This thread was started in September, 2013
Karl.A
September 2013 edited July 2021 in O Scale Builds
With the imminent release of the O Scale Sawmill I figured now would be a good time to do some of the ground work in preparation for it’s arrival.
So, here’s the machinery I will be building to install into the mill when the time arrives.
Starting with an overall shot of most of the packages that the machinery arrives in.
As with all of Brett’s castings the parts are incredibly clean and crisp. The intricacy and accuracy of these components is just unbelievable with a level of detail in even the tiniest pieces that blows me away every time I see them.
I haven’t really done anything like this before so it should be a really fun learning experience for me…
Onward…
Feel free to join in if you have a set waiting to be built.
Karl.A
Comments
Jerry
September 2013
I can hear the saw a ripping through the wood now!!! Should be real interesting to see how you do these.
Hell I might even join you!!!
Jerry
Karl.A
September 2013
Thanks Jerry good to have you along. Join on in!
I opened a few of the packages and spent some time blackening the pieces.
This was followed by dips into two containers of water with toothbrush scrubs after each.
The next step is to start polishing some of the pieces to show wear and activity.
As you can see, lots and lots of pieces as I’m sure Joe Morgan can attest to after his recent completion of these machines, in darned fine style I might add.
Karl.A
morganhillrr
September 2013
Hi Karl: Looking forward to seeing your work on these great pieces of machinery. I enjoyed building them and learned a lot along the way. I love your comment about the imminent release of the sawmill…Joe H. in Morgan Hill, CA CCCModOn30
Karl.A
September 2013
Thanks Joe. I’m starting off with the main double husk saw.
Karl.A
Jerry
September 2013
Karl I’m in the process of ordering the wood. As soon as I get it I’ll be with you.
What color stain did you use?
On the above glad your at the helm of the ship!!! I’ll remember to check before moving on.
Jerry
Karl.A
September 2013
Thanks Jerry, I look forward to you (and anyone else) joining in.
Colour is Rembrandt 408.3 washed in with alcohol then lightly wiped off while wet with a clean cloth. This makes the grain pop a little more.
Karl.A
Wes
September 2013
Hey Karl
Great start buddy. Love the wood colouring.
Bill
September 2013
Wow! So much more detail in the O-scale version!
Seeing the little dogs for the log carriage is giving me a flashback. Even in O-scale they’re still pretty tiny!
Looking good, Karl. Are you loving it?
Karl.A
September 2013
Thanks Wes and Bill, yep Bill it’s a great set of kits, enjoying it ALOT.
I spent a few days away working on ‘other’ projects but got back to the machinery this evening.
Not much left to do but a few details, the second belt and the blades. Touch up and weathering of course.
Well I got the saw finished up except that the blades aren’t glued on yet. I want some access to the inside of the saw to place some sawdust before I install it into the mill.
Now to decide which one of these great pieces to build next…
Karl.A
Jerry
September 2013
Excellent job. Real sweet!!!
Jerry
ironmountainlumber
September 2013
Amazing castings and modeling. Everytime I see your modeling it is definitely something to aspire too. Keep it coming!
How is the sawmill coming along? Is there alot of CHB details that Brett has stored away to produce yet?
Jim Richards
Bill
September 2013
Incredible!
What’s the belt material made of? Nice job keeping the slack out of them.
And what is this piece?
Karl.A
September 2013 edited September 2013
Thanks very much for the kind posts, Jerry, Jim and Bill.
Jim, what is even more amazing about the castings is that that is the way they came out of the packet from Brett, no clean up required whatsoever, perfect quality.
The Sawmill is really coming along well, lots of great progress has been made. I’ll leave it up to Brett to post specifics when the time is right.
Bill, I can never remember the name of the stuff, I’ll look it up and let you know tomorrow.
The circled piece is called the ‘slitter’. It is a small disk mounted on the end of a short shaft. The disk (should be) lined up perfectly with the blade. Mine needs to be dulled down somewhat, too shiney.
From what I can understand, as the log travels through the saw (from left to right) the slitter goes between the log and the plank being cut. This will keep the cut open as the log continues to travel and be cut, thus preventing the blade getting ‘sandwiched’ tight and binding up.
Hopefully that made sense, I can post a better pic if you want one..
Onwards with the “Log Carriage”
A great little kit and a lot of fun. Still a few more pieces to add when I attach a log, and the weathering of course.
I started working on the live rolls and dead rolls this afternoon, quite good progress so far.
Karl.A
Jerry
September 2013
Very nice work and detail to those metal parts.
Jerry
Karl.A
September 2013
Thanks Jerry, good to have your support.
Live and dead rolls pretty much done, I need to add the friction drive wheel to the live rolls but that can wait until I install it into the mill floor to ensure it all lines up correctly.
Aside from that all that remains is weathering, I will do this for all machines at the same time prior to installation.
Karl.A
Wes
September 2013
Hi Karl
Another beautiful update. I cant wait to see all the kits together in the final sawmill diorama.
ironmountainlumber
September 2013
Wow! The machinery will look awesome in the sawmill (BTW awesome build on the water tank and fuel tank).
Jim
Karl.A
September 2013
Thanks very much Wes and Jim, great to read your comments. Gotta decide which one to do next now…
Karl.A
James
September 2013
The quality of these kits and your build are breathtaking! Absolutely stunning!
And as always thanks for posting assembly photos - helps to see how the masters do it!
Karl.A
September 2013
Thanks for the kind remarks James, really appreciated.
Next I decided to build the “log Carriage Drive”. This is basically a winch system that drives the log carriage via a cable attached underneath.
The drive is powered by a shaft that exits beneath the main saw.
Karl.A
Jerry
September 2013
Nice one Karl.
Jerry
Karl.A
September 2013
Thanks Jerry, figured I’d do a smaller one for a quick breather…
Now the edger next I think.
The Edger.
Blackened and buffed.
Karl.A
Jerry
October 2013
Oh my God!! He’s alive!!!
Nice start on that edger Karl.
Jerry
Joel
October 2013
Nicely done. What an amazing set of castings. BTW what sort of glue are you using?
Karl.A
October 2013
Yep, I’m still kickin’, thanks Jerry.
October 2013 edited October 2013
Thanks Joel, they really are amazing, and whats even more amazing is that I have only had to file away one small casting mark in the whole process, everything has fit perfectly.
I have used epoxy throughout all of the machinery for metal-metal and metal-wood. I will admit however that I got lazy on this one and used some superglue for the wheels and shafts.
Time to glue everything together. Only the main frame is epoxied at this point, everything else is just ‘sitting’ in place.
October 2013
October 2013
Got this one pretty much ready to go. As with all the others final weathering and touch up will happen after the install.
On to the last one which will be the cut-off saw.
Karl.A
KKarns
October 2013
Hey Karl, The wizard at work…love the subdued green color you’re working with even without final weathering it looks fantastic. Machinery design and fabrication is unreal…Noticed your parts bins with the SierraWest labels…sweet! Ken
Bill
October 2013
Damn, that’s some nice work Karl.
Yet again, the bar has been raised!
James
October 2013
Oh man, that is real nice on the eye! Amazing. I love the paint job too and it looks like you applied it with a brush after at least partial assembly? There is nothing like these kits which comes even close…
On the issue of epoxy- I find sometimes it’s thickness is an issue, particularly in visible locations where it might goosh out a bit. Is there such a thing as thin epoxy in the same manner as ACC?
Karl.A
October 2013 edited January 2021
Thanks very much for the kind words Ken, Bill and James.
The green is bright “Christmas Green” from Apple Barrel craft paints Ken. I like it for machinery and bottles, it dulls down nicely with some chalks..
The bar has been raised ??? Holy cow, I hope they raised the bar stools too. This could be disastrous, I’m only 5’9" !!
Indeed James, the main body was assembled and then painted, once dry the rest of the construction continued.
If you very slightly warm the two parts of the epoxy in the bottles before pouring and mixing they will become thinner James, more watery. I haven’t done this for several years so I’m not sure if it effects curing time. 5-10 secs in the microwave is what I vaguely recall doing.
If you get a little ooze between parts I have learnt from Brett that if you let it dry to a rubbery consistency it is fairly easy to peel off the excess with a toothpick and leave no residue.
We all seem to use a little ‘too much’ glue sometimes, just to make sure it holds well I guess, that’s my excuse anyway, ha.
Moved onto the Mill Engine and Boiler, first layer of paint on the boiler body, a little bit further on the engine itself.
Karl.A
Jerry
October 2013
Nice Karl. Your usual up to expectations.
First coat on boiler Black spray paint???
Jerry
Karl.A
October 2013 edited October 2013
Thanks Jerry,
yep, 99c flat black rattle can . Dry brushed with silver. Chalks will follow.
October 2013
Preliminary chalking complete on the boiler, final touches after the install.
Karl.A
ironmountainlumber
October 2013
Hi Karl,
The machinery and boiler looks fantastic, The wear marks on the machinery look very realistic and placed just were you expect them and the boiler weathering is superb!
Jim
James
October 2013
Awesomely awesome!! The boiler and the mill engine are amazing. Love the dusting on the boiler. Thanks for tips on the epoxy…
PaulSmulders
October 2013
This is amazing Karl, kind of makes me want to switch to O, after I’ve finished the Shipyard … of course. BTW, is that a mirror you’re working on … or a piece of glass with black materal under it…?
Paul
morganhillrr
October 2013
Hi Karl: Excellent work on all the machinery but the weathering on the boiler is just incredible. When I built mine a couple of years ago, I really blew it- too much rust. I was able to recover, but doesn’t look anything like your work. WOW…Joe CCCModOn30
Karl.A
November 2013
Thanks for all the great comments Jim, James, Paul and Joe. I’m really happy with the way the boiler came out.
Paul, I have a large piece of glass inset into my work bench, which theoretically gives me lots of workspace, I somehow always end up working in a 6" area surrounded by clutter.
Bigger desk = Bigger mess.
I got the cut-off saw assembled yesterday. A most enjoyable project. still need to add the belt and dull down the green in a place or two.
Karl.A
Jerry
November 2013
Karl Boiler looks awesome.
Nice clean work area to display another masterpiece of machinery.
Jerry
Wes
November 2013
Hi Karl.
Just catching up after some time away. Wow what a visual feast for the eyes over the last few pages. Stunning stuff.
November 2013
Hi Karl.
Just catching up after some time away. Wow what a visual feast for the eyes over the last few pages. Stunning stuff.
srankin6
November 2013
Karl, fantastic work…I know Bill asked sometime ago what material you are using for the belts,never did see the answer…Maybe I’m blind…could you repost the answer
Thanks
Scott
Karl.A
November 2013
Thanks very much for the great posts Jerry, Wes, Wes, and Scott, really nice to read on my return to the thread.
I decided to take the plunge and have started adding the next layer of weathering to the machinery, namely sawdust.
Still need to add a final layer of super fine dust on top and do a little clean up on some areas such as can be seen below on the levers.
Karl.A
James
November 2013
Very cool. Is the sawdust fixed at all? Sawdust always looks great in sawmill dioramas.
Re: belts- I believe people were talking about various coated papers or mylar as Mr. Doan uses (more durable). I got my hands on some old WSM and CHB machinery kits and the belts appear to be a thin Mylar but haven’t opened the bags yet. The instructions say to buff or polish them. As with any paper, if used, I presume one should use archival or acid free paper…
November 2013
I meant vellum not Mylar
Jerry
November 2013 edited November 2013
I believe Brett uses Tyvek.
Karl nice job with the sawdust. Very realistic looking.
Are you going to do sound will the mill?? Maybe even a little smell of the dust blowing around. I know you can do it.
Jerry
Karl.A
November 2013 edited November 2013
Thanks James and Jerry, good to read your comments.
Brett has used Tyvek in the past as Jerry says. My machinery shown here uses frosted Mylar spray painted with Rustoleum Camo paint colour Earth brown.
Indeed, the sounds and the smell are already figured out Jerry.
Karl.A
srankin6
November 2013
Thanks all on the belt material…Karl,.saw dust looks great…keep it coming
Scott
ironmountainlumber
November 2013
Hi Karl,
Very nice touch with the sawdust. I am really looking foward to the sawmill build.
I really appreciate the amount of time you put into posting and commenting. I still think Brett and yourself need to do a dvd or book on techniques. Hopefully I will someday be able to attend a class at the Modeling Expo.
Jim
Karl.A
November 2013
Thanks Jim, much appreciated.
DVD’s hmmmmm… need some more hours in the day first.
Karl.A
ironmountainlumber
November 2013
I like the hmmmm… may be it could turn into YESSSS!!
Jim
Karl.A
May 2014
Now that the Sawmill has been released and is shipping I can show the installation of the machinery into my mill itself.
Some of the machinery is installed as the floor to the mill is being laid down and the floor is boarded around the machinery.
More of the machinery is installed into the headers after the walls are built such as the cutoff saw and log turner.
The line shaft is also installed at this point.
There are some addition items included in the kit which supplement the line shaft kit to provide power to all machines. This is what we have been waiting on, so, now lets get going…
May 2014
Lets have a quick look at the castings that are included in this incredible kit.
I’m going to start with the metal details as that is specifically what we need at this point. I will however also go through and show the vast quantity of resin castings that are included in the kit.
The details come in the kit box as two separate boxes, one for resin and one for metal. The casting for the concrete boiler base is loose in the box wrapped in bubblewrap to protect it.
Opening the box of metal castings reveals four individual bags of castings. This is great as some specific items have been separated out for you to avoid searching through the large assortment.
The first bag contains the parts for the exquisite wheelbarrow, I love this casting.
The next bag contains the parts used to extend the original dead rolls that was built earlier in the thread. Doubling its length for installation into the mill.
The next bag contains the huge assortment of miscellaneous detail castings.
And when I say huge assortment I mean it !! A variety of tiny hand tools , bottles, clevises, wheels and many more up to the larger castings such as gas tanks.
And of course being SierraWest castings they are all beautifully cast, crisp and clean with no flash.
Finally the bag we have been looking for. This fourth bag contains items to supplement the “Line Shaft Kit” in order to get your mill up and running. It also contains the pipe connectors for the blower ducting to be installed under the mill.
As before, everything is crisp and clean, gotta love Bretts castings, unmatched quality.
Now I have what I need to move forward. I’ll go through the resin castings in the next post just for fun, then box them back up till they are needed.
May 2014
Opening the resin castings box you will immediately notice that it is filled to the top with no fluff or filler packaging, and this is not a small box at 2" deep and 4"x5".
Emptying the casting box is like opening one of Brett’s kit boxes, you take out and look at a bunch of stuff admiring it only to discover more great stuff underneath.
The top layer of the castings box is strewn with drums barrels crates etc. Once you start digging through this initial layer you start discovering the more intricate and exquisite details below.
Once the box is completely emptied it creates a danged impressive pile of resin on your desk.
Now we can spread them out and take a closer look.
Over 95% of the main resin castings in the Sawmill kit are brand new details mastered specifically for this sawmill project
The vast assortment of castings just seems to go on, this certainly wont be a project for a couple of evenings work.
More of the highly detailed details.
Time to pack these back up till later and move forward on the machinery install.
Karl.A
sdrees
May 2014
Karl,
I go along with the idea of a DVD. I live in the Southwest and it would be impossible to attend the Modeling Expo in the East. Say YESSSSSSSSSSS!!!
Karl.A
May 2014
Maybe…
May 2014
The floor joists and beams are assembled over the 24"x36" templates after graining and staining the wood. The legs are then added to this framework.
I’m building my mill to be removable from the base for display purposes so I will be deviating slightly from Bretts excellent instructions in this part of the process.
The floor boards are applied in sections of the mill floor, placing the machinery as you go along for fitment. This creates a logical and very well thought out process which ensures everything fits perfectly.
The finished floor with holes for the saw, live/dead rolls, edger and blower.
Once the floor was completely boarded I went back and added all the cross bracing, extra supports, nbw’s giving plenty of interest to the underside of the mill. This should have been done earlier per the instruction manual.
Now that the floor was done I could move on with installing the machinery.
Karl.A
JohnM
May 2014
Karl, this is exciting to see. Your detailing is of course exquisite. Please continue with the minute details of what & how you are doing things . . .
Respectfully,
John
shay987
May 2014
Looking great ! Wow that is a lot of castings. Can’t wait to see whwt you do with them.
StuartW
May 2014
Karl that is one big structure it looks like a lot of real estate needs to be cleared on the workbench before starting. The shots of the underside show just how much work is involved in this kit (just over 120 legs) I think this is going to be a very long term project when mine arrives. What colour did you use on the strip wood as it looks great.
brownbr
May 2014
Floor looks great. Did you use the rubbing chalk method described in the manual? If so is it possible to get a super close up of one of the boards?
I notice that you did not accomodate an elevation change with your piers. How will you address the log rollway? Will this create any problems with the height of the boiler under it’s cover?
LSNRwyAl
May 2014
Fantastic Karl.
Ojaste
May 2014 edited May 2014
Karl, it is looking great. It is massive. Must be tough keeping it flat.
I love the dock colors! Which chalks did you use?
Marty
Karl.A
May 2014 edited May 2014
Thanks for all the replies guys, its great to read them all.
John M, I will keep you informed throughout..
John 987, I’m certainly looking forward to doing them also, the variety, quality and opportunities keep me motivated.
Stuart, this is indeed a BIG kit, but don’t let that daunt you, it has been so well engineered and designed for the modeler that it is a pleasure to build. The strip wood on mine so far is all 408.5 and 408.3.
Bryan, I used all the techniques as described in the manual in my build. I will get a close up of the boards for you in the next day or so, Brett’s rubbed chalk effect is superb, well worn and smooth, depicting plenty of foot traffic and age.
My ground elevations will remain the same as designed, thereby not effecting the boiler area. Originally my piers on the opposite side of the mill did not accommodate the elevation change so that the structure could be removed from the base and stand alone on a flat surface (there would be holes in the contoured base to accept the piers). I have since decided this was unnecessary and cut my piers accordingly.
Marty, working on a level surface (glass work top) keeps it perfectly flat throughout with no problems, and yes, it is massive. The only chalk used so far is 408.5 and 408.3.
Thanks again.
Karl.A
Jerry
May 2014
Nice coloring Karl. Very nice joinery.
Jerry
brownbr
May 2014
thanks for the close ups. It looks great. I’m going to give it a try.
JohnM
May 2014
Karl, I am looking over and over and have concluded that you are going to be painting castings for the rest of your life - I see no time available to build . . .
John
Karl.A
May 2014
Thanks for the comments Jerry, Bryan and John, most appreciated to see them.
Indeed John I will hopefully be painting castings for the rest of my life, however they wont be for this kit… 
Using the techniques I outlined in the detail painting thread the process will go quickly for this vast amount of castings. We will find out next week…
May 2014
The next picture is a good shot showing some of the components that were installed into beams and joists BEFORE the floor was added and how they look now with the floor in place.
The first shot shows the rail risers that the log carriage rolls on. Below this you can see the cable sheaves at either end and the drum in the center which connects to a drive shaft coming from the double husk saw. These components make up the carriage drive system.
Behind the carriage, incorporated into the floor joists you can see the drive wheel for the live rolls and the shaft leading to the friction rollers which power the live rolls.
The second shot you can see the blower and blower ducting which runs under the saw and other areas of the mill. This is also connected to and driven by the double husk saw on a separate drive shaft to the carriage.
The detail is starting to build up as one layer is added ontop of the previous layer in construction. The manual takes you step by step through these layers which are incredibly straight forward to build by themselves. But once you start putting them ontop of one another the intricacy and detail is amazing.
This layering philosophy is carried throughout the entire structure resulting in an incredibly well designed and developed kit which is very enjoyable to build.
The floor is then constructed in sections around the machinery and head frame.
Once the floor is completed the edger can be added over the hole. Ducting runs here under the floor. Sawdust from the edger falls into the hole and is sucked through the duct pipes to the sawdust bin. I don’t have a pic of the edger in place unfortunately.
My live rolls and dead rolls were only lightly tacked in place while I was building the floor around them.
I did this so that I could remove the assembly and show here how the friction drive operates in conjunction with the rolls.
The rolls are now glued in permanently, and yes, I have since touched up the shaft where the black came off.
With the machinery now set permanently in place and the floor complete the next steps will be to build the walls and headers.
Karl.A
BrianM
May 2014
Karl, thanks for your ongoing description of the various pieces of machinery, how they function and the construction steps to put the whole lot together. I was very impressed when I saw the pilot model at EXPO 13 but until now I did not really appreciate the extent of the not-so-visible details and huge number of components involved. I really appreciate the time you are taking in posting your progress photos and invaluable advice.
What a kit!
I’m not into O scale so I really look forward to getting my HO version of this mill and hope that in its own way it meets my expectations set by it’s big brother.
Karl.A
May 2014 edited May 2014
Thank you indeed for your comments Brian.
I was really hoping that by taking some extra time and showing and explaining some of the not so visible aspects of this kit that modellers would be able to see and appreciate just how incredible it really is.
Your comments have encouraged me.
Brett’s kits always exceed expectations, you know that.
Karl.A
morganhillrr
May 2014
Hi Karl: Total agreement with Brian, your detail posting and photos are terrific and certainly will aid me when I begin construction. Weathering on the floor boards is excellent…Joe CCCModOn30
JohnM
May 2014
Exquisite Karl . . .
Respectfully,
John
Karl.A
May 2014
Thanks Joe and John, great to have you reading along, your comments are appreciated..
May 2014 edited May 2014
The stripwood for the walls is coloured using the same techniques from the manual and as everything is ‘under-roof’ my colour tones remained the same as for the floor and subfloor.
The walls are assembled over full sized templates and the use of Bretts cutting jigs ensures that all of the angles are nice and tight for the bracing and main supports.
Once the main walls are assembled the first wall is epoxied to the deck with the aid of more templates for positioning and the use of ‘squares’ to ensure it is true.
The rest of the walls and headers are based from this wall ensuring that everything will line up perfectly. A surprisingly simple and very effective system of construction.
The walls in place with the main headers installed.
Cross bracing and NBW detail is added to these walls during construction, this adds another layer of detail to the walls while they are easily accessible, building on the overall impact.
NBWs are also added to the backside of bracing to increase the realism.
Additional cross headers are added during construction which will support the belt drive system and drive shafts.
Cut off saw, shafting and more layers of detail to follow.
Karl.A
morganhillrr
May 2014
WOW! This just gets better and better…Joe CCCModOn30
Ojaste
May 2014
Ditto. Karl, did you epoxy or use white glue to attach the posts to the decking?
Marty
BrianM
May 2014
I really like the color you have chosen for the wood with the subtle variations but overall harmonized consistency.
Did you use any pins on the joints where the main cross members intersect the wall header beams and where the stringers intersect the main cross members?
srankin6
May 2014
Karl,
All I can say is absolutely FANTASTIC,just wish I had the room! Keep up the great blow by blow.
Scott
brownbr
May 2014
Are you going to light it?
Karl.A
May 2014
Thank you for your comments guys, they are very appreciated. Those of you that share your builds with us here know how encouraging it is to receive some feedback and a simple comment. It is very rewarding to know that others are following along.
May 2014 edited May 2014
Thanks Joe, the layers of the kits design are starting to build on eachother and show what a masterpiece this is.
Marty, the wall frames all used wood glue in their construction and were then epoxied to the main floor. Because the construction of the walls themselves follow the prototype structure they are very stable and strong. In the model world epoxying them to the floor creates an extremely rigid structure when they are all connected together.
Thanks Brian, I wanted a woody colour for the interior, the greyer sunbleached tones will show more on the exterior components. There was no need for pins or extra stability, the structure is very strong.
Thanks Scott… make room!
Bryan, yes it will be lit, I have already mocked up the trusses and determined how the wiring will be hidden and how the lights will be realistically hung. You may have to wait a week or two to see it, but, the structure has been lit, the plans laid and the tests fully completed… The structure needs to be shafted and detailed before we can get to the final install of the lights though.
Talking of shafting… that will be my next update. Thanks again to you all for your comments.
Karl.A
StuartW
May 2014
Karl thanks for going into such good detail as to how all the machinery all links together. It will be most helpful when I get to that stage (in the far distant future) and have to install all that machinery.
Please do not hold back on the details of how you install your lighting as it will make a huge impact on the mills appearance by highlighting all the interior detail that Brett has put into the kit.
JohnM
May 2014
Oh my gosh, it’s really coming to life now Karl!
Respectfully,
John
Karl.A
May 2014
Using the full sized templates I cut all the shafts for the overhead drive system. I then blackened all of the required pillow blocks in preparation for the install.
I laid out all of the shafts and blocks in their respective positions to make sure I hadn’t missed any or made any mistakes. Some shafts are still a bit long at this point and have not been cut to final length.
The manual explains a great technique using reversed clothes pins to hold the shafts in their final position below the headers.
Using the clothes pins and a square as described in the manual ensures that everything lines up perfectly, both with the machinery and each other. A great and hassle free method.
The pillow blocks were then epoxied and clamped in place and left to dry. Even though I used 5min epoxy I left it for a good two hours before ‘fiddling’ with anything.
The first four pics are pretty accurate of true colour incidentally.
Karl.A
Ojaste
May 2014
Karl,
You are just moving along so quickly. I guess it shows how good the kit and construction manual is; or how very talented you are.
Marty
Karl.A
May 2014
Thanks Marty much appreciated. I would say both, the kit and construction manual are exceptional, and I guess I do have some talent.
As for the ‘speed’, keep in mind these are ‘recap’ photos, I’m not posting “as it happens”, yet.
Very shortly though the pics will have caught up to where I actually am.
Karl.A
brownbr
May 2014
excellent progress.
JohnM
May 2014
Beautiful Karl . . .
John
Coors2u
May 2014
Incredible work Karl.
shay987
May 2014
Looks great !
Karl.A
May 2014
Thanks for posting guys, the comments keep me motivated and wanting to spend the time to show more, they are greatly appreciated.
Karl.A
LSNRwyAl
May 2014
Your usual beautiful work. Thank-you for the pics and words.
brownbr
May 2014
I’m curious if you have figured out your approach on the lights. How to mount and how to hide the wires.
Jerry
May 2014
Karl what can I say. Beautiful work. And your wording on how you do it exceptional.
Jerry
StuartW
May 2014
Making great progress Karl.
Great shots of the line shaft install, I might offer to put out the next load of washing so I can pocket a few pegs
Wes
May 2014
Looks perfect from my side of the pond Karl.
waynelp
June 2014
I looked at the pins (clothes) and it took me awhile to figure out what I was looking at. I spent the next few minutes reversing a hand full of pins for my use. I had always used them the “correct” way with not much luck. They work Grrrreat this way. Thanks for the Pictorial tip,
Karl.A
June 2014 edited June 2014
Thanks for the great comments Alan, Jerry, Stuart and Wes. They will come in very useful Wayne in many situations.
Yes Bryan I have the lighting figured out and have built a mock up to check it works.
The next step was installing the shafts, wheels and belts. This was one of the moments in my build that gave me a “wow” feeling. After a few hours modelling following the instructions you lean back and look at where those steps led.
And then I just sat back and smiled…
Onto the maintenance shed, storage room and sawdust bin.
Karl.A
shay987
June 2014
You can almost hear the gears turning and the belts flapping. Nice work !
StuartW
June 2014
What a huge difference the line shafts make to the appearance.
This project just gets better with every new step.
Keep up the great work.
morganhillrr
June 2014
Watching you build this kit is just amazing. Your photos are terrific and will certainly help us modelers who will build this kit…Joe CCCModOn30
Jerry
June 2014
One word comes to mind. Exceptional!!!
Jerry
KKarns
June 2014
Karl, of course you smiled, that’s one fantastic piece of work my man! The line shafts and belt treatment are suburb. This is one monumental kit you and Brett developed, it oozes quality and craftsmanship. Can’t wait to see more and what a treat to see other quality builds of this kit going on at the same time…
Ojaste
June 2014
Tempting, very tempting.
KKarns
June 2014
Marty, I can’t keep up with your modeling pace as it is…now the Sawmill? Hard not to get hooked on this one!
brownbr
June 2014
Very impressive. I’ve been thinking about the differences of working on this model planted as mine is or loose as yours is. I’ve come to the conclusion that I would be scared to death working on it loose. It’s very large and heavy I can just see it cracking in half any time it gets moved.
Wes
June 2014
Ive seen better. Nooooooooot.
Beautiful fantastic realistic stunning work Karl. WOW
Karl.A
June 2014
Thanks for all the great comments and compliments everyone they are greatly appreciated.
Come on Marty, join in. I’ve said it before and i’ll say it again, this kit makes an incredible stand alone diorama to show off if you are a HO guy.
Indeed Bryan a lot of care is being taken. It is sitting loose on a piece of blue foam so it is not too bad in the scope of things.
Thanks again, guys,
Karl.A
waynelp
June 2014
This would be a lot of work and overkill on details, but, would the rafters, joists and such be held together by “t-brackets” (simpson strong ties) ? I have always tried to make some and put them on other projects when the look is needed. Or just long lag bolts thru the wood beams to hold together. I am just wondering if it would be worth it or too much little detail to work with.
Karl.A
June 2014
Finished the basic construction of the walls for the storage room and maintenance area.
(not glued in yet)
Karl.A
June 2014 edited June 2014
Time to move forward and start getting some of the castings started.
There are some amazing castings in this kit (as with all SierraWest kits).
One of the casting innovations is the combination of cluster castings such as these below, and the extensive use of individual items (to be shown later)to create incredible, realistic detailing.
The castings below will primarily be used on the shelves in the ‘store room’. Because this will be a low visibility area the use of these castings is perfect. They aid the modeler in creating a highly detailed scene while simplifying the process in an ‘out of the way’ area.
Extra time can then be spent on the individual items and extreme realism for the castings which will be placed in highly visible areas and up front.
As shown earlier in the thread, below is only a tiny sample of the castings included in the kit. I will be working on the castings a few at a time throughout the remainder of the build.
Castings spray primed with rustoleum khaki.
Onto the chalk colouring.
Karl.A
brownbr
June 2014
The walls look good. The framing is very precise. It’s not always easy to cut them on a template to fit that way.
Karl.A
June 2014
Thank you Bryan.
June 2014 edited June 2014
Karl.A
ironmountainlumber
June 2014
Hi Karl,
Absolutely an amazing kit. I am really enjoying looking at the pictures bryan and yourself are posting for all of us to marvel at. The amount of detail is superb and your building techniques are impecable. I am certainly aspiring to get to the level of building you are doing. Looking foward to more!
Jim
Karl.A
June 2014
Thanks Jim, it is indeed an amazing kit.
Time to take a break from the yard work and work on a few more of the castings.
Karl.A
JohnM
June 2014 edited June 2014
Karl, you are a man of energy! Thank you for showing the detailing . . .
Respectfully,
John
Karl.A
June 2014
Thanks John…
Moving on to a few of the more intricate details.
Most of the empty spaces on some of the benches and cabinets will be filled with individual details later.
Progress…
Such an amazing collection of details already and still plenty more to do..
Karl.A
Ojaste
June 2014
Karl,
You are truly an artist. Only if you could bottle it up and sell it. Oh, wait maybe you could…
Marty
brownbr
June 2014
Nice job on the details
Coors2u
June 2014
Castings look fantastic as always Karl.
Ojaste
June 2014
Karl, how about doing a video or two on painting a casting? It would give a chance to look over your should while you do your work. You don’t have to talk and we promise not to interrupt you. I wonder how many more castings in our kits would look better?
Just an idea.
Marty
morganhillrr
June 2014
Looking great Karl. I have to admit finishing castings is not my favorite part of kit building, but is absolutely mandatory to be done correctly (like yours). It’s all in the details…Joe CCCModOn30
Wes
June 2014
Beautiful Karl. How about showing us one of your screw ups sometime so we know you are human.
Keep up the good work my friend.
admin
June 2014
It’s pretty obvious Karl NEVER screws up and is most likely an alien…
Wes
June 2014
It’s pretty obvious Karl NEVER screws up and is most likely an alien…
HAHA. Brett I think you are right. His modelling is out of this world.
Karl.A
June 2014
Thanks for all the great comments guys, they are really appreciated. I should be getting back to some more progress over the weekend.
Karl.A
Jerry
June 2014
Yes Karl your doing a exceptional job on this model.
Jerry
Karl.A
June 2014
Thanks Jerry, great to hear from you. Call me soon!
As always I’m just following the instructions.
Karl.A
davej
June 2014
Hey Karl
looking fantastic, really enjoying watching this grow.
cheers
Dave
Karl.A
June 2014
Thanks Dave.
JohnM
June 2014
Oh boy, Karl, wonderful. There are so many pieces that are a great reference on “how to do it”. Thank you for the pictures and comments.
Respectfully,
John
kebmo
August 2017
how did this movie end?
Karl.A
August 2017
Thanks for your interest and pulling this thread back up Kevin…
Actually it never ended, its still sitting on my “almost but not finished yet” shelf..
After a couple of years of not modelling I’m not ready to go back to it yet, but,
my woodcutters shack thread will hopefully get a re-appearance in the very near future,
just a few details and the scenery to do on that one to pull it all together and move it to the “finished” shelf.
After that, who knows…
Karl.A
trains4ms
August 2017
I don’t mean to pry, but you are such a great modeler, I hope that whatever caused you to stop has passed, and you will be able to get back into it soon.
Mike S.
Joel
August 2017
Here, Here!
Jerry
September 2017
Sure would be nice to see you back at it again!
Jerry
Karl.A
September 2017
Thank you all for the encouragement, it is very appreciated.
After my Wood Cutters Shack is finished the sawmill is on a short list of three to finish next. I haven’t decided the order yet. All in ‘O’
Sawmill is 70% done
Bluesky is 50% done
LocoShop is 50% done
Currently the sawmill is favorite.
Karl.A
EricMG
January 2019
Has there been any progress? Since I’m in the saw mill business now, I’m extra interested.
Karl.A
January 2019
No, no progress yet eric. I’ll be working on some smaller projects before I do any big ones.
TomMich
January 2019
Karl,
Love following along while you share your amazing builds. One thing you missed in this build when opening the resin casting box was the unmistakable aroma of the resin castings. It is a distinctive smell and all part of the Sierra West experience! I confess I am a casting junkie, and Sierra West castings are by far the best!
vietnamseabee
January 2019 edited January 2019
Tom…I bet you used to like the ‘aroma’ of Floquil paint as well ;-))
Terry
TomMich
January 2019
Terry, I miss that! But nothing beats the smell of opening a box of SW resin castings!
Karl.A
January 2019 edited January 2019
Thanks so much for your kind words Tom , it’s so great to hear/read that people enjoy my threads and get something from them.
Unfortunately Tom when you’re around that resin smell 24/7 for a long period of time your nose becomes immune to how wonderful it is. Lol.
However, fortunately the eyes never become immune to how amazing, crisp, clean and perfect they are.
Indeed the best by far you will ever get, and the most plentiful.
Karl. A
Pappy
April 2021
Would love to build this kit but almost $1k to purchase all Parts 1,2,3…maybe some day when I collect enough plastic bottles and cans…lol
Great work Karl as always!!
Karl.A
April 2021 edited April 2021
Thanks Pappy, this is definitely the most incredible sawmill kit that has ever been offered to the modeling community.
I’ll be getting back to it later this year to finish it off. Quite a few other smaller builds first though.
Every modeller I’ve spoken to who has built this monumental kit, (or just bought this kit and looked in the boxes) has said the contents of the boxes far exceeded their expectations.
I look forward to your comments when I get back to posting progress in a few months and hope you enjoy seeing what I do with this masterpiece.
CraigH
April 2021
you must model 8 to 10 hours a day to get as much done as you do…is Brett paying you buy the hour.
brownbr
April 2021
Agreed. A great build. Would love to do it again some time.
EmeryJ
April 2021
Truth be told, I searched a long time for a sawmill. I kept coming back to this model, as it is the very best available. This was my introduction to Sierra West. I dont yet have the kit, but that is ok. Brett is smart to start me off with some “less challenging” kits.
KKarns
April 2021 edited April 2021
Nice story Emery…same thing with Ho/HOn3…Brett’s iconic Deer Creek Sawmill is without question the finest 1:87 scale sawmill of all time!
kebmo
April 2021
maybe after we close on our refi…
Robert.G
April 2021
The O scale Sawmill Project, like I said before, The Mother of all Kits… It gave me a year of modeling fun.
admin
April 2021
A year of modeling fun! We had a great time watching your efforts as well…
KKarns
April 2021
That’s for sure Brett…what a treat it was to see Roberts stellar build of your wonderful Kit…
Robert.G
April 2021
For those not familiar with this build, here it is..
Alan_H
April 2021
That’s an amazing kit and build.
KKarns
April 2021
I still have pictures of it on my Mac desktop!
Robert.G
April 2021
Well worth every penny. !!!
vietnamseabee
January 2022
Another “old” thread I’ve been reviewing. I’m building a “Brand X” sawmill with “Brand X” interior equipment as a tune-up to building Brett’s O Scale sawmill which I have on order and anxiously await.
As far as this HO modeler ‘going over to the dark side’, there is no “dark side” for me. Until I get an HO layout up and running, I find enjoyment and relaxation merely in modeling regardless of the scale
Terry
randyp
January 2022
KKarns said:
Hey Karl, The wizard at work…love the subdued green color you’re working with even without final weathering it looks fantastic. Machinery design and fabrication is unreal…Noticed your parts bins with the SierraWest labels…sweet! Ken
Great work Karl. I to love the green color. Can you name the brand and color? Or is it a custom mix. I have all the original CHB machinery and some day want to build a machine shop and like that color. Thanks Randy
Karl.A
January 2022
Thanks Randy,
The green is “Christmas Green” by Ceramcoat … Craft paint.
Jim M
January 2022
Karl, I’m impressed that you remember that color or that you take great notes. I can’t remember what I did yesterday.
The sawmill is fantastic. Maybe this should be my next project.
Karl.A
January 2022 edited January 2022 172.58.142.195
Thanks so much Jim,
It’s an amazing kit and incredible fun to build.
This is due not only to the quality of everything Brett does with design, castings and components in the box, but also the way the build is structured and described in the amazing manual, guiding ANY modeler to easily build this kit through the layers of construction.
Get it now if you haven’t already !!
I wish I was impressive, but, I have to admit that the green is still on my desk and is still my standard colour when painting machinery or castings, so, no memory needed… 
admin
January 2022
and Karl should not be modest. We designed this kit together and built the pilot model together. It is as much his “project” as mine.
randyp
January 2022
Again Karl beautiful model work. I want to also think you for posting the pictures with the clothes pens clamps. I needed to see them in order to make them. Did eight in about ten minutes. Thanks, Randy
Jim M
January 2022
Karl, I do have the sawmill. I just need to decide if I want to tackle that big project now or maybe an easier/smaller one after my O’neill’s. Decisions, decisions.
Robert.G
January 2022
Begin when you feel ready for it. It is a huge building project and you have to keep your head with it. I enjoyed looking in the box , taking everything in it out , admiring it, putting it back on the shelf, reading the manual, reading it again, and again for months.
Just knowing I had this wonderful kit within reach, that it was mine, gave me already satisfaction. So when you’re over this mental phase of preparation, attack the build.
And know that this forum is as useful as the manual.
geoawelch
January 2022
Very sage advice, Robert.
Cheers,
George
Karl.A
January 2022 edited January 2022
Thanks Brett and Randy,
probably the best, most enjoyable 2+ years of my modelling, a great time.
Randy, dont forget to make a couple of my corner braces too, now that you’re almost ready for your wall assembly on the truck repair.
Great words Robert,
also remember Jim there are a few smaller components that can be done separately before the main build.
Looking over at mine I see…
The machinery obviously can be done at anytime, if you havent already.
The sawdust bin is a great little model all on its own you can build.
The log rollway can be built.
And of course the many details can be done in small sections and put away ready to be installed.
Those are some smaller items to get you started before jumping into the main build.
Enjoy !!
vietnamseabee
January 2022
Karl…if it’s not inappropriate I’d be interested in the ‘back story’ of how you Brett (and Kevin O) got hooked up/got to know each other
Terry
kebmo
January 2022
vietnamseabee said:
Karl…if it’s not inappropriate I’d be interested in the ‘back story’ of how you Brett (and Kevin O) got hooked up/got to know each other
Terry
i second that.
kebmo
March 2022
this thread will be my guide post when i start this kit.
Karl.A
March 2022 edited March 2022
Thanks Kev, I hope this thread helps you out along your great journey with this amazing kit.
Remember though that my floor layout/outline shown here is slightly different to the final version that comes in the kit. We adjusted it and rebuilt it again a fourth time during development after this floor build, to get perfection for the actual kit. So, don’t use my layout/placement as a reference.
I think the final kit is an inch longer combined with a slight layout adjustment at the storage/office area if my memory serves me right.
At the time I decided I could ‘adjust’ this version and carry on with it for myself, while we finalized, rebuilt and adjusted the final version for the actual kit.
I guess I need to get back to this soon, it keeps calling out to me…
kebmo
March 2022
Karl.A said:
Thanks Kev, I hope this thread helps you out along your great journey with this amazing kit.
Remember though that my floor layout/outline shown here is slightly different to the final version that comes in the kit. We adjusted it and rebuilt it again a fourth time during development after this floor build, to get perfection for the actual kit. So, don’t use my layout/placement as a reference.
I think the final kit is an inch longer combined with a slight layout adjustment at the storage/office area if my memory serves me right.
At the time I decided I could ‘adjust’ this version and carry on with it for myself, while we finalized, rebuilt and adjusted the final version for the actual kit.
I guess I need to get back to this soon, it keeps calling out to me…
i thinki can speak for everyone when i say we can’t wait for that. i think i just heard it calling out to you..