the official semi-kit building guide

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Booklet revision 02-2013.
2
1 Dedication
This project, from the design stage to production, would not have been made possible without the support of
many other people along the way, and I am forever grateful for their help. I'd like to rst thank Disney and its
people for their passion to preserve Walt Disney's legacy, and for the inspirations they give me.
I am also grateful for everyone that has helped me on my blog and the Burnsland forum, and for everyone who
supported me by purchasing a copy of the Plan Book at ckhollidayplans.com. Your interest and support help
make this model possible.
I'd like to extend my thanks to Steve DeGaetano---for his input, knowledge, and most of all, his friendship. And to
Paul Boschan---for the inspiration, insights, and the opportunity to work alongside him on the Ward Kimball.
Finally, this work is dedicated to Lynne---for her endless patience, support, and love.
2 Inventory
2.1
Plastic Parts List
Part No.
100
103
105
202
210
220
223
300
301
306
307
308
311
312
316
318
409
500
516
518
521
531
532
Name
Frame
Boiler Brace
Draw Bar
Axle Box
Axle
Side Rod
Main Rod
Pilot Truck, Equalizing Bar
Pilot Truck, Axle Box
Pilot Truck, Frame, Bottom
Pilot Truck, Frame, Top
Pilot Truck, Pedestal
Pilot Truck, Transverse Bar
Pilot Truck, Swing Casting
Pilot Truck, Swing Link
Pilot Truck, Wheel
Driver
Boiler
Smokebox Front
Smokestack Saddle
Smokestack
Firepan
Sand Dome
Quantity
2
1
1
4
2
2
2
4
4
2
1
8
1
1
4
2
4
1
1
1
1
1
1
Part No.
533
612
654
655
701
703
713
877
910
1000
1001A
1001B
1002
1003
1005
1006
1007
1008
1009
1010
1011
1012
3
Name
Steam Dome
Saddle and Cylinder
Rocker
Rocker Mount
Link
Lifting Shaft
Crosshead
Headlight Box
House Bracket
Air Compressor
Air Compressor Mount, Top
Air Compressor Mount, Bottom
Air Brake Cylinder
Air Tank
Firedoor
Gauge Stand
Waterglass
Safety Valve
Air Brake Stand
Whistle
Steamchest Oil Cup
Reverse Bar Arc
Total Parts
Quantity
1
1
2
2
2
1
2
1
2
1
1
1
2
2
1
1
1
3
1
1
2
1
83
2.2
Wood Parts
Name
Cab
Pilot Beam
Pilot
2.3
Parts No.
A01-E01
F01
P01-P13
Total Parts
The major components of the engine were manufactured by subcontractors. Of note are the engine's
frames, which were cut from a single piece of steel.
Dixon Boiler Works constructed the boiler, and Wilmington Iron Works casted and machined the wheels. Other
parts were made by Disney's crew using wood patterns.
Quantity
33
3
22
58
The two engines were nished in summer of 1955. After being steam tested at the studio, they began their
rst run around the park at Disney's Fourth of July party
while the park was still under construction. Thus, the
Santa Fe & Disneyland Railroad became the rst operational attraction at Disneyland. Shortly after the party,
Walt Disney was at the throttle of the EP Ripley at the
park's opening day, July 17, 1955, before giving the
famous Welcome dedication speech on Main Street.
Plans Index
Sheet No.
A001
A002
A003
A004
B001
B002
C001
C002
D001
D002
Name
1:20 Erection, Right
1:20 Erection, Front and Back
1:20 Erection, Left
1:20 Erection, Top and Bottom
Pilot Truck Assembly
Frame and Boiler Assembly
Cab Framing
Pilot Assembly
Flat Sheet Pattern
Wood Pattern
Through today, the engine has changed little since her
birth. She underwent a major rebuild in 1999, and has
worn several different paint schemes. She is a magni cent living machine who has entertained, captivated,
and educated countless guests, and will continue to do
so into the far future.
For more history on the engine, its operation, and information on the Disneyland Railroad, one can reference Steve DeGaetano's Welcome Aboard the Disneyland Railroad! (Steam Passages Publications, 2004,
steampassages.com), and Michael Broggie's Walt Disney's Railroad Story (Pentrex, 1998, carolwood.com).
3 About the Engine
The CK Holliday was one of the rst two locomotives
built and operated at the Disneyland Park for Walt Disney's Santa Fe & Disneyland Railroad. Designed by railroad draftsman Ed Lingenfelter, under the supervision
of a railroad veteran, Earl Vilmer, the rst drawings were
penned in late 1954, with the construction taking place
alongside the engine's twin, EP Ripley, in Burbank, California.
4
Walt Disney based the look of the engine on his oneeighth scale live steamer Lilly Belle, which is itself a
scaled replica of the Central Paci c Railroad CP173.
The engine was meant to evoke the look of an American 4-4-0 locomotive popular in the mid- to late 1800s.
Typical of the American 4-4-0 design is the large balloon
smokestack, brightly colored paint, and brass trims; in
fact, this type of engine is what most people associate
with images of the American West.
Engine Statistics
Builder . . . . . . . . . . . . . . . . . . . . . . . . . . . . Walt Disney's WDI
Architect . . . . . . . . . . . . . . . . . Ed Lingenfelter, Earl Vilmer
Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . June 1955
Boiler Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.5''
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10'' X 15''
Operating Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 125 psi
The engine is named after Cyrus K. Holliday, the founder Driver Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36''
and rst president of the Atchison, Topeka and Santa Fe Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23,200 lb
Railway.
Tractive Effort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,427 lb
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5 About the Model
6
The Model Parts
The semi-kit includes parts produce from both hard plastic and laser cut wood.
For years, fans of the Disneyland Railroad have been
asking for an accurate model of the engines to have in
their own homes. But the railroad fans have always been
a small group, and Disney did not see that marketing to
this group was pro table.
The majority of the parts in the semi-kit were produced
by 3D printing from polyamide plastic. As a result of
the manufacturing process, there may be some white
powder residue on the parts and the surface may feel
rough or sandpaper-like. To assemble the parts, this
Outside of Disney, there have been attempts to produce plastic reacts best to cyanoacrylate glue, JB Weld, and
Disneyland Railroad models. But due to scal issues, to some extent, Plastic Weld.
the models were never completely accurate. So instead
of having an accurate model from the ground up of their Again, due to the manufacturing process, it is normal
favorite railroad, fans were left to 'kit-bashing' existing for the round plastic parts to have stepped or faceted
models together to form an engine or rolling stock that faces. For plastic parts that require a smooth nish,
resembles the real railroad.
such as the boiler jacket, a thin sheet of steel, styrene,
or even paper can be used to wrap the part and then
In 2011, I set out to study the Disneyland Railroad's CK painted. Flat sheet pattern for the boiler jacket has been
Holliday solely for the purpose of gaining a better under- provided in the kit plans for this reason. Use carbon pastanding of my favorite engine. To ensure that I under- per to transfer the at pattern onto the sheeting.
stood the engine completely, I decided to rebuild the
locomotive in its entirety in a computer aided drafting The included wooden parts may appear to be charred
environment. Everything had to match the real engine or burnt. This is the result of the laser cutting process.
as closely as possible, from the frames to the rocker These parts actually have masking tape on both front
pins. The result was a computer model that is a true and back surfaces that must be removed before the
representation of the engine.
parts are assembled, so that the burn markings are removed. If the tape is not removed, the parts will not asAfter completion of the model design, a plan book was semble correctly as the tape will eventually fall off from
published to showcase the computer engine model. The being worked.
result was a comprehensive set of engineering plans
and drawings to help other fans gain an understanding Plan sheets C001-C002 show the assembly of the
of how the engine was built and run.
wooden components. To identify the individual parts,
lay the parts onto the wooden pattern plan, sheet D002.
It was then obvious that the computer model could be
used as a basis for the most realistic scaled model of The included plan sheets show the general layout and
the CK Holliday possible. The locomotive components assembly of the kit's major components. Their part
designed in the computer were sent to a 3D printing numbers refer to the parts in the CK Holliday Plan Book,
shop to create highly accurate scaled parts out of hard available at ckhollidayplans.com, so the modeler
polyamide plastic. These parts form the base upon may refer to the engineering drawings of each compowhich the modeler can build the CK Holliday, or many nent directly.
other full or narrow gauge 4-4-0 locomotives.
After designing and receiving the parts, the model prototype construction started in November 2012 and
was completed in February 2013. The documentation of the building process can be found at the blog:
whiskeybeforebreakfast.wordpress.com.
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Building and Detailing
The process of building this model set is slightly differNow, with the semi-kit, modelers can nally have an ac- ent from other kits. Instead of offering step-by-step incurate scaled replica of Disneyland Railroad's iconic lo- structions, the method and order of assembly is at the
comotive.
modeler's discretion, exactly similar to how Disney built
5
the original engine. As such, a little knowledge of locomotive construction may be useful. So, while the CK
Holliday Plan Book mentioned in previous sections is
not required to complete this model, it is nonetheless
a highly recommended resource to allow the modeler
to gain further understand and insight into the construction of the engine, and will greatly assist in the building
and detailing process of the model.
land Railroad Modeling Forum at burnsland.com/
disneyrailroads offers some guidelines on nding
the right paint colors and mixtures. The colors used
will also depend on the era that the model is portraying,
since the engine has worn different color schemes.
8
Review the drawings and carefully plan out the assembly order, which should closely mirror the construction
of the real engine. The included assembly plans do
not show the placement of every parts in the kit,
since it is expected that the modeler will use additional
resources such as the Plan Book and pictures of the engine to complement the building and detailing process.
EP Ripley Modi cations
With some modi cations, the semi-kit can be made into
a model of the EP Ripley since both engines share many
similar parts and constructions. The following is a list
of suggested modi cations:
• Extend the smokebox by wrapping a wide sheet
of metal or plastic around the smokebox. Fix the
smokebox front as usual.
It's also may be helpful to review how the prototype
model was constructed. Its building process is documented at the blog mentioned in the previous section. When in doubt, feel free to ask for help at the unof cial Disneyland Railroad Forum at burnsland.com/
disneyrailroads.
• Replace the domes, smoke stack, and headlamp.
Trackside Detail offers beautiful casting of such
parts that may be appropriate for the Ripley.
Many parts are still required to be furnished by the modeler to detail and nish the model, but they can easily
be made from various stock materials. For example,
styrene plastic comes in many forms and sizes, such
as squares, circles, and thin sheets. The styrene plastic
can be cut and formed easily into many different shapes.
• Modify the cab's roof framing, parts number A01,
C01, C02, and D01, with wood putty into arch
type. Also, neglect the center post A03.
• Use only one crosshead guide on each side instead of four.
By design, all of these additional parts require only very
modest amount of work by the modeler to make. For example, the crosshead guides and running board brackets can be cut from styrene squares, the crank cut from
styrene or metal rounds, and the running boards from
thick styrene sheet.
• Modify or remake the pilot into a shorter type.
• Shape the running boards as straight instead of
split type.
9
For components that are part of the brightwork, such as
the boiler bands or the dome covers, using real brass offers the best realism. Brass also comes in many forms
and sizes. For example, brass strips can be used for
the boiler bands, and brass sheets can be cut to wrap
around the domes to make real brightwork nish on the
model.
Conclusion
This challenging, unique model semi-kit, when completed, will certainly allow you to own the most accurate
replica of the Santa Fe & Disneyland Railroad CK Holliday available. But more than that, the kit will also allow
you to discover how the real builders constructed the
Other specialized details, such as the bell or the handrail engine, as the model will be built in a similar process,
stanchions, can be adapted from many railroad detail- starting from the frames up.
ing kits. Trackside Details, tracksidedetails.com,
I certainly hope that you'll enjoy the end result as well
offers many detailed parts cast in brass.
as the journey. It is because of your support that this
Painting is somewhat subjective and will depend on one-of-a-kind model can exist, so I hope you'll take pride
the modeler's judgement.
The unof cial Disney- and ownership of it. Now, go make a great model!
6