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The Denver & South Park, and other Colorado railroads changed over some of their flatcars to coal carriers. This was quickly accomplished and the extra bodywork MAY have been removable.
There were two sizes for this body, being either two planks or three, and the plank widths could vary as well. For example Aagain on a 26 ft flatcar a three plank version could be built with plank widths (from the lower plank first) of 10", 6", 8". There are other minor detail differences as well.
My body is a 2 plank one with the planks being a scale 2" thick and 12" wide, (3mm x 15mm). The ends of the coal box will fit inside the sides.
The first things to make are the side stakes. All these stakes are from ¼" square timber, and are 1.75 inches long, this is just a touch longer than needed, they will be filed down to size later. In addition cut four more 1.25 inches long and put them on one side for later. The lower half inch of the side stakes need to be filed to a smaller section to fit the
stake pockets, do all of them checking the fit as you go along, when all have been adjusted to fit put them on one side but mark them as to which stake pocket they are for. The side planks are now cut, at 15.25 inches long, you need four from the 3mm x 15mm planks that you have cut on the circular saw. Hold the first against the side stakes and mark their positions;
continue the lines with a square to the top of the plank. Now glue the plank to the stakes, I used Evo-stick ensuring that the stakes are vertical, they will be sticking up, because there is another plank to be fitted when the glue has dried. Do both sides and keep the separate and marked so you know which side they apply to.
When both are dry add the second plank to both sides, and it should be level with the top of the side stakes; any difference can be sanded off when the sides are again dry. Find the 4 extra pieces that were put 'on one side' and glue them to the inside of the sides at the very ends of the sides, and let dry. The lower ends of the side stakes, being a softwood are a bit weak; I painted all of them with a resin hardener intended for hardening wet & rotten wood - this will make them far stronger. It dries very fast (sinking in - it is like water) and give them a couple of coats. Now that the lower (smaller) ends have some strength mark any extra length below the stake pockets and cut it off, I have cut mine just about a millimetre up inside the stake pockets so there is no chance of them peeping through. Extra information has shown that these may well have been longer - so the lower ends peeped out!
Fit both the sides in position, and carefully measure the distance at the bottom between them; cut a couple of planks to this size. IF you want
to add some 'old age' to your vehicle here is where it can be done - make the top planks slightly longer - then the side will slope out just slightly! Glue the planks in position against the inside of the pieces that you glued onto the inside of the ends, use enough glue but not so much that it oozes out, and leave to dry. Meanwhile cut another 4 pieces which should be, if possible, just over ¼" square, and rectangular in shape (one dimension more the ¼"). These are for holding together the end planks, and should be projecting just a bit past the ones inside the end of the side planks. Glue them in position, when dry you now have your coal box, which should be quite strong. It now needs some detail.
This is a very utilitarian vehicle so nothing fancy is going to be needed. All the side stakes have a couple of fixings per plank, so there are 4 per side stake, both inside and out; this makes a total of 80 discs. I have a small set of punches which are quite invaluable for circumstances like this, all the discs I used are 2mm diameter, and cut from .010 black plasticard. These fixings will have been coach bolts with the nuts fitted outside, that way they are easily checked and tightened up if required. I made my nuts from a strip of .020 x 2 (glue it together - it is easier to cut that way), making them a 1mm cube, a quick dab of glue, and fit a nut to each. Do not fit any nuts to the end (nails) that hold the ¼" square bits on the extreme end - these I think were just nailed. Give all the nuts an extra wash of glue to ensure that are well glued - they are likely to get hit and need to be secure.
Above the step(s) on the side sills another grab handle needs to be fitted on the top plank (if making a 3 plank box, there should be two grab handles here). Make them from 1/16th inch (.060) brass wire, glue them in position.
On the exterior also add a couple of NBW's below the grab handle, then in the same position add a disc on the inside.
That is the building of the coal box complete, now you can paint it: mine is red oxide inside and out, with black ironwork, and especially the inside lots of muck/coal dust. The outside should also be given some dirt (they call it weathering!), as well, the amounts are up to you. I used acrylic paints for both, the main outer coat (before weathering) should be if possible the same as the re-painted Flatcar. Time to put it together and off it goes, a very useful, in either form wagon for your railway.
© Peter Bunce 27th May 2003
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