Questions and Comments.

INDEX


New Questions. 

......”I also have a couple of questions about the Bentley wheels:
   1. After threading the stainless steel wire through the wheel components utilising the jig; how is the wire secured or tied off to maintain the tension of the spoke wire when the lacing is complete.
   2. When painting the Bentley wheels, is the stainless steel spoke wire impervious to the self etch primer and does this cause adhesion problems with the paint?  I should imagine painting a wire wheel is a bit of a nightmare because of the shadowing effects of adjacent spokes and the importance of not over painting
the spokes to give an over scale thickness. Can you ‘off the record’ and with the usual disclaimers give me a brand name of a self etch primer with a performance you were happy with?”
-Trevor-

1.  Each spoke is pulled tight as it is formed (as tight as possible) then when you have a fully spoked wheel removed from the jig, you will probably have several pairs of odd ends, as I have not found it possible to completely spoke a wheel with a single length of wire.  The pairs of odd ends of the wire are twisted together, then snipped off a couple of twists from the rim, and laid flat in the rim under the tyre.
2.  The paint that I use is SELF ETCH PRIMER from ‘H.Marcel Guest, <http://www.hmgpaint.com/>, then a grey primer followed by several colour coats.  These are cellulose paints as used on the cars originally and they give me no problems.
I use an airbrush for all painting (check photos 274 to 279 Gallery-19 of Bentley Build) In photo 274 you can see a couple of wire wheels, one on each end of a length of dowel ready for spray painting.  Slowly turn the wheel and spray in short bursts from different angles and you should have no problem with shadows or paint build up.
GAW
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Workshop.
"...Received CCM 1& 2 books Saturday. They will be very helpful in the planning and organization of my shop and. the scratch building of model cars. I'm looking for a lathe and milling machine for my shop. Do you have any suggestions?" 
- William - 
Regarding my recommending a lathe and milling machine for making parts for model cars;  The size of a lathe is usually stated as the distance from the top of the lathe bed to the centre of the lathe spindle or chuck.  In my case I am using a 4 inch (height of spindle) lathe which is ideal. but anything from one and a half inch up will also produce all the necessary parts. You can turn very small parts on a large lathe but machining large parts on a small lathe can be very time consuming.  If you have the room, go for a 4 inch lathe if you can. 
There are a number of lathes on the market now with vertical milling columns attached, these are quite adequate for producing the model car parts at 1/15th scale. 
- GAW - 
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Wheels
"...The Weinberger Royale plans are great. I am ready to cast my first RTV tire and need a little help. What Dow Corning product do you use? Also I noticed from your build photo of the Bentley you use a mix of black and blue colorant (tint). What is it? What proportion to each other and then to the RTV?" 
- Kent- 
Firstly, I have been given to understand that in the USA there are a number of Silicone rubbers available, that were not available thirty years ago in the UK, when I made my first ones, some of which are black from which you can produce black rubber tyres, However, to keep my work consistent, I have stayed with my original material and methods as follows; 
the rubber I use is Dow Corning Silastic 9161 (which is white) with catalyst 9162 which can be obtained as a  0.5 Kg pack complete with a small bottle of Catalyst. 
The pigments are black iron oxide 5.5oz and ultra blue .5oz per 0.5Kg of rubber, Sorry about the mixed measurements, it just happens that is how I work. 
The pigments should be added a little at a time and well mixed in with a power mixer, then left to stand for a day or two and again mixed with a power mixer until there are no lumps at all. 
The advantage of using 9161 is that it can be made to harden very quickly, so preventing air bubbles moving to the surface of the mould.  I use an old fashioned glass and rubber eye dropper to add the catalyst to a measured portion of rubber as follows; 
20 drops (from the eye dropper) = 1%. 
3% of catalyst to rubber will set in 7 minutes. 
4% of catalyst to rubber will set in 3 minutes. 
You will need to check this out in trial and error for yourself as the room temperature can affect the times as can the size of the drop from your particular dropper. 
For further details check out Complete Car Modeller One. 
- GAW - 
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"...I have read and re-read the section in Vol 1 on the subject of wire wheels and remain confused.  Here is the issue: 
Looking at Plates 31 and 32 on p.35 and concentrating on the front spokes, it appears to me that each spoke crosses 2 of the spokes laced in the opposite sense, one near the hub and one about mid-point between the hub and the rim. When I  examine Figure 15, it appears that each spoke will cross three of the opposite sense spokes, near the hub, at mid-point and again near the rim." 
-Alan- 
You will go cross eyed if you try to gather an impression of a wire wheel by looking at it as a whole, as what you see will depend on the angle that you view it from. It is best explained if you go the the diagram at the bottom of page 36 (CCM-1) Note that there are 28 spokes in the front and 42 spokes at the rear. Each spoke crosses two others in its row. I would not attempt to count how many front and rear spokes a single front spoke crosses. 
Take two pieces of tracing paper and scribe two circles on them for the rim and hub. On one sheet divide both circles by 28 and lace them as shown. On the other divide by 42 and lace as shown. Put a datum line on each as shown and place one sheet on top of the other with the datum lines matched. You now have an true impression of a Bentley wire wheel. 
-GAW- 
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"...On the cover of CCM 1 the tire tread is great! how is that done?" 
-Ken- 
To make a tread pattern such as on the Duesenberg tyres, you first need to make a simple tool. This consists of a wheel with the pattern machined or hand filed around the edge. 
The wheel is best turned from steel of about half an inch in diameter by about a quarter inch in width. Depending on the size of the pattern required the out side edge should be reduced to a width of one sixteenth of an inch and kept in the centre of the circumference of the wheel. A hole should be drilled in the centre to take a small spindle on which it will turn. 
The 1/16” flat around the circumference is now either milled or filed with the pattern to match that on the tyre. In the case of the Duesey tyre this was a small zig-zag groove. To make this, small ‘V’s are cut on alternate sides of the steel pattern wheel to form the zig-zag pattern.  The pattern wheel is then fitted in a holder so that it will spin. With small grooves already formed in the tyre pattern where required, the pattern wheel is now pressed into each of these to open them out to form the zig-zag tyre tread pattern. 
GAW 
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"...I do have a question concerning your wire wheels. Is the wire used strong  enough to keep the offset if slightly mishandled once it (the wheel) is removed from the jig? I use individual spokes which are very strong and do not allow any flexing once the entire wheel is laced. Did you try using individual spokes at any time in the past? I am in awe of your site and your skills. The machining I can learn but the body building is something that I (hate to say it) looks extremely 
complicated and tricky!" 
-John- 
Wire wheels, check out Bentley Build-photo-18 and you will see that we stitch our wire wheels with stainless steel wire (012” diameter). As such they are as solid as a rock.  I have seen a 1/15th scale 14” (full size) Duesenberg wheel and a similar (thick spoked) Packard wheel spoked by your method and they looked fine.  However I would have my doubts that it would work with the Alfa, Bugatti and Bentley wheels, all of which have a lot of very thin spokes. 
Body building (car models) is no where near as complicated as it looks.  If you can hit a piece of copper sheet with a hammer, you are half way there, 
The hardest thing to grasp is that you can hit a piece of metal and actually make it thicker. Normally you would expect it to get thinner. Having accepted that phenomenon all else is just time. 
The basic principle in achieving the above, is to crimp (make several humps) at the edge of the sheet copper (or brass), then flatten the out side edge leaving a bump where the hump was. (Hope that makes sense) In flattening the edge of the copper you have work hardened it, so that when you now hammer the bump, the edge can no longer stretch so the metal is forced into its self so making it thicker. Repeating this will cause the sheet to dish, if you now hammer into the centre of the dish you can extend it even further by thinning (stretching) the sheet. 
Use these principals on and around hard wood blocks as you can see being undertaken in the ‘Bentley Build’ photo collection, and you have all the parts for a car body in no time at all. 
-GAW- 
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Patterns

"...I am going to try to make something out of copper this winter and will follow your advice. Now I'm worried about forming the bucks...any tips?" 
-John- 
Take a block of fine grained  hard wood (any fruit wood such as pear, apple cherry) and draw on one side (from your plans) the side view of the car body. Then with milling machine, or mallet and chisel remove the waste wood straight across the block, back to the line.Do the same for the top view and the front or back. Your should now have a squared body block. Round the corners on one side to your satisfaction and provide the block with a centre line all round. Cut a card template, from bottom up and around to the centre line for several sections along the body block and use these to round the other side to match the first. You now have a ‘Buck’ to form your sheet copper over and around. 
-GAW- 
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Bodywork.

"...Referring to your book, the pictures seem to indicate that you 'hammer' in the fender bead and beltline details. 
Without being presumptuous, may I ask how you accomplish this feat on models much smaller than the scale I work in?  May I inquire as to your technique?" 
-Pete- 
Mouldings are formed in brass or copper and soft soldered in place on the bodywork, as is the beading on the inside edge of fenders. 
-GAW- 
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"...When you fix the Bentley fenders and side pieces to the chassis are they held in place with screws, if so how many?" 
-Jimmy- 
The louvred side aprons are first bolted to the top of the frame in positions that can later be used to bolt the body in place. The fenders front and rear are then soft soldered to these and bolted to the side of the chassis frame at the point of the fender stays. When the body frame is fitted to the frame it is drilled with clearance holes at the positions of the first set of bolts so that these can then be used to hold the body in place. 
-GAW- 
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"...How often did you need to heat the body metal (current project photo 189) to anneal it for making the shape?" 
-Sandy- 
It was probably reheated about a dozen times before I had the finished shape and the silver soldering at each end.  Annealed copper will take quite a lot of bashing, however as soon as it shows signs of wanting to spring back and will not compress further, it should be reheated to a cherry red and quenched to make it workable again. 
-GAW-
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"...Why is it that when I anneal copper sheet and quench it in water, it always comes out black - yet when you show it with the Bentley model it is always bright copper? " 
-Stephen- 
Before reworking the copper I put it into a pickle bath of a weak solution of sulphuric acid (car battery acid) that removes the black oxide caused by heating. There are many safety issues involved with the use of acid in the home and workshop that you will need to consult before attempting this, so I cannot recommend its use. Abrasive paper will remove the oxide in the final stage. 
-GAW- 
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Louvres

"...I am sure you have recieved many requests for your method of making louvers with the only tool being a pencil. So here is mine to add to the list." 
-Bob- 
In this method of making louvres, I use the etching process to do the cutting, so all that is needed is the art work for the etcher. 
To draw a simple louvre we need four lines. The first ‘A’ is the cut line, parallel to this and slightly shorter is a second line, with lines three and four at the top and bottom as quarter radius joining the second line to the first. These last three lines together are crease lines ‘B’. 
The practice in the UK when producing the art work for etching is to draw the lines that are to be cut through the metal (etched from both sides) in black, and those for etching on one side only, ie. detail, or in this case for creasing, in red. It is also the practice to produce the art work four times larger than the finished size. The etcher, when he makes his films, will, in the process, reduce this to the finished size. 
I now draw the complete set of louvres four times size, cut lines ‘A’ in black and crease  lines ‘B’ in red, this is the art work from which the louvres will be etched. 
I then make a copy of this but have all lines in black and the area between the lines ‘A’  and ‘B’ (the louvre) blacked out.  Just outside the area of the louvres, draw two circles half an inch in diameter and fill these in in black also. This is one part of the tool for forming the louvres, and you will require six etched sheets to be produced from this art work for every one of the louvres proper. The etcher will copy and repeat this in making his etching film so only one drawing is required. 
When the six ‘tool’ sheets are returned from the etcher, they are stacked one on top of the other on a piece of flat hard wood. The round holes (now one eighth inch in diameter) are lined up and a one eighth drill passed through into the hard wood. Into these are fitted short pins to hold the sheets together. 
These tool sheets have louvre shaped holes where the louvres would be, the stacked sheets now form cavities, so when the louvre sheet is located over this, the actual louvres can be pressed (formed) into these cavities, crease side up. To do this, take a small scrap piece of brass or hard wood and make a rounded dome on the end twice the width of a louvre, then file half of one side away. With the flat side against the cut of the louvre, press down and move back and forth to form the louvre into the cavity. 
.008 inch brass is best used for the etched sheets, however I prefer a hood to be at least twice this thickness, so I make a second copy of the louvre art work and black out the area of all the louvres. This will produce a brass panel with a large hole in it, exactly matching the size and shape of the louvred area. 
Tin one side of this and the inside of the louvred panel and soft solder together with a soldering iron, trim and form panel to shape. All 2.9 Alfa Romeo louvred hoods were produced using this technique.  Click on the eye ball at 125-E to see the results (64 - 65 - 66 & 69) 
-GAW- 
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Materials

"...I am trying to locate some small 1/32" hex rod in either aluminum or brass? Any ideas? I have already found the Special Shapes company." 
-Stephen- 
Regarding the question of 1/32” hexagon rod in brass or aluminium, I do not think that I have ever seen any that fine. If I have a need for it in small pieces, I put a length of suitable diameter in the three jaw chuck on the lathe, and with a fine flat file put the flats on with that. With the file held horizontal and one jaw at the top, file the first flat, turn the chuck slightly so the next jaw is pointing down and file the second flat. Rotating the chuck in this way - three jaws up and three jaws down - with a slight flat applied at each setting will produce a very good hexagon rod up to about 1/16” 
-GAW- 
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"....I want to realize pieces in brass for personal models during my leisure time. Could you tell me the wood you use to build patterns for forming car bodies?" 
jean-bernard 
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Apple, Pear, and Cherry are very good. Make sure it is dry and stable, and glue blocks together to make up the thickness before shaping. 
GAW
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Painting.
"...I always dread the moment of painting the car. Right now I am busy building a Creative Miniatures Associates  1970 Ferrari 312B formula 1 car in 1/12th scale. It is a resin body and I primed it twice with a grey pimer and I have given the body four red coats of Dupli Color acrylic paint. Right now I am wondering if I should give it one or two additional clear coats. Do you ever clear coat your models? On a seventies racing car I'm afraid it is not realistic to put on such a high shine. I have seen pictures of the car in the Donington Collection and it looks quite battered. What is your advice? Go for a high shine or remain faithful to reality? I know you advocate polishing your model after the final coat, but a complicating factor in this case is that the body is fully riveted and that I will lay bare all the rivet heads while polishing. Have you got any idea on this?" 
-Ham-   
All of my painting is undertaken with the original Cellulose paint finish that was used on the cars in the 1930s.  This has the advantage that each layer eats into the previous one as you build up the grey primer and/or top colour coats, so that when you rub this down and polish the final finish, you do not get the ring pattern that you sometimes get with other paints. 
I have no experience with acrylic paints and do not know if they work in the same way, so cannot offer you advice on the use of these paints. 
In general though I do not like the very high (glass) gloss finishes that can be obtained with acrylic paints. I much prefer the polished sheen that has always been the hall mark of a cellulose finish. 
I would think that if you have built up a good thickness of colour on your model, and you have a smooth finish (apart from the rivet heads) then a gentle rub over with a very fine metal polish, would take off he high gloss and replace it with a sheen, more befitting the scale. Any rivet heads that  appeared to have been polished through could be touched up with the original paint, using a very fine paint brush. 
-GAW- 
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Techniques
"...Although I have followed your work ever since the publication of the first edition of CCM, it is of great value to see your latest ideas and be able to use them in my own models. If you were to ask what sort of topics you could cover in the future I would suggest the making of the very small items that give such authenticity and incredibility to the final product.eg, the steering arms and brake lever parts for the current project shown in Photo 121, Gallery 9. 
A problem which is currently taxing me is the production of the engine cooling water hoses. The straight or slightly curved ones are straightforwardly made from suitable rubber/plastic tubing, (although material for the very small sizes is difficult to find) but those which in the prototype are moulded to give right angled bends are proving awkward! Have you any advice please? Further to this, could you also give guidance on the associated pipe clips, Jubilee clips in my own case? 
John 
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Regarding your water pipe bends, why use rubber or plastic?  Why not use brass or nickel silver and paint it. Regarding Jubilee clips, I turn the ‘rubber’ and the clips (squeezing the rubber) in nickel silver, then drill the centre to fit the pipe. If you need to add the locking screw this can be added with silver solder to the two rings. After polishing, the rubber part is painted in matt black to simulate the rubber. 
Items like brake levers are turned on the lathe in brass or nickel silver slightly smaller than required, then hit with a large hammer (not on the lathe) on a steel anvil to flatten them.  After drilling the two ends they are ready for assembly.  Larger items like steering arms will also be turned on the lathe but have the two flats filed on them while still in the lathe, before parting off. 
GAW 
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...'Really enjoying your galleries. The more pictures of details the better! 
I am wondering how to remove the brass from INSIDE your headlights. I am clear on using a formed tool for the outside housing but the inside I am thinking using the mill? But then you would not have a bulb...???? 
And how are you making the rings for inside the headlights  (reflector assemblies or lens holders) 
And last, but not least...are your lenses made from glass or plastic?' 
-John- 
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Check out Gallery-17 photos 244 & 247 in  ‘View Bentley-Build’ and 
Gallery-5 photos 70 & 71 in ‘View Duesey-Build, and take a close look at the head lights. 
These are made in one piece from brass rod with the first operation being to bore out the reflector and the bulb together with a recess under the front rim to take the lens, which is cut from clear plastic. 

I use an ‘L’ shaped boring tool for this operation. If you can imagine the long leg of the ‘L’ in the tool post and the short leg being away from you and turned to the left, being the business end.  This is ground with cutting edges on both sides and is used with the lathe running in reverse. It is used to carve rather than form the inside of the lamp.  The back cutting edge has a radius and a lip on it coming around to a straight cutting edge at the front nearest you.  Rough bore the inside of the lamp to remove most of the material, then with the machine in reverse, form a small recess under the front rim of the lamp with the lip on the tool, then bring the tool across at an angle to form the reflector to the diameter of the bulb, then out and around to form the radius on the bulb.  It sounds complicated, and does take a little practice but it is how I have made all the lamps for the past thirty odd years.  When polished and chromed with the lens pressed in place, they look real. After the inside of the lamp is bored to shape, the outside is carved in a similar way. It looks at first that if you were to make a form tool the shape of the outside of a lamp and force this into the brass bar you could form the outside shape in one operation.  By forming the lamp with it facing out, you will be reducing the material at the back as the cut gets heavier and it will break from the bar with a very bad finish before the operation can be completed.  It is best to rough down the back conical shape and part finish with a file, leaving just the tip to be finished in a second operation with the lamp held in a split collet (photo 245 Bentley-Build) 
-GAW- 
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'...I'm experiencing great difficulty to locate an outside firm capable of nickel and/or chrome plating very small parts.  In fact, to date, I have not found anyone that is willing to do small scale plating. 
I have to imagine there are other scale model builders that require said services.  Do you have 'contacts' over here in the U.S. that may lead me to a reliable firm specializing in plating small parts? 

At this point, I'm contemplating the purchase of a plating kit.  There are several companies that offer the kits for nickel and chrome plating, but I'm hesitant to do so for fear the results may not be satisfactory as I have no experience in this area of expertise. 
Please advise me as to the best possible solution. 

My next question is with regard to the appearance of the engine cooling radiator core.  I'm having difficulty replicating the 'honey comb' look as it would appear when viewing the radiator core from inside the engine 
compartment.  Help with this would be greatly appreciated. I'm also having difficulty choosing the 'correct ' abrasive blasting media to clean up various components.  Is there one type you prefer over others? 

I have constructed a 'blast cabinet' and have obtained the blast gun, rubber gloves, ventilation system, etc.  In addition, I have reviewed technical information regarding the various blasting media... crushed glass, soda, corn cob, walnut shells, etc. but am reluctant to purchase same (at $40.00 to $80.00 per bag) until I better understand what media I should be using.' 
-Pet- 
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Nickel Plating - I do not know of a plater in the USA, however I would not discuss plating very small parts with a plater as they will run a mile if they think that they will have to handle them.  I have found it far better to go see them with all your parts soldered to a wire tree,(see photos in ‘View Bentley Build’ and ‘View Duesey Build’) so all they have to do is twist the end of the wire onto they plating frame, dip it into the plating bath and then give it back to you. 

I would not contemplate purchasing a plating set-up unless I was intending to make far more models than I currently do, and then I would hesitate. 

Radiator core -  On most models I use fine brass wire mesh as it is usually painted black and hidden for the most part by the engine and fan.  Other wise I have drawn a pattern of the honey-comb and used it to have it etched into thin brass sheet. 

Sand blasting -  I find the very fine sand supplied for the purpose to be the best for cleaning the model parts, however care is needed in using it as it does CUT, and can, if the air pressure is too great, cause problems with very small parts.  Fine glass beads are also very good for a fine satin finish, but they do shatter to dust so do not last as long as the fine sand. 
-GAW- 
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"...I have a question concerning electroforming. I think you briefly discussed this in one of your books and it's been my longtime desire for you to go into the subject further. Do you use this process?  Does your process involve a plaster electrode soaked in a electrolyte?  It seems to me that over the years I recall you mentioning this in one of your books and then I followed up with research and found that there is a electroforming process that uses a plaster electrode that has been cast from a male or female master pattern and is then bathed and kept wet with an electrolyte liquid,  then placed against a metal block and electrical current is used to etch the metal away until you're left with the shape you desire in metal. 
-Byron- 
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With regard to the ‘electroforming’  and ‘ etch forming’ (called spark erosion)  these are two different processes.  In the former you are building up a metal layer to form a thin shell and in the latter you are etching away metal to form a shaped block. I have used the former but not the latter. 
In electroforming, a female master is made then sensitised to allow it to pass a current of electricity.  This is then placed in an electro-plating bath to grow the part.  I did experiment with the process some years back, with the help of my local plater, to form car bodies in nickel. However, I have since found it much easier to beat them from sheet copper and brass and so I no longer use the process. For your interest, I first carved a hard wood block to the shape required, for example a fender. This was then finished to a high gloss and polished. A thin fibre glass shell was made from this and painted with a silver paint on the area of the required shape.  This is a special paint used in the electronics industry to map out circuit boards and consists of a suspension of silver in a liquid.  When it dries it will pass an electric current, unlike aluminium based silver paint. With the actual fender shape only so treated, a screw or two are fixed to a waste portion of the shell in contact with the silver paint and wires attached for the plater to wire the part to his plating frame.  My plater would leave the part in the nickel plating bath over night until we had a deposit of about ten thousandths of an inch thickness.  However, you do need the cooperation of a friendly plater to be able to experiment with the process.  I did find that the nickel deposit was very brittle but would probably improve with a further deposit of copper. 
-GAW- 
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"...I was just studying the photos of the Bentley project on your web site. I notice that you are using a torch on the chassis and axles. Why is this preferred to resistance soldering?" 
-Rick- 
Resistance soldering is used for soft soldering, cored lead solder, while the torch is used for hard soldering, silver solder. It is possible to silver solder with the resistance soldering carbon rod but it is apt to spark erode the metal in the process. 
Resistance soldering is ideal for soft soldering very small pieces to very large pieces as the heat builds up very quickly just at the point of contact, as soon as the solder runs, switch off the power and the residue heat dissipates just as quickly with out disturbing other joints. With a flame or large soldering iron a much larger area will be heated to soldering temperature, so providing  the chance of disturbing other soft soldered parts. 
-GAW-
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"...Why do you need to put the green padding inside the gas tank?" 
- Randy - 
The petrol tank still has some work to be done on it after the sides are soldered in place and cleaned up, such as drilling the side holes and fitting the brass angled beading around the end to hold the mesh in place.  As the tank is quite large and the brass sheet only .018” thick, it would still be quite easy to distort it without this added padding. 
- GAW - 
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"...What thickness of brass sheet are you using to make the shock absorber parts from?" 
- Doug - 
I am using nickel silver sheet for the shock absorber leaves of .010 “ thickness. This is slightly harder than brass sheet, which is an advantage here. 
- GAW - 
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"...When you are silver soldering large pieces like the chassis frame in photos 8 and 9, (current project) and very small parts like in photos 42 and 53, are you using the same torch or do you have a large one and a small one. And what gas do you use?  I am thinking about getting one of the small Acetylene torches - would that be suitable?" 
- Mark - 
I use Propane gas torches for silver soldering, a large one for the big jobs like the chassis frame and a very small one for the more delicate work, both are run from large gas bottles. 
There are a number of these on the market now with small replaceable bottles that are suitable for silver soldering, both large and small sizes, and quite inexpensive.  For very small work I have seen some not much larger then a fountain pen that are charged from a gas canister such as those used to recharge cigarette lighters. I have one of these which came complete with six different sized interchangeable nozzles that I use from time to time and it is quite adequate for very small work. 
I would not recommend Acetylene torches, however small, as the temperature is much too high for silver soldering and you have every chance of melting the parts.  The aim in silver soldering is always to heat the parts to be soldered (not the solder) to soldering temperature and let them melt the solder when you apply the solder wire to them. 
- GAW -
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"...On the Bentley chassis X members, I couldn't see holes at the ends. Have you provided them, and are they held with tiny dowel pins during silver soldering? If not, how are they aligned and held during soldering?" 
-Raman- 
The first operation in making the chassis is to mark out and drill small pin holes wherever something is fitted to the side member, inside or out. This is done to a master pattern directly from the plans, which is then used to mark and drill each of the actual side members. Several of the holes are then used to pin (rivet) the side members together for machining or filing to shape. After this they are separated and the flange top and bottom is silver soldered in place. The frames are then bent to match the plans, in the case of the Bentley - parallel over the front and rear springs and tapering from rear to front between them. The cross members, although of ‘U’ section, are in fact fabricated from thicker brass on the vertical than the flange at the top and bottom. When placed between the side members, the drill holes can be extended from  the side member into the thicker vertical ends of the X member. These are then provided with small pins to locate the parts for soldering permanently in place. 
- GAW - 
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"...I have ordered a lathe and milling machine and renewed my interest in building model cars. Have one of your books and love your website. In gal 6 you show shock fittings with a nut and bolt affair.  Are these machined out of hex brass to show an assembly or are they actual nuts and threaded rod?" 
-John- 
The shock absorber brackets (photo 58 Current Project) are machined from brass rod, threaded 14BA and fitted with brass nuts machined from hexagon brass. 
-GAW-
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"...I can see lots of very small hexagon head bolts on your Bentley model, the only screws I can find have round heads, who is your supplier or do you make them?" 
-Phil- 
I make most of my hexagon head bolts as follows. If they are very small and only for show (do not need to be threaded) they are made from round headed rivets 1/32” and 3/64” in diameter. Hold the stem in a small pair of pliers and with a second pair pinch the head in three places to form the six flats. 
For small threaded bolts that are needed to hold parts in place I use cheese head screws and fill the slot with hard (to be chromed) or soft (to be painted) solder. Then holding the stem in pliers and with the safe edge of a fine flat file against the pliers jaws, apply the six flats two at a time.  With a little practice perfect hexagon headed bolts can be produced as needed in very little time. 
Never use slotted screws where they can be seen on a model car.
-GAW-
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"...Why use stainless steel tube for hinges - why not use brass?  Where can I get stainless steel tube from in these small sizes." 
-Don - 
I use stainless tube silver soldered to nickel silver sheet because in most cases the hinges on the actual car are chrome plated. If these parts were made with brass tube and then chrome plated, unless a tiny allowance has been allowed for at each segment of the hinge, there is every chance that the plating will lock the hinge into a solid piece. Also, soft solder will not stick to chrome plate, so the area to be soldered would need to be masked from the plating. Using my process saves these complications. 
When completed and fitted, these hinges can be polished and will be in distinguishable from chrome plated ones. 
To obtain the stainless steel tube you need to check your local library trade directory for suppliers of hypodermic needles. These are the people for whom the tubing is made.  I purchase mine in one metre lengths.  If you have problems finding a supplier and you are in the UK, let me know. 
-GAW- 
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"...When using a very small drill, eg 0.020" dia. or less, how do you prevent its wandering without the benefit of a centre punch or centre drill mark?  I am thinking particularly of something like the spoke holes in a wire wheel hub or rim such as in Plate 27 of The Complete Car Modeller 1, and when trying to keep the drilling central in material rotating in the lathe." 
-John - 
The answer to your problem is that you need a very short drill. 
Check out ‘Current Project’ (www.Wincol.com) Gallery-2, photo-15, and you will note that the shank of the drill is a larger diameter than the actual drill, note also that the actual cutting part of the drill is very short.  It is possible to obtain these drills in a number of small diameter sizes all with shanks of about .060” in diameter. Check with your drill supplier. 
If you cannot obtain this type of drill, then try having only a short length of the drill coming out of the drill chuck. Another answer is to drill a short length of brass in the lathe (starting with a centre drill) turn the out side diameter down to about .060” and soft solder the shank of a short drill into this. 
For things like spoke holes a drill with flutes of less than 1/8” length is plenty long enough, and with a larger diameter shank or the drill close in to the drill chuck, will prevent any drill wander. 
- GAW - 
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"...When you assemble your models what sort of glue do you use, is it some sort of superglue?" 
-Ken- 
A little super glue will be used in the final assembly but not to hold parts together but rather to stop them coming apart. Parts that are not held in place with small bolts or screws if they cannot be seen, are held in place with dowel pins, for a positive fit.  It is these pins that may be given a spot of Superglue in the final fitting out of the model, to stop them coming apart. 
-GAW- 
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"......I am curious about one thing ( actually more) and that is, how do you make the flexible exhaust pipes on the Duesenbergs, Cords etc.? 
 - Ken -

There are a couple of ways of recreating flexible exhaust pipes that I know of, one of which that I use and another that I have seen other people use to great success. 
The first is to make the exhaust pipes from copper bar or tube and bend to shape, then wind these with a flattened copper wire to simulate the flexible pipe. When complete, polish and have the assembly chrome plated.
The second method requires that you apply a course (screw thread) die of suitable diameter to a copper bar, in such a way that you do not form a full thread, more a flat topped thread. The bar would then be annealed and bent to shape, polished and chromed.
GAW
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".......When the Bentley is finished, I would like to take some external photos with houses or background landscapes, like those that appear in your books. I have the images that appear in your galleries of the Bentley, but I would like to ask you some questions.
Which lens should be used? 
Do you fit a filter? 
What roll of film do you use? 100 ASA?
I suppose that the diaphragm should be closed (between 16 and 32) and low speed (between 1 and 8) as the light meter indicates?
What material do you use in the base where the car is placed, to simulate the road?  It is sandpaper?"
- Francisco -

Regarding photographing models: the lens you need is a 28mm lens and the base is a piece of thin plywood nailed to a couple of cross pieces of hard wood that are curved on the top surface to represent the camber of the road. This is then covered with a large piece of sand paper, that is then sprayed black. Check out Bentley Build > Gallery-21 photos-302/305 for the set up. Stop down the lens to f16 or f32 for maximum depth of field, focus on the far side of the model and adjust the time setting from the lighting of the model. I found that a good sunny day with the sun behind but to one side of me gave the best results. I also found the open country to make the most realistic background. Something with short grass in the foreground with trees and or large building in the far distance. A house close by is tricky, we are just lucky that we have a long enough garden to just make it right. Check out the 2.9 Alfa Galleries, particularly two and three, for what I consider good examples. 
100 ASA film will be OK but it can be better to use maybe 400 ASA to have a higher shutter speed in case of wind movement of the grass or trees close by,
- GAW-
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Website

"...I find the Bentley photos so useful to see how you build a model from scratch. Will you be selling a portfolio of the photo set when you have finished the model?" 
-Dick- 
No, I have no plans to publish the photos. When the Bentley Project is finished and we move move on to Duesenberg,  the Bentley Project will be moved over to the Model Gallery as Bentley Build along side 2.9 Alfa Build. To find the Model Gallery click any ‘eye ball’ on the Car Galleries, or you can find it at < www.geraldwingrove.com >
-GAW-
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"...I would like to order the 1924 H6CHispano Suiza, do the engine plans and prints come with this set?" 
-Vincent- 
Yes the Hispano plans (146-A)and photos are complete with engine and chassis detail and are those used to build the models illustrated. Although my models of this car only have the top engine detail included because there is a full length under tray on the car, the full detail is included on the plans for anyone looking to build a complete chassis. The Hispano Supplementary photos (146-AA) also includes a good selection ofthe engine and gear box shots, of a car being rebuilt from the ground up. 
-G.A.W- 
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"...In regards to the photos in the different groups I ordered,  is it possible for you to provide them on a CD in IBM-PC JPEG format(the higher resolution the better)?" 
-Gene- 
Sorry,  we cannot supply the photos on CD. 
-GAW-
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"...Are the prices listed in the cat. US funds or Pound Strl.?   Also I can't seem to get to your home page thru www.wincol.com on AOL, I find it thru an Italian model house." 
-Teg- 
If you cannot get to the www.wincol.com web site with AOL, I think perhaps you may be using AOL-Mac-5  on an Apple Mac computer.  If this is so, it is a problem with the AOL-Mac browser not your computer or the web site, and they do not seem interested in fixing it.  It seems they are not interested in Mac people anyway, hence the PC AOL browser is now up to version 7 and they have no plans to upgrade the Mac version.)  I also have an Apple Mac (makes life so much easier) and I have the same problem. 
If you can get hold of a copy of Internet Explorer, or Netscape Navigator, you should have no problem. 
The prices are initially in US Dollars, however if you place an order, when you get to the order form you will find a converter for UK Pounds and Euros. 
-GAW-
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"...I would like to order drawings of the 1930 Duesenberg J. 120 Murphy, but if  I understand the website correctly, drawings are not yet available.  Should I check the online catalog from time to time to see when drawings are available, as I assume they will be available at some time in the future?" 
-Louis- 
If you click ‘ORDER’ for one of the subjects that is available, and then click one or more of the ‘REQUEST’ items, on your order form you will note that no charge is made to your credit card for the ‘REQUEST’ item, only the ‘ORDER’ one is charged at the price listed.  However the ‘REQUEST’ details come to us with your order so that we can log them. As soon as we know which of the many subjects people are most interested in we can then determine the order that we proceed with the drafting of the remaining plans. 
-G.A.W- 
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"...I keep looking for a link on your web site to the gallery of model photos. Do you have a link or have I missed it?" 
-Joseph- 
We tried to keep the site as simple as possible with as few buttons and links as we could get away with, so there is no marked ‘Model Gallery’ link.  However, click ‘Content’, then  ‘Car Galleries’.  Here you will see, if you scroll down, a series of eye balls (50) against individual subjects.  All of these will take you to one of the Galleries showing the models built from the plans and data photos available here. 
When in the Model Gallery you will find at the top a row of links to the other pages of model photos, including ‘2.9 Alfa Build’ showing the building of a 2.9 Alfa Romeo.  When the Blower Bentley is complete and we start a new CURRENT PROJECT, this is where the Bentley photos will be stored as ‘Bentley Build’ 
-GAW-
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"...a request: Can you give us more information on the tools and supplies used?  The link for small tools has only one type of hammer and it's for watchmaking. Where does one obtain a repousse hammer?  I have The Complete Car Modeler, volumes 1 and 2. In these books you mention various grades of sheet brass and copper. Can you give us a source for these?  The most commonly available sheet brass and copper in America come from K&S, but it's 'generic'" . 
- James - 
We are based in the UK so it is not possible for us to locate  suppliers for all things, particularly overseas. My hope is that fellow model makers will, in due time, be able to provide this information and we can add it to the site. 
My own supplier for the repousse hammer was H.S.Walsh & Son Ltd in London, who have a web site at <www.clockmakerstools.com> but you have to purchase a paper copy of their catalogue. Not every one is fully on line yet unfortunately.  However I can recommend having a copy of the Catalogue if only for the illustrations of the wide range of tools and materials that they hold, very many of which are priceless for the model engineer. 
-GAW- 
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Books
"...A quick question on your books - you show three books - the Complete Car Modeler (original - Hispano on cover), and then CCM 1 (Duesenberg on cover)and CCM2 (Bugatti on cover).  Are they three separate books, or is CCM1 a reprint, with a different cover, of the original? 
Also, I tried to actually see the pricing on some of the portfolios, but couldn't seem to get there - can you please tell me where I can find this info?" 
- Peter- 
CCM-1 is a reprint of the original CCM with the Hispano on the cover, except that is has a different set of plans at the back, and an additional section on building the P3 Alfa and the ‘louvre press’ for pressing the louvres for the P3. 
CCM-2 covers the work shop, materials, and the building of a single model, the Weinberger Bugatti Royale. The plans and data photos for this subject are 132-D and 132-DD Gallery-11 (WinCol.com) 
Go to WinCol.com, Home page. - Contents, - Car Galleries, - select a Gallery, - at the top you will see (blue links) ‘PRICE GUIDE’ clicking one of these will take you to a page explaining the pricing and giving the individual prices.  Also if you click on ‘ORDER’ this will also give you the price, which you can then cancel if you so wish. 
-GAW- 
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"...When you released the book on the Bugatti Royale and I read and reread the ink from its pages, I knew this was the direction my hobby was headed. I have built a better shop with the tooling required, practiced my skills with these tools. I also long awaited the release of your book, The Anatomy Of A Bugatti Royale, as a guide. Has this book ever been published?  It certainly would be able help me begin to scratch build this car with the information you provide." 
-Kent - 
Unfortunately the book ‘The Anatomy Of A Bugatti Royale’ was never published and we have no idea how it ever came to be listed on the ‘Amazon’ web site.  However the plans and data photos that were to be part of it are now available as Portfolios 132-D and 132-DD in Gallery-11. 
-GAW.- 
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"...Could you please advise the difference in content between "The Complete Car Modeller" and "The Complete Car Modeller 1"?  Are they the same editorially just published at different times?" 
-Dave- 
Complete car Modeller-1’ has an added section dealing with the Louvre press (offering an alternative way of forming hood louvres) and a different set of car plans at the back, from the original ‘Complete car Modeller’. Otherwise they are basically the same book. 
-GAW- 
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Comments

"...Just received the plans and photos of the Rolls 40/50. The plans are extremely detailed and I spent the whole evening glossing over them! Please convey my compliments to Phyllis on documenting the car in such great detail. It was most interesting to see details such as bottom view of crank case,  6 views of gear box, many views of transmission brake as well as chassis and engine details. 
I'll make a sincere attempt to model this car to the extent possible!" 
-Raman- 
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"...How many people do you have working for you and do you take apprentices? I really like all those photographs of the Bentley model being built. How long does it take to build a model like that?" 
-Darren- 
I work on my own with a working week of about 70 hours most weeks, and I am very sorry but I do not take on apprentices.  The Blower Bentley project was started in December of last year.  However all of the drawings, tools and patterns had already been made for a previous project. 
-GAW- 
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"...I think the portfolio represents a tremendous value for the individual who wishes to build a model from scratch. But I feel this document would be appreciated by a non-modeller/engineer as well. I know this to be a fact because when I opened the portfolio in my office every engineer in my department suddenly acted as if I was their best friend and they spent about an hour at my desk pouring over the scale plans. 
I enjoyed your brief biography at the beginning of the document. I must agree that I prefer the vehicle dressed in its original black with yellow accents. It is a shame Charles Chayne painted it white. It changes the gestalt of the entire vehicle. I am not sure of the provenance of those hub caps but I prefer the original wheel design. I also noticed an elephant 
mascot on the restored version - did this appear on the original? 
The photos are very helpful. The epson printer did a fine job of reproducing these images. It appears that you have been able to go where few others may to obtain these photos - when I was at the Henry Ford museum I could only photograph this vehicle from the front and a partial profile of the driver's side from afar. The vehicle was roped off and not approachable. This made me appreciate the ACD museum even more - there I could walk up to any vehicle and photograph it from any angle I wished. 
The scale drawings stand up on their own. They are works of art unto themselves. Combined with the photos and your books I feel confident that I could build the chassis once I obtain some skills in using the requisite tool set." 
-Rick- 
Very many thanks for your e-mail and assessment of the Weinberger Portfolio.  We are very pleased that you found what we had hoped for and you did not think that it was overpriced having now seen a copy.  When you have been as close to this thing as long as I have, you can convince yourself of almost anything, so you can appreciate how relieved I was to read your review. 
No the elephant mascot was never part of the original Weinberger Bugatti Royale, as may be seen in the original photos of the car when new. 
-GAW- 
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