Railcar Project Techshop

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Introduction: Railcar Project Techshop

Our idea was to build a motorized rail cart to explore the many abandoned rail lines across the country.  We built the structure at Tech Shop (http://www.techshop.com) from the ground up, starting with the hull.  The concept was a truss fame with eight tubes and transverse stiffeners.  The chassis would split apart so a single person could carry each half as they would a rickshaw.

Step 1: Frame Prefab

After going through some initial concepts, it was decided to build a truss frame.

The tube strength was tested by placing tubing sections in a bender and measuring the deflection with a dial indicator.  The test is representative of the point load case.  Based on this test, we were able to select an appropriate tube size.  We then cut out the transverse channels from a solid piece of sheet metal which was to be bent into a C-channel shape.  The 2D template was created using Solidworks and then exporting to a dxf format where it was imported and used in the CNC plasma cutter.  Features were placed in the part to mark bend center-line.

The 2D shapes were then placed in a punch press.  The punch press has a set of dies that can be used depending on the length of bend, bend radius, and material thickness in use.  The vertical range of travel must be adjusted so that there is something somewhat greater than the material thickness clearance between the dies at maximum travel in the cycle.  After bending the channels, they were welded to make a seamless channel.

Step 2: Welding the Frame

The frame was setup on saw horses and welded together starting with the bottom part, then the sides.  The side channels were welded onto the bottom channels in order to transmit bending moment, but primarily compression from the seats, which are supported by the top tubes.  The height of the top tubes is at a comfortable sitting height.  After the frame was welded together, it was painted to keep the bare metal from rusting.

Step 3: Brakes and Drivetrain

In this step, we recycled wheel bearings from a Honda Civic to make something strong enough to support at least five full sized people.  The caliper bolts were identified as a strong point to tie into with a truss.   The steering knuckle joint was used as a third support point and way to adjust wheel toe. The wheel toe is important to tinker with because it adjusts how the train rides on the track.  The spline the half shaft normally goes into was adapted to a pulley and driven from the "pumpkin" which houses the final drive reduction to the gearbox.

The brake housing was welded together out of aluminum using a fixture to align everything.  The driveshaft is keyed and supported at 3 points using flanged ball bearings.  The Tees here were the original way we planned to tension both the chain and pulleys.  The outer tees are still in use for pulley tension, and the all-thread rod below tensions the chain now, with ball end joints on each end to make alignment easy.

Step 4: Finalizing

As with any project, considerable time was involved in testing and improving things.  We went through sets of seats, fabricating a driver console consisting of a gas tank, control switches and a throttle/brake actuator.  The friction throttle is modeled after a boat and holds the cable at a specific setting.  This has been tested and preformed well on the track.

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    37 Comments

    Hey d_c I have been wanting to make something like this for a while now but I have been having a hard time finding train wheels... Did you make yours and how did you?

    I think it's awesome, I would put a top on it and hit the abandoned mountain railroads, but take a chainsaw and sledge hammer

    pl;us only some who's cuasing mishaps an wild fires would put the gas tank above the switches. if i was doing it, i would gove with a seperate fuel tank with a low pressure fuel pump set - up.

    Beside pulling up the rail you have to remove the ties and the ballest and the sub roadbed and the right of way has to be returned to its natural state. Besides that, if the right of way is left intact, it makes it easier (though still very costly) to put the line back in to service should the need arise.

    All that aside - nice looking project.

    The railroads have a real incentive to remove the rails as soon as they are legally declared abandoned or surplus. Not only is there a real scrap value for the rail and other metal along the right of way there is also the tax incentives of not requiring the same amount of taxes to be paid. And they significantly decrease legal risks of being sued. And when the rails are removed there is a very real lower probability of having to reactivate them for a client.

    When a railroad abandons a line it is because it is too costly to maintain service along it and they have proven that there is not enough traffic to justify continuing servicing it, and there is not a realistic hope of an increase in traffic to make the line financially viable. There is a long legal process to abandoning a line and as soon as it is declared surplus the rails are removed. There is not the requirement to remove all of the ballast and sub roadbed nor to return it to its natural state. Many rail line are converted into trails. And it is still easy to see where many rail lines used to go because the roadbed is still somewhat intact and visible.

    When you see a rail line that you assume is abandoned it is not. The railroad may be in the process of abandoning it but that does not mean that there is not the occasional train using it. There may not be many trains using it but do you really want to be stuck on the rail line when a train, however infrequent, does come along? Encouraging people to put things on the tracks is not a wise thing to do and creates undue risk to those doing so. The train may not be going very quickly but it also cannot stop immediately.

    Also when you are going on a rail line when you cross road ways the drivers are not going to be expecting you. The railroads have a procedure for when light vehicles come to a roadway and that is to stop and ensure that all traffic on the roadway has either stopped or the way is clear before crossing the roadway. The Employee rule books warn that the rules for operating a railroad have been paid for in blood and unless you are going to follow the same sets of rules you are taking inordinate risks that you should not be considering.

    Please do not assume that any rail lines are abandoned and will not have a train running on it nor encourage others to take those risks as well. If there are tracks present then there can also be a train that runs on them and that train is going to have a lot more weight and impact than you ever will on it.

    "Many rail line are converted into trails." True: we have one on New Zealand that follows the old rail line from Middlemarch to Clyde (site of one of our hydroelectric dams). At risk of sounding like an advert, the Otago Central Rail Trail is 150km of beautiful South Island highcountry. There is a lot of accommodation along the way, so the Trail can be done in very easy stages. Pinegrove is one of my favourite places.

    user

    I'm not encouraging anyone to do this nor am I liable for anyone's lack of common sense.

    True; you are not advocating that others do this and you are also not responsible for the lack of common sense in anyone but when I see things like this I really get a bad feeling that someone is going to do something that will get them into trouble. Getting a ticket and being charged for trespassing is the least of anyone's problems that this, and other things like it, can lead to.

    There's a bunch of lines around here (Midwest USA) where they've just pulled the rails...all the rest was left as-is. Been that way for years.