Scratchbuilding a car in styrene

Fred Jansz

Hi all,
Since there's no model or kit commercially available of WP's first (1916) Pullman-built box car -and there won't be in the near future I understand- I chose to try to build one myself.
Since I'm not afraid to rebuild, refine, DCC & paint brass engines or kitbash existing plastic or styrene models and kits, I thought; well let's give it a go.

First problem I encountered was scribing the styrene horizontally, to resemble the 5 1/4" T&G sheating.
For this I used various tools, obviously all not suited for making a clean gap: knife, sharpened dentist pick, 'scriber'.
So the question is; how do you make a clean cut in styrene without damaging the edges?

Second problem I encounterd was the Z-bracing.
The 3" bracing is not available in HO-scale, 5" is, but widht is too large.
So I decided to make my own from strip sryrene.
At least I thought I could, since gluing these tiny pieces together to form a Z-shape is only possible when you're a robot.
However, I succeeded to produce exactly one 3" Z-bar in half an hour.

But now the third issue came along: how to resemble the hundreds of 1/2" SQUARE thin head bolts that were used to slap this car together?
I'm aware Archer makes more or less the correct size, but these are dots, not squares.

If the above problems could be solved, I could try -again- to build this WP car.
For the moment I called it quits.

The 15001-series car ran (renumbered) untill the end of WP and is a 'landmark' WP car that's dearly missed in my WP collection.
I even have drawings of the unique run board saddles that could be replicated as brass etchings.
Hope the pros in this group can give me some how to advise, so I can build this car following the Pullman drawings.
Thank you for your assistance.

best regards
Fred Jansz

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