Gaiety N2 - pony truck

If you remember the pony truck was missing a wheel. Rather than take the sensible option of just fitting a pair of 12mm wagon wheels (Romford would suit) I decided to turn up a pair from brass. I started by turning two discs to the correct width and flange diameter, drilled 3.8mm for the insulating bush. These were then mounted on a mandrel and a step turned for the tread, leaving .1mm on the dia.;

With my compound slide set to 3 degrees the cone angle was turned on the tread;

After which I profiled the flange using a graver and my watchmakers tool rest, working by eye. Then the recess in the front of the wheel could be turned, to match the original wheel;

Job done;

I chose to blacken the wheels, and I was going to paint the inner face but I like the finish as it is so I've left them in blackened brass. I turned new stepped axles from 3mm silver steel. The original axle was 2.5mm, and a sloppy fit in the pony truck which is drilled, badly, 3.2mm(ish). I could have fitted bushes to the truck, drilled after fitting, and I may yet go back to that idea.

Here's the wheels fitted, with the old wheel and the fixing rivet;

Insulating bushes are turned from Acetal, and I probably should have sourced a length of red to match the old bushes.

The pony really is crude, just a bent piece of metal, surprising really as the company made decent quality die castings;

Here's the truck fitted, with the tension lock coupling attached;

I don't think the new wheels look too out of place.

Pick-ups next, then testing.

Paul.