1602 - EXTREME LOAD no. TWO Kit Features: 22' 4 " x 14' x 3'-6 Oversize Load 49mm (1.9") actual height Bolt Head Details Welded Load Mounting Fins Painting Handles Tools Required: Hobby Knife Tweezers White Glue or Wood Glue Small Brush Fine Flat File Small Weights Small Bar Clamp P R E C I S I O N D E S I G N C O Recommended Paints: X-I-M Primer/Sealer/Bonder Spray Paint Any yellow paint of your choice in HO scale Inspired by this photo taken by Barry Silverthorn of TRAINMASTERS.TV...
pg.2 Parts List: Frame Floor Floor Bottom Cover Frame Riser Pocket Rear Cover Plates Pocket Side Cover Plates Bottom Inside Rib Middle Inside Ribs Side Bolt Plates Side Plates Face Plate Braces Top Rib Back Plate Top Sill Plate Spline Braces Top Spline Lift Ring Plate Bolt Plate Details Welded Load Mounting Fins Deck Rings (for Chains) Middle Inside Ribs Floor Top Rib Bottom Inside Rib Paint Handle Welded Load Mounting Fins Frame Riser Frame Back Plate Side Plates Floor Bottom Cover Pocket Side Cover Plates Lift Ring Plate 1 6 0 2 made in canada Top Spline Face Plate Braces P R E C I S I O N D E S I G N C O HO EXTREME LOAD no. TWO Spline Braces Pocket Rear Cover Plates Top Sill Plate Deck Rings (for Chains) Chains for this load are available online at: www.pdc.ca/rr/catalog/1017 Bolt Plate Details Side Bolt Plates
pg.3 1. Remove the Frame & Floor pieces from the parts tree. Lightly file the sprue locations smooth. B is for Bottom 2. Check the orientation of the Floor piece, the B designates the bottom of the piece. Apply glue to the Floor piece with your brush and attach the Floor piece to the Frame. Use a few weights to clamp the pieces together, ensuring they are square to each other. Allow to dry for at least 20 minutes. Floor Frame 3. Remove the Floor Bottom Cover, Frame Riser, and Ribs from the parts trees. 4. Glue the Floor Bottom Cover in place. 5. Glue the Frame Riser in Place. 6. Glue the Pocket Rear Cover Plates to the back of the Frame Riser. 7. Glue the Bottom Inside Rib in place. 8. Glue the 2 Middle Inside Ribs in place. 9. Glue the Pocket Side Cover Plates in place. Pocket Rear Cover Plates Frame Riser Floor Bottom Cover 10. Lie the Frame Assembly face down and allow to dry for at least 20 minutes. 11. Sand the edges of the Pocket Side Cover Plates flush. Bottom Inside Rib TIPS FOR WORKING WITH WHITE GLUE or WOOD GLUE: - Use a scrap of cardboard to hold a dollop of glue for working with. - Put out more glue than you think you will need. You don t want - to run out in the middle of a step - it dries quickly! - Replace your glue dollop as soon as it begins to skin over. - Keep a cup of water handy to clean the glue brush between steps. - Use the water to thin the glue as needed. Middle Inside Ribs FINISHED FRAME ASSEMBLY Sand Flush Pocket Side Cover Plates
pg.4 12. Remove the from the parts tree and file the sprue locations smooth. Notice that laserboard has one nicer side. Lay this piece nice side down on your work surface. Apply an even coat of glue to the entire face of the Frame Assembly, making sure to cover all the way to the edges. Corners and edges with no glue will be weak. Press the Frame Assembly onto the back of the Front Face Plate and align it carefully so that the plate is even with the floor AND the verticals overhang equally on both sides of the frame pieces. Lie face down and apply weights. See Photo No.1 EQUAL OVERHANG Allow to Dry. Side Plate EQUAL OVERHANG Photo No.1 Side Bolt Plate Photo No.2 13. Remove the Side Bolt Plates, Side Plates, Curved Face Plate, and Face Plate Braces from their parts trees and file the sprue locations smooth. 14. Install the Side Bolt Plates on the uprights, Flush with the bottom of the. 15. Install the Side Plates above the Side Bolt Plates. Use weights to clamp them lightly in place. See Photo No.2 16. Insert the Face Plate Braces into the notches along the bottom of the. Square them up but do not glue these yet. Face Plate Braces
pg.5 17. Test fit the in the Frame Assembly before applying glue to the Frame Ribs. To install the, follow these steps: insert insert push Glue Edges From Backside snug into corner snug into corner 18. Remove the from the Frame Assembly and apply glue to the Frame Ribs. Re-install the. Apply glue to the outer edges of the from the backside. 19. If there is a gap between the and the Floor, Clamp the assembly as shown in Photo No.3. Use Metal or wood blocks to prevent damage to the model. Only tighten the clamp enough to close the gap. Photo No.3 Allow to dry for at least 30 minutes. Clamp to close gap here SAFETY TIP: Secure your load with HO Chains from www.pdc.ca
pg.6 20. To install the Top Rib; apply glue to the inside curve of the Top Rib and adjust it so that it is flush with the top edge of the. Top Rib T is for Top 21. Apply a thin, even layer of glue to the Rib and Frame surfaces on the back of the assembly. Install the Back Plate so that it is even with the edge of the Top Rib. Use weights to hold the edges of the Back Plate down until dry. See Photo No.4 Extra bars used to distribute weight Back Plate Photo No.4 22. Apply a thin layer of glue to the surface fo the Top Rib and install the Top Sill. Be careful not to clog any of the openings in the Top Rib. The Sill should sit flush at the front corners and flush along the notch along the front edge. It should otherwise overhang the load assembly on the front and back sides. 23. Remove the Spline Braces from the parts tree and insert them into the Top Sill. Spline Braces This Edge Sits Flush With Face Notched Edge Sits Flush With Face Top Sill Plate Fix these in place with a wash of thinned glue. Dry your glue brush and use it to remove any excess glue.
pg.7 24. Carefully insert the Top Spline into the Spline Brackets. Work along the length of the Spline seating it into one Bracket at a time. Slide the Spline to center it and make sure it is evenly curved. Press it down so it is fully seated against the Top Sill. Top Spline Do Not to the Highlighted Areas. Use your brush to run a wash of glue into the joints. Do Not To The Areas Indicated or the part will deform. Dry your brush and use it to remove excess glue. 25. Apply a thin, even layer of glue to the back of the Lift Ring Plate. Install the Lift Ring Plate in the gap along the Top Sill. Use a damp brush or your knife blade to cleanup any excess glue around the edges of the part. Use a weight to hold the Lift Ring Plate in place while it dries. 26. Remove the various Bolt Plate Details from the parts tree and install them on the face of the load assembly. Working under a magnifier will help in this step. Pinch your brush dry in a paper towel to give it a sharp edge. Use that edge to pick up a tiny drop of glue. Apply the drop of glue inside the locator marks on the face of the load assembly. Use the blade of your knife to pick up the details and press them onto the glue. Use the knife to adjust the position of the details until they are straight. Use the tip of the knife to remove any excess glue from around the details. 27. Allow to Dry... 28. Prime and Paint. Hold the model using the handy dandy paint handle located on the underside. 29. Install the Welded Load Mounting Fins 30. Load em up! Precision Design Co. Box 1874 Altona, MB. R0G 0B0 info@ pdc.ca 204.324.8711 made in canada