Heljan Class 52: Brake Detail

Full Brake Gear

Centre Brake Components

Start with the brake rigging for the centre axle.

Check that the holes in the components are clear to pass the 0.6mm wire, and make the folds in the components.

You can use the brake gear templates, included in the kit packaging, as a guide to assembly. Stick the templates to a flat base of wood or tufnol, for example, and drill in to the base to take the 0.6mm wires. Cut the wires overlength and insert them into the holes in the base. Assemble the components on to the wires, and trim the wires back to length when all is soldered up.

Centre Brake Hangers/Shoes Fit the assembled components into their slots in the outriggers. Support and/or heat-sink them well to prevent them coming apart while making the joints.

Centre Brake Hangers/Shoes

Fold the adjuster etches (D1) back on to themselves and thread them on to the 0.45mm wire at the base of each hanger. Note that the half etch housing in the side of the adjuster takes the outward facing extension of the inside lower pull rod. Secure them with a small amount of solder.

Centre Lower Pull Rod Fit the lower pull rod, noting that it fits into the half-etched housings in the sides of the adjusters.

Centre Upper Pull Rod Fit the upper pull rod, noting that the kit designer hasn't given you much help to position it - it's just soldered on to the face of the hanger, D3, and to the top face of the fold over tag at the top of the rear centre lever, D2r, lined up with the outside edge of the tag.

Now move on to the gear for the front and rear axles.

Front Levers Exploded

Again you can use the pivot wires as armatures, in conjuction with the printed templates on a wood or tufnol base, on which to build up the laminations. Note that the nut detail tagged to the top of part D6 folds over on to the outside of part D9. The thinner hanger (D4) is suggested on the outside as you might need every fraction of clearance here to get enough turn on the bogie.

Fitting front levers

Clear the holes in the subframe with a drill to take the 0.6mm wires. Suggest you use full cross wires of about 23-25mm length and cut/trim them when assembly is finished. Fit the boss details D7 and D5. Then slide on the hanger/shoe assemblies; if you have some 0.6mm bore micro-tubing, you can make up some spacers to aid alignment (about 0.85mm for the front, 0.95 for the rear), to slide on to the cross rods inside the hangers.

Fitting front adjuster Fold and fix the adjuster D1.

Fitting front pull rod Fit the pull rod over the 0.31mm wire and fix its other end into the half-etched housing in the adjuster. Trim back the 0.31mm wire to represent the pin.

Inner Pull Rods Trim and/or bend the inner pull rod stubs to clear the wheelsets. It might be as well just to shorten them, especially in cases where a touch on a wheel rim would cause a short-circuit.

Use the wheelsets to check the alignment and clearances of the brake components, and make adjustments as necessary. Sideplay of the central wheelset is particularly relevant here.

All you have to do now is repeat the above for the remaining sets of brake details. Please take heart from the photo which shows that reality is not as clean, crisp and perfect as the line drawings might have you believe!