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The kit referenced here has now been released to Thingiverse and limited copies are available for sale on eBay.

This instructable describes the assembly of a 3D Printed kit for a 1:100 scale replica of the famous Bailey Bridge of World War 2.

From Wikipedia:

  • The Bailey bridge is a type of portable, pre-fabricated, truss bridge. It was developed by the British during World War II for military use and saw extensive use by British, Canadian and the American military engineering units.
  • A Bailey bridge had the advantages of requiring no special tools or heavy equipment to assemble. The wood and steel bridge elements were small and light enough to be carried in trucks and lifted into place by hand, without requiring the use of a crane. The bridges were strong enough to carry tanks.
  • Bailey bridges continue to be extensively used in civil engineering construction projects and to provide temporary crossings for foot and vehicle traffic.

The design for this kit was done in Sketchup from images of plans found on the Internet. The goal was to be as accurate as possible in terms of following the famous design, but obviously having to make allowances for the scale such that it be assemble-able, for the fact that the kit will be 3D Printed, and finally to minimize print time as much as possible.

There are currently four variants of the Bailey Bridge that can be built with this kit though only the Double-Single version is for sale on eBay. The bridge can also be printed with a road that is 55mm wide to support Flames of War game play. The kits for sale on eBay include this as an option.

Step 1: Inventory Your Parts

We are building a two section bridge of the Double-Single variety (Double Panels, Single Level). The parts for this model are:

  1. One Road Bed with built-in Transoms
  2. Four Panels
  3. Eight Rakers (vertical bracing)
  4. Six Bracing Frames (horizontal bracing)
  5. Two Foot Walks
  6. Four Double Base Plates
  7. Two Ramps (Optional)
  8. Two Ramp Supports (Optional)
  9. Two Walk Way Ramps (Optional)
  10. One Section Joiner (Optional)

Note that part #6 has been altered as you can see in the second image above. This Instructable will be updated prior to release of the model files to reflect any build testing changes.

Beautiful model! I would love to print and build one. Have you put the files up on thingverse as of yet?
Shooting for this coming weekend. What kind of printer do you have, and more importantly, what size nozzle? This model can be printed with a more standard size nozzle but you may not be pleased with some of the fine details (http://raspberrypirobot.blogspot.co.uk/2015/11/more-on-topic-of-interchangeable-nozzles.html).<br>I will post another comment here when I send the files up to the Thingiverse!
I have a Lulzbot mini at this time I have a 0.5 mm nozzle installed and a 0.35mm nozzle is on order.
<p>I am pretty sure the .5mm nozzle will not handle a forced extrusion width of .3mm and deliver decent results but it will be interesting to see how the .35 nozzle does. By the time you get it and have it dialed in I should have uploaded the models (and posted something here to that effect). If you get it in sooner shout out again.</p>
Question...what color(s) are Bailey Bridges?
<p>Amazingly detailed model. Well done.</p><p>The Bailey was one of the first bridges I tested in my first professional job. The Bailey, the AVLB (armored Vehicle Launched Bridge) and the FFB (Folding Floatable Bridge) were the first three I did stress/strain testing upon. Wonderful engineering design that found a great compromise between strength, portability, ease of assembly and durability. </p>
<p>Glad to have it be liked! That portability requirement posed the biggest modeling challenge at a scale of 1:100. Those parts are tiny and some, obviously, disappeared in favor of super glue! Of the parts that I did keep the Raker turned into a rectangle with a brace as opposed to a simple strut and the base plate turned into something that I rationalize as a base plate on top of a foundation! I was going to print the road in it's components, building on top of transoms, but it added nothing to the look and a lot to the print time. </p>
<p>Great looking model bridge.</p>
<p>Thanks...may have gotten a little OCD over it.</p>
<p>Brings back memories of building them! Good work!</p>
<p>Thanks. They were, and still are, an amazing piece of engineering. The files will be available in the public domain after some user testing if you want to get one printed and build another one!</p>

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Bio: I design, and occaisionally even implement, solutions that exploit single board micro-processors crossing the physical interface between the computer and the real world. Chosen platforms ... More »
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