A Precision Steel Car Flat Car with the "Wright" Touch

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After the bolsters were welded on both ends, I spread the center beam apart and installed the four cross braces. I welded them one at a time making sure they were clamped so that the tops were even with the top of the center pieces. Also, VERY IMPORTANT, I used a straight edge on the outside of the horizontal braces to check alignment. See red level in the photo.

One could make a quick fixture from some angle and clamp it to both sides before welding. I welded one, checked, and moved to the next one and checked. This is important because if the frame is racked at this point nothing is going to fit right. When the car was complete I found that it had racked about .050 less than 1/16 of an inch. That was no problem.

Next I positioned the front horizontal bolster parts in their slots. I used aluminum blocks and clamps to make sure the parts were straight and had a heat sink. I only put on the front bolster part at this time so that the sides would not ride back and forth on the front and back pieces making them hard to align. Also remember, these parts are different so check and make sure you have the correct one.

The side pieces were clamped to the horizontal bolster using some aluminum blocks. Measurements were taken to determine that one side rail did not stick out farther than the other. A good carpenter square can be used for this. Once I was satisfied with the location the sides were welded to the bolsters.

Because it is difficult to weld vertical, the frame was clamped up right on to the 4” angle. This kept the sides straight and made it easy to adjust the horizontal braces for proper location before welding.

After the basic frame was welded I installed the TOP SHEET BRACE as pictured in step 6 of the instruction book. I backed this piece up with a piece of 1” x 1” angle to make sure it was straight and the ends are located as per instructions.

Next came the SMALL DECK FRAMES. If they fit correctly you are home free. I used several very small welds for this installation. Note in the photos.

Now it is back to step 4 in the instruction book, the application of the FRAME END. I used my brake and turned the bottom 5/16” under forming a right angle and stiffend the part. Note: PSC is in the process of switching this part to 1/8" material which will greatly improve its rigidity.

I then cut and welded on some small pieces of ½” X ½” angle to the outside ends. This makes it much easier to weld the ends to the sides.

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