This is a NSWGR 27 foot high Distant signal that shows fine detail such as bolt heads, various components, etc. A set of detail parts containing a 'fish tailed' Distant signal arm and other details such as finial (Finial - officially known by NSWGR as a Pinnacle), lamp top, lamp 'backlight blind', cast ladder base and counterweight lever is included with this signal.
This signal is cast in brass using the lost wax process from a 3D printed wax model.
Being brass the signal is very strong and has the detail that is expected from this quality model.
The tallest signals (27 foot posts) have a separate finial (pinnacle is the correct term) cast on the signal base with the other detail parts. This will need to be soldered or glued into the hole in the top of the post. Shorter posts have the finial cast in place on the post.
A jig has been designed onto the WSF signal base to bend up the critical operating rod from the counterweight lever to the signal arm.
The detail parts on the bass can be removed using a pair of transistor nippers but a cutting disc in a hobby tool could be used with care.
There are a number of holes to be drilled with a 0.4mm drill bit for handrails and operating wires. The positions are marked by small starter holes, some of which may have cast as holes although as this is on the limits of the process. If there are cast holes then these will still need to be drilled with the correct size drill bit.
The pivot hole for the signal arm is undersize because of the wall thickness design minimum for printing and needs to be reamed out with progressively larger drill bits starting with 0.7mm and then 0.8mm, 0.9mm and 1.0mm. The pivot shaft on the signal arm will need to be very lightly filed to clean it up as it may be slightly out of round. The pivot hole and shaft need to be carefully fitted for a smooth rotating fit. It might be necessary to use a 1.1mm drill bit but don't make it a sloppy fit. Being a brass on brass bearing, once the signal is painted a small drop of light oil is a good idea.
To complete this signal a White Strong and Flexible mechanism needs to be ordered and glued underneath the signal.
A ladder for the signal is also needed and a sprue of two 21 foot ladders printed in Frosted Ultra Detail acrylic material can be ordered from this Signals Branch Shapeways Shop. A sprue of 10 ladders with cast iron bases are also available. These ladders are relatively flexible.
If you wish you could instead purchase an HO etched brass ladder.
A suitable etched brass ladder kit and a ladder forming jig are available from Keiran Ryan Models: http://www.krmodels.com.au/
Or a ladder kit from Peter Boormans Workshop: http://peterboormansworkshop.com.au/
And a ladder kit from Mechanical Branch Models: http://www.mechanicalbranchmodels.com.au/
Also required are:
0.015" phosphor bronze wire for operating rods, handrails, etc. (Tichy Train Group have the wire - #1102 0.015" 12 straight 200mm lengths).
1 x #4 6mm screw
1 x 3mm I.D. washer
2 x 2-56 12mm screws (either Kadee #1709 1/2" stainless screws- preferred or #256 1/2" nylon plastic screws - come in KD5 coupler packets)