styrene tubing through the structure as a drain (remember I was filling the voids with foam) but initial tests suggested that water adhesion required rather large tubes to work. I did even consider a wicking material. In the end I decided not to bother. I’m still not sure I was right. I was probably over-influenced By the fact I had none in stock.

Now I’m second guessing myself.

Andy
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Re: Ginnerbeck viaduct for Rylston Light

Post by RylstonLight » Fri Jul 10, 2020 8:29 am

LNR wrote: Fri Jul 10, 2020 2:20 am
PS a little concerned as to how your crew are going to get off the structure, a case of "watch the first step, it's a doozy!!!"
Rylstondale is a very isolated place even to this day. Lots of the inhabitants still use Yorkshire vernacular and the place names have hidden Norse meanings. They have many arcane traditions stretching back to pre-Christian times. One quaint tradition if one of the Dales folk really need anything they have to spin three times widdershins and fall to the floor whilst calling “I do believe in Odin’s hand, I do believe in Odin’s hand”. On this it is rumoured Odin’s hand has been known to descend through the clouds from Valhalla to correct all ills.

It is even murmured by older railway staff that the occasional derailment has, in distant times, been solved by this plea.

Of course this is just quaint tradition and is actively discouraged by the Rev Peabody.

Andy
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Re: Ginnerbeck viaduct for Rylston Light

Post by LNR » Fri Jul 10, 2020 8:40 am

Still laughing :lol: :lol: I'm wondering if Odin appeared over my railway recently, when I wrote "that a giant pair of hands came down from the sky, removed the mill and its subterranean foundations, levelled the ground and we will start again."
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Re: Ginnerbeck viaduct for Rylston Light

Post by FWLR » Fri Jul 10, 2020 9:01 am

This as been an absolutely brilliant read and build. I would love to have something like yours on our new line, but unfortunately my building skills come no where near to what is so expertly done. Don't think for one moment you are not by the way. :thumbright: :thumbright:

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Re: Ginnerbeck viaduct for Rylston Light

Post by RylstonLight » Fri Jul 10, 2020 9:25 am

Building Ginnerbeck viaduct: Appendix

Thanks for all the positive feedback. This includes praise for the quality of the stonework, and I really didn’t discuss this aspect at all just starting with “I used standard RLR building sheets”.

The basis of all the stonework is the JigStone system.
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My moulds are maybe 20years old and up to this project pristine. One mould had some rubber pulled off from a mortar line when demoulding last week. Although initially expensive they last and last. They are still available from https://modell-werkstatt.de/jigstones-2 which is a German site but has a Union Jack to click on to translate. He also has lots of other obscure things. This year I got a very nice cast brass weather vane for St Luke’s Church. Payment was easy, it arrived 1 day later.

I did get a set of brick moulds as well but I found the smaller distances between mortar lines made jointing the blocks much more time consuming. They have been used for chimney stacks.
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Fit a long time I used the blocks as intended, assembling individual blocks into quite large structures such as Rylston station. BTW the station is self-coloured U-pol not painted.
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However the blocks are quite thick and wasteful of resin. I noticed that pattern of the stone work in the building walls of one Major 16mm supplier was similar to the JigStone repeating pattern. I wanted to modify that building to suit the Rylston Light better so I made a sheet master from JigStones and made a mould. The resulting sheets match the thickness of the building supplier’s kit.
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So the viaduct is basically a JigStone project. As it is it required 245 separate cast pieces; I cannot calculate the number if I used the original block size. But the quality of the stone-work is definitely JigStones. I would encourage anyone to buy JigStones; they work well, thy last well. And they can be adapted to local need.

I have even adapted the stone-pattern to another use but that is part of the teaser of the cunning plan. After all these lead-in teasers it better bl@@dy work.

Andy
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Re: Ginnerbeck viaduct for Rylston Light

Post by Jimmyb » Sat Jul 11, 2020 9:54 am

Jig-stone, love it, when I did 00 a number of years ago there was a similar system, though designed for plaster, and you had a whole package of parts, and when moving up to G/16mm I looked for something similar but couldn't find anything, but this is it :D :D :D

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Re: Ginnerbeck viaduct for Rylston Light

Post by RylstonLight » Sat Jul 11, 2020 11:05 am

Jimmyb wrote: Sat Jul 11, 2020 9:54 am . . . a similar system, though designed for plaster, and . . .
My first build was a small PW hut, now designated for a quarry office, cast from resin plaster from Gedeo. The moulds work well in most casting materials. Cheapest is ordinary cement with fine aggregate and I have cast some dry stone walling in that. It doesn’t quite hold the detail as well as resin or resin plaster, and take a while to cure.

Andy
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