DK Pilot 01: Introduction to the pilot model

Introduction to the pilot model:
The Dick Kerr "pilot model" is a kit of parts that build a Dick Kerr petrol locomotive.  Two versions of the pilot model have been designed, an as delivered version and a contemporary version.  The pilot model is largely a body kit, with brake details and other accessories.  Other versions may be produced.  These instructions are being provided as an aid to those building the pilot model. Subsequent versions (if produced) will incorporate enhancements and attachments for a mechanism based on the experience of the pilot builders.  Brake shoes for the pilot model have been designed to fit a Hollywood Foundry drive, details of which will be provided after testing.  Final installation of the provided brake details will be left to the model builder in this pilot phase, as the nature of the installation depends on the chosen mechanism.

Selecting glue:
The kit consists of 3d printed acrylic parts, many with very fine sections.  The best glue to use for these parts is a 2 part epoxy.  Thin cyanoacrylate glue (CA), a.k.a. super glue, is also useful for mating brass parts to 3d printed parts.  Although CA will bond the acrylic pieces to each other, the bonds are easily broken: epoxy should be used for best result.  Solvent glues will not work with the type of acrylic used to produce the model.

Tools required:
The kit can be assembled with a minimum of tools, including:

• A selection of fine files, preferably dedicated to working with resin to avoid contaminating material with brass or other metals.  These should include rounds and flats in a few sizes;
• Flat and round files for brass.  The flat file will be used to shape the horizontal cross pieces that hang just above the rail.  The pointed round file will be used to open the 1/16" tube used for the exhaust pipe;
• A razor file for cutting the flat rafts off the sprues;
• Sprue cutters;
• A #17 X-acto blade for cutting sprue nibs from flat surfaces;
• A fine philips screw driver for the coupler screws;
• Wire cutters;
• A pair of chain nose pliers to form the lift rings;
• A pair of flat pliers to form the hand grabs;
• Steel blocks and angles to brace and align assemblies for gluing;
• A piece of glass or flat work surface for assembly;
• Tooth picks to aid with glue application;
• A pin vise and a set of miniature twist drills to open or enlarge holes if needed;
• A small piece of 400 grit sandpaper for smoothing some surfaces and rounding rivets.

In the box:
The pilot model is hand packed, and includes all of the necessary acrylic parts.  Also included are springs to be used for the journal boxes, and brass pieces that interface with 3d printed parts, such as the cross pieces and the exhaust pipe.  You will need to provide fine wire for the lift rings, and music wire for the hand grabs unless otherwise noted.  Holes are provided for these.

Removing the parts from the carrier:
Parts are hot glued to cardboard carriers on their sprues so that all of the parts can be removed from the box in an organized fashion.  As these are very much one of a kind kits, the exact arrangement may vary.  Be careful removing parts from the cardboard.  The support rafts are stronger than the parts they support.  When prying parts from the cardboard, handle the rafts.