EASY-BUILD DERBY LIGHTWEIGHT CLASS 108 DMU Assembly Instructions Manual Download Page 11

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angled downwards. However, it’s getting a bit crowded in there and they can also
foul the bogie on tighter radius curves. We suggest fitting the horn to the bogie
front against the guard iron. If you opt to do this, reduce the length of the mounting
bar to just above the first horn and butt it up to the bottom of the front channel.

ADDING THE REMAINING BODY DETAILS

45)

Now would be a good time to assemble the control desk details as per the diagram and check

for fit inside the cab. Solder a 14BA cheesehead bolt (or a short pin) into the central hole of the brake
wheel E18 to mount it onto the desk and a short length of thin wire (about 2.5mm long) through the
hole in the wheel spoke to form a turning handle.

46)

On the driver’s side of the cab you will need to drill three 0.7mm dia. holes through the seam

between the cab end and the body side moulding. These should be positioned to align with the other
door hinges (approx. 4mm, 20mm and 28.5mm as measured from the bottom of the body). Also, open
drill the holes for the long handrails E22 (approx. 4mm 21mm and 38mm as measured from the
bottom of the body and 1.5mm from the right hand edge of the door). Check these measurements
against the pilot holes provided in other locations to ensure accurate alignment on your particular
model. These long cab handrails were painted body colour, so fitting now is appropriate. 

**Note - Door hinges are always on the left of the door.

47)

Prepare the exhaust stacks C21 and mount on the rear of each unit.

Position each stack to clear the rear windows (DMBS) and to clear the corridor
connection, the final position being approximately as shown right. The bottom mounting bracket should
be 17mm from the bottom of the end.

48)

Decide whether to fit the small destination box (C6), or the larger headcode box (E15 & E16).

Casting C6 (destination box) simply sits directly onto the cab roof gutter. Some trimming will be
required to achieve a good fit of the boxes around the complex curves of the cab roof.

49.1)

LARGE HEADCODE ONLY: Fold E15 to form the box ensuring the corners are square and

solder the joints. Offer the unit to the cab so that the bottom of the front is about 2mm above the
gutter. Some filing and filling will be required to achieve a fit that makes the box appear to be an
integral part of the cab roofline. Patience is the key here.

49.2)

The front of the large headcode (E16) has not come

out right on the design - sorry about that. What should have
been produced is a front cover with a raised beading around
the opening. However in the process of adding the guard’s
door handles inside the opening we inadvertantly messed up
the main article! Having removed it from the main fret and
removed the handles you will find a half etched line (broken in places) on the rear. This etched line
represents the finished size of the appeture, carefully remove the material to the outer edges of the
half-etched line. On the front you will see an unbroken half-etched line - solder a beading of soft wire
(0.4mm) into this to produce a raised beading. Clean up as necessary. Once painted the cover can
be glued to a piece of clear styrene with headcode behind and attached to the front of (the now also
painted) headcode box.
49.3)  If the large headcode is used a destination display made from E27 & E28 is supplied for fitting

Back

Front

Before

After

Half etch

Raised bead

Summary of Contents for DERBY LIGHTWEIGHT CLASS 108 DMU

Page 1: ...will also find numerous additional prototype and model images to assist you create an outstanding model GETTING STARTED The basic steps are the same for both car types so unless there is an operation...

Page 2: ...ype without the butterfly mounting part E11 It is probably unusual for this arrangement to have survived throughout the unit s working life so if possible check photographs of your chosen unit before...

Page 3: ...es not need marking because the motor cut out in the floor makes orientation obvious 13 Check the floor molding for flatness if it appears too distorted some curvature is quite normal gently bend it i...

Page 4: ...should now be drilled out as required No provision is made for this in the kit and so it is up to the builder to determine how best to achieve the installation NON CAB ENDS PREP These are our standard...

Page 5: ...it but not sloppy if necessary clean hole with a 2 5mm drill Do not fix in position as adjustments will be made later 28 3 Using a pin add a tiny drop of oil NOT WD 40 into the bearing surface 28 4 Pl...

Page 6: ...ogie stretcher While the basic bogie assembly sets identify and remove the bogie front channel guard irons speedo drive mount and bogie steps from the etched sheet 28 14 Fold up the bogie channels E3...

Page 7: ...is might need further adjustment later on 29 5 Bolt one sideframe assembly to the bogie stretcher plate with 2x 2mm nuts and bolts provided 29 6 Insert the wheelsets into the assembly ensuring the set...

Page 8: ...mm x 0 7mm 30 thou step treads and fix to the step supports as required BODY ASSEMBLY CONTINUED NOTE BEFORE PROCEEDING MAKE SURE YOU HAVE GOT THE CORRECT ROOF AND BODY PAIRED TOGETHER DMBS WITHOUT WAT...

Page 9: ...loor molding 37 Check the floors will fit within the sides and end molding It is likely that you will have to adjust the floor width to gain the best fit Do this carefully removing the minimum amount...

Page 10: ...U cables some method of attaching cables is necessary if not the castings can simply be fitted as is with the exception of C1d which should always be prepared as described 43 1 After cleaning up the c...

Page 11: ...connection the final position being approximately as shown right The bottom mounting bracket should be 17mm from the bottom of the end 48 Decide whether to fit the small destination box C6 or the larg...

Page 12: ...90o and fix solder glue into the half etch pads in the rear cab walls so that the folded projection forms a slot with the fold at the bottom of the cab partition See photo Partition with floor support...

Page 13: ...See photo mid body strengthener and cab walls Cl 129 model for this additional much wider support as used on the Cravens Class 129 54 Cut a piece of 1mm 40 thou styrene 15mm wide to fit between the mo...

Page 14: ...le assemblies have been mounted the exhaust stub on the diesel engines can be soldered or glued to the rear of the exhaust flexible canister the round cylindrical bit to give extra support to the exha...

Page 15: ...e installing the etched window frames check the fit of the window glazing within the openings Carefully file the edges of the glazing panels until they fit snuggly but not sloppy nor tight Using a slo...

Page 16: ...floor to be fitted Paint and fit toilet cubicle as appropriate FINAL ASSEMBLY 69 Find the windscreens you put in a safe place some time ago and fit using small amounts of adhesive If you have some RC...

Page 17: ...and secure as before 79 Assemble the underframes onto the appropriate bodies and secure in place 80 Mount the bogies and ensure they are free to rotate The speedo drives can be connected to the soleba...

Page 18: ...mm taken from rear of roof 99 8 8 237 21 Water filler DMCL only 46 5 DMBS BAGGAGE AREA ABS DIVIDER PARTITION WITH DOOR SEATING ARRANGEMENTS SHOWING FACING DIRECTION HALF PARTITIONS DMCL DTCL PARTITIO...

Page 19: ...4 C15 C32 C13 C26 C30 C27 225mm 235mm 242mm 249mm C30 C31 C26 C13 C23 C19 C14 C11 C24 C15 C32 C13 C29 E8 C22 C25 C10 C17 C13 C18 C26 C31 100mm 104mm 132mm 146mm 156mm 181mm 203mm 220mm 230mm 242mm 245...

Page 20: ...20 DMBS DMCL CASTINGS CONTROL DESK DETAILS...

Page 21: ...EIVER BACKING for small casting C6 E14 SPEEDO SENDER BACKING for large casting C6 E15 LARGE HEADCODE BOX E16 LARGE HEADCODE BOX FRONT E17 LAMP IRONS E18 BRAKE WHEELS E19 2 DIGIT HEADCODE FRAME E20 HEA...

Page 22: ...o with the round aluminium mounting is securely in place as described in the main text file or cut off the edge of the floor motor opening and mounting sufficiently to allow the motor to move through...

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