here are some pictures of my recent constructed overhead system

I think they look too heavy.
A lot of work there!

Dale you're right but the reason I've chosen the thicker wire (0.7mm) is using the pantograph as a power supply the wire 0.3mm didn't have the strength to use the overhead system as a power supply.

John

Edited by user 11 July 2018 10:16:18(UTC)  | Reason: Not specified

It does look a bit chunky, given that you are using thicker wires and doubling up on some places to add mechanical rigidity in the cross span support wiring, etc. But as you mentioned, you need reliable power transfer so providing something less-movable for the pantographs to press against is certainly one way of addressing that power pickup issue. The benefit of the soldered overheads is there should be no transitions that could catch a pantograph in passing and nothing to pop loose of arms, etc.

Not quite, it has to be a 100% clean soldering job (contact wires) as I solder all my wires and construct the overhead system, in a stretch of 500mm there are 5 vertical wires to be soldered, my new method is these vertical wires I bend at both ends to give the overhead more strength and stops breaking in case of an interference from humans. as the wires are 520mm long every end has to be soldered onto the next wire and so on, the same goes for the top wire but has no function as far the running characteristics is concerned, therefore the contact wire has to be absolutely smooth on the bottom surface to avoid any pantograph to catch on it. this is why I clean all the soldering joints after with a Dremel drill accessory tool,.
another crucial point is to have the wire in the right position going from left to right, its not a problem with German pantographs wipers as they are wider then SBB or Austrian wipers and than you have locos which are wobbling from one side to another (I've fixed this by he tightening the housing and bogies (less play),
Over years one learns from the mistakes made in the past and it is now enjoyable to do such a demanding task.

another thing I've found out Sommerfeldt has a 0.5mm wire (previously mentioned a 0.5mm but this should have read 0.3mm) its not copper coated but a grey zinc finish but unfortunately to late as I didn't discover it until recently..
practicality and good looks are not compatible with this type of operation and constructions
the whole set up is rigid but at the same time the tension is slightly flexible

John

Eric,
I do cut them where there is an excessive legnth left over but I don't cut everyone them except at the freight and passenger terminal (my current work on the overhead system) whereas the registration arm (right on the boards edges) interferes with clothes one is wearing (catches it), I've only seen a few prototypical examples whereas the registration arm is cut (at curved sections),

I see what you mean (pictures), just make sure the arm is lined up with the top loop in a vertical line.

I may use a slightly different method, I'll drill the hole for the mast and than use the guide to see where the side holder arm should be soldered onto the registration arm.

John

I think it is so that they only have to make one item. They probably had too many customers needing to return short ones for longer ones, when they used to make long and short versions.

It also allows some flexibility in pole placement. IMHO

Hi,
Its a never ending job with the vertical supports, got another 252 bits to go. 7 within 2 cross spans x 9 tracks x 4 cross spans.
I first solder the upright in the middle between 2 cross spans

Eric, I'm sure the 088 wire is 0.35mm. using so many of the wires it is much cheaper just to buy the wires on its own, in theory yes it would be quicker to buy them of the shelf but in practice I prefer to do it my self. the soldering spots will eventually be filed down and painted so it will not look like blobs of soldering can be seen.
using just the wire I can solder them together at 1.5m length and it doesen't matter where the mast is located, it also diminishes 2 loops at the end of each wire.

John

Eric, this looks very clean and professional

John