EMD F7A with 3D-printed Windshield Frame

[bogieman]

I bought plans on Brick Train Depot for the Tony Sava-designed F7A and B locos but when I got to assembling the windshield, I just wasn't satisfied how it looked and it's robustness. Since Lego doesn't offer parts to do what I considered satisfactory and since I own a 3D printer, I designed a windshield frame and windows that to me is a major improvement. By not requiring the internal supporting structure, it frees up space in the cab interior for engineer and fireman mini-figures.

Here's the completed A-B set with the Southern Pacific Black Widow paint scheme:

 

This shows the cab roof removed. The roof holds the windshield via the four studs attached, there is no attachment on the bottom.

This is the windshield piece. I cut windshield glass from 1x4x6 Glass 57895 that snap into the frame with nubs on each end.

I opened up the interior to fit a battery holder with 3 - 18650 batteries:

There are two train motors in the A unit and one in the B unit which is connected by a 4-conductor 3mm plug/jack to connect the B unit motor and it's rear headlight. As I have on several of my other locos, I am using a MRC Loco Genie wireless DCC system to provide the motor control, lighting, and sound functions. The 40mm speaker is mounted on the floor at the rear of the A unit. I purchased PUP jacks from China to connect the motors without having to cut off the plugs. These are the control components; there is an audio amplifier to the left of the speaker. I used 1206 SMD LED's for lighting:

Here's a shaky and poorly narrated video of the locomotive in operation:

Dave

[Ayato Zechs]

This is pretty awesome! I wish I had a 3d printer to print a windscreen for my 8-wide Santa Fe F7. 

[Toastie]

Hi Dave,

"So, I hope you enjoyed" is what you are saying at the end of this breathtaking video ...

... I am "on" a 60 x 2 years birthday party - just quickly cycled back to our home to give our lady dog her eye medicine; she had surgery on Tuesday otherwise she would be blind in a couple of months the told us, recovery seems to be going well so far, but she needs to get her drop every to hours for text two weeks.

There is so much more than enjoyment here - I must say I am completely up in the air. Man, everything is so nice in this video (the lovely mess(!), the layout, the woodwork - and the windshields are making all the difference!!! Wonderful.

I am so glad, you posted that here - fantastic.

And I also love, love to see that power switch having its very own hole in the plate - TLG doesn't make these - so you made your own. Entirely my approach as well - so nice.

So much more to say, but I have to cycle back to the party.

All the best - wait, yes, also from Beanie, our dog.

Thorsten

[zephyr1934]

22 hours ago, bogieman said:

This shows the cab roof removed. The roof holds the windshield via the four studs attached, there is no attachment on the bottom.

This is the windshield piece. I cut windshield glass from 1x4x6 Glass 57895 that snap into the frame with nubs on each end.

That looks AMAZING, and takes an already top notch model up to 11. That hits all of the hard to reach corners of the very curvy prototype. Did you start out thinking you might use the glass for 1x2x3 windows but it turned out too small? Is that painted or were you able to print so close to lego colors (black is easier than the yellow windshield you show in another video)?

 

I bet there are other folks who would love to get their hands on these (e.g., I'd like a pair in 6 wide dark green, grin). If you are not interested in selling them yourself, you might want to the folks at Brick Train Depot or similar to produce them.

Regardless, it is always great to see your layout in action. Very well thought out and interesting operations. Much better than simple circles.

 

[bogieman]

Thanks for the kind words Thorsten, I hope Beanie makes a quick recovery. The grandkids are here today playing around the layout, they don't have much interest in the trains, despite my best efforts, maybe in time.

Dave

[bogieman]

26 minutes ago, zephyr1934 said:

That looks AMAZING, and takes an already top notch model up to 11. That hits all of the hard to reach corners of the very curvy prototype. Did you start out thinking you might use the glass for 1x2x3 windows but it turned out too small? Is that painted or were you able to print so close to lego colors (black is easier than the yellow windshield you show in another video)?

 

I bet there are other folks who would love to get their hands on these (e.g., I'd like a pair in 6 wide dark green, grin). If you are not interested in selling them yourself, you might want to the folks at Brick Train Depot or similar to produce them.

Regardless, it is always great to see your layout in action. Very well thought out and interesting operations. Much better than simple circles.

 

Thanks Zephyr. I did make a version using the 1x2x3 window glass but I felt the window opening was too small and didn't look right; it would work in a 6 wide version I'm sure though. I printed it in black ABS filament but sanded and painted it to make it smooth and glossy to try to match the Lego black. I tried acetone smoothing the ABS but it warped it badly. I think I printed 12 or more samples to get the shape right and figure out the best print orientation.

I have been working with Brick Train Depot to sell this design, but not sure how soon they'll be ready to offer it. 

I designed the layout so I didn't have to crawl underneath it to access all parts of it, hence the shape. I've had both knees replaced so crawling without putting on knee pads it a no-go.

Dave

[dr_spock]

Good work. Very realistic.

[zephyr1934]

21 hours ago, bogieman said:

I printed it in black ABS filament but sanded and painted it to make it smooth and glossy to try to match the Lego black. I tried acetone smoothing the ABS but it warped it badly. I think I printed 12 or more samples to get the shape right and figure out the best print orientation.

I have been working with Brick Train Depot to sell this design, but not sure how soon they'll be ready to offer it. 

I designed the layout so I didn't have to crawl underneath it to access all parts of it, hence the shape. I've had both knees replaced so crawling without putting on knee pads it a no-go.

The hard work definitely paid off, and neat to know that you are working with BTD. They do good work. As for your layout, from the spectator perspective accessibility is just a bonus, it is well laid out operationally. It is always neat to watch your videos of trains running around the layout.

[ivanlan9]

Sweet!  I'll take several of the 6-wide ones in Santa Fe red, please.

You could always provide stl files for those of use dumb enough to try to print them ourselves. 

[bogieman]

On 5/28/2022 at 3:57 PM, Ayato Zechs said:

This is pretty awesome! I wish I had a 3d printer to print a windscreen for my 8-wide Santa Fe F7. 

Thanks, Brick Train Depot will be selling the windshields and frame, hopefully in the near future.

[bogieman]

Thanks all! 

Ivan, I haven't done a design for a 6-wide windshield frame since all my models are 8W. Looking at the construction of the LEGO F7 10020 set, it would take a redesign of much of the front to do something similar.

Dave 

[dtomsen]

5 hours ago, bogieman said:

Thanks, Brick Train Depot will be selling the windshields and frame, hopefully in the near future.

Please in red too. I'm willing to pay with my kidney if needed 

[Ropefish]

Wonderful post process work on the 3D printed part, I am considering a similar option as I want to build a SP PA/B-1 to sit along with my AC-9, what was the design process for the part like?

[bogieman]

16 hours ago, dtomsen said:

Please in red too. I'm willing to pay with my kidney if needed 

Thanks Dennis, I might need to take you up on that, the Dr. says I have to lay off the Naproxen Sodium to save my kidney function! But seriously, I think that is in the plan when BTD is ready, you need to prod Cam on Discord.

9 hours ago, Ropefish said:

Wonderful post process work on the 3D printed part, I am considering a similar option as I want to build a SP PA/B-1 to sit along with my AC-9, what was the design process for the part like?

Thanks! As far as design process, I started with one of the many webpages with Lego brick dimensions, then got my caliper out to take some measurements. I own a seat of ProEngineer (now Creo) from my consulting days so used that for the 3D design while looking at F unit pictures to estimate the window size and shape, then did test prints and iterated the shape and print support and orientation until I was happy with the fit. The clutch of the studs surprised me actually how good it was. I have a small metal cutting bandsaw that made cutting out the windshield glass easy.

[XG BC]

looks pretty accurate. dont get me wrong i dont dislike your idea or the design but it just looks a bit weird to me. i cant pinpoint why though. maybe i am just used to brickbuilt cabs on us diesels or idk.

[LEGO Train 12 Volts]

Wonderful train and elegant solution for that 3D printed windshield.

The video is absolutely gorgeous!

[Paperinik77pk]

Spectacular windshield - it should have been quite a work! 

The locomotive look is amazing!!!

Great job and spectacular video!

Davide

[bogieman]

Thanks all for the comments, appreciated!

Dave

[DMRR WOLFE]

Wow! Thanks Bogieman for a great and inspiring post!! You're a credit to the Eurobricks Train community!

Excellent work on developing the windscreen design and hats off to your Black Window version of Sava's F7a/b! It looks really sharp in that livery! Did you print the decals/stickers yourself too?

 

 

[bogieman]

Thanks much! No, credit for the stickers goes to Andy at OKBrickworks, who does really great work. When you buy the plans for Sava's F7A&B from Brick Train Depot, you can specify either the SP Black Widow version or a Union Pacific yellow version. The assembly instructions are downloaded and OKBrickworks mails out the decals.

Dave