-
R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA
SCOTIA kit #RLW-1650
© 2021 Republic Locomotive Works 1650 – pg. 1
HISTORY:
From the Sherbrooke Village Museum, Nova Scotia website
( https://historicnovascotia.ca/items/show/224 ):
“The first sawmill in the Sherbrooke area was erected around
1809 by
James Fisher, who came from Truro in 1805. In 1814, another
sawmill and a grist mill were set up by David Archibald III,
also from
Truro, at the site of present-day Sherbrooke.
The year 1826 marked a unique development in Sherbrooke’s
sawmill
industry. William Thompson Archibald, son of David Archibald
III,
and Henry Cumminger entered into an agreement to erect a
double
mill at the southern end of the village, now part of the
Sherbrooke
Village restoration area. With this agreement, the Archibald
mill was
relocated to its new home and a second set of machinery was
installed
by Henry Cumminger. To supply power for the water wheels, they
also
dug a canal, which ran from Sherbrooke lake to St. Mary’s river
and
was approximately 260 metres long, 3 metres wide, and nearly
5
metres deep.
By 1856 ownership of the double mill was acquired by the
McDonald
Brothers. By 1900, however, the mill was abandoned and allowed
to
fall into ruin. For many years, nothing remained of this once
active industry except the hand-dug race, which assumed the
character of a
natural outlet from Sherbrooke Lake.
In 1970, when restoration work commenced on a part of the
village of Sherbrooke, transforming it into a typical 19th century
Nova Scotia
community [https://sherbrookevillage.novascotia.ca/] the
decision was made to reconstruct a working replica of a
water-powered, up-and-
down sawmill on the site of the former McDonald Brothers’
mill.
The sawmill building is a two storey structure with hand-hewn
post and beam
construction and board and batten exterior cladding. The roof is
covered
with long board shingles with 40-centimetre exposure to the
weather. The
lower storey contains the belt and pulley gear for the mill, and
provision is
made for a shingle mill and other woodworking equipment.
Upstairs is the
log carriage and up-and-down saw with their simple but
ingenious
mechanisms…. With a bountiful supply of water from a chain of
five lakes,
the reconstructed McDonald Brothers’ Sawmill is believed to be
the only one
of its kind in Nova Scotia capable of full waterpower
production.”
The Up-Down sawmill (also called “frame sawmill”, “English gate
sawmill”,
“upright saw”, or “sash sawmill”) is a mechanical application of
its hand-
powered predecessor, the Pit Saw. A crank driven by the
waterwheel moves
the saw frame and single saw blade in an up and down motion,
cutting into
the log on each downward stroke. The up-ward motion of the saw
is also used
to move the log carriage forward by means of a system of levers
and a
ratchet. Several minutes are required for each cut through the
length of an
average log.
For additional exterior and interior photos, see:
https://www.republiclocomotiveworks.com/show_item.php?ID=1338
GENERAL:
This is a craftsman kit consisting of laser-cut wood and paper,
cast urethane resin, white metal, 3D printed acrylic plastic parts,
brass wire,
embossed foil, and paper templates. (See “Parts Identification”
for images of included parts):
Some resin castings may contain minor flash or small bubble
holes. Otherwise, good castings will NOT be rejected for small
flaws; it is
assumed the modeler will have the skill to fill these small
flaws. Finishing recommendations are included under “WORKING
WITH
RESIN CASTINGS” below.
The laser-cut wood parts include many very thin parts; handle
carefully. Also, three thicknesses and two types of wood materials
are
used for the laser-cut parts: 1/64” (.016”) plywood, 1/32”
(.032”) plywood, and 1/16” (.063”) bass wood. The latter is not
plywood, and
Reconstructed McDonald Brothers Sawmill, Sherbrooke Village,
Nova Scotia – photo by Marshall Thomson
Interior of reconstructed McDonald Brothers Sawmill,
Sherbrooke Village, Nova Scotia, showing vertical saw and
log
carriage – photo by Marshall Thomson
https://historicnovascotia.ca/items/show/224https://sherbrookevillage.novascotia.ca/https://www.republiclocomotiveworks.com/show_item.php?ID=1338
-
R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA
SCOTIA kit #RLW-1650
© 2021 Republic Locomotive Works 1650 – pg. 2
care must be taken not to break these parts. Finishing
recommendations are under “WORKING WITH LASER-CUT WOOD” below.
The 3D printed parts are an acrylic plastic. While strong, these
are not as strong nor as flexible as the engineering plastic or
styrene you
may be used to working with. Carefully remove parts from
attached sprues. Parts should be carefully washed with isopropyl
alcohol or
mild dishwashing detergent before painting with acrylic
paints.
Every different procedure or method is discussed in detail in
the instructions; however, once it has been discussed, it may not
be repeated in
detail again.
This kit is not intended for use by novice modelers, or
individuals under the age of 18 without the supervision of an
adult. Additionally,
the modeler assumes all liability regarding the proper use of
this product, or any product suggested. The user must become
familiar with
the kit instructions, and instructions on any product used to
complete this kit. Please read and follow all safety procedures for
all products
used to finish this kit. Details may vary between scales and
from the sample model shown.
Follow safety requirements and manufacturer’s requirements as
stated on all paint, chemical blackener, and adhesive
containers.
WARNING: Pursuant to California Health and Safety Code section
25249.6, the manufacturer and distributor of this product
warns you that this product may contain substances known by the
state of California to cause cancer, birth defects and/or
reproductive toxicity.
Tools & Materials:
small drills, including #80, #76, #67 clips for holding parts
together – Mueller Electric BU34
flat file - Nicholson 6" Mill Bastard magnification such as
Optivisor or Edroy Opticaid
small files - Micro Mark #83180 paint brushes and air-brush
model building knife – Xacto or equal, with #11 blades paints –
see detailed instructions
finger-nail clippers or Xuron flush rail cutters Rustall and
Weather All (www.rustall.com )
Tweezers and smooth-jawed needle-nose pliers adhesives – 3M 77
Spray Adhesive, CA, 2-part epoxy, Sanding board (make by gluing
sandpaper to piece of wood)
Rotary cutter – Olfa, Excel or equal Pliobond, and Titebond wood
glue, Pacer Canopy Glue
glues: 3M 77 Spray Adhesive; CA; carpenter’s or “white”
glue;
Optional:
Water Wheel and Sound Animation kit (RLW #1651)
logs – Details N Scale
outhouse(s) (RLW-211N – includes parts for two outhouses)
figures
horse-drawn wagons – Musket Miniatures, Langley, Republic
Locomotive Works, Preiser
miscellaneous details: tools, etc. – Republic Locomotive
Works
miscellaneous scenery materials to complete scene
Order of Assembly
The instructions are arranged as follows:
• Water Wheel & Motor Mount
• Laminations
• Base and Basement Level
• Upper Stories
• Water Wheel Flume
• Roof
• Interior Details
• Ancillary Structures: Drying Shed, East and West Bridges;
Sawdust Bin and Conveyor; Sawn Lumber Conveyor
• Finishes (this section will be referenced in above sections as
appropriate to assembly sequence.)
• Site: Dam, Bridge Abutments, Log Dump (with terrain
suggestions) (NOTE: Instructions for assembly of Water Wheel
Animation, and Sound Animation add-on kits are included with those
add-on
kits; important aspects of interfacing these add-on kits with
the base kit are included in the sections above.)
Orientation
Throughout the instructions reference will be made to the
cardinal reference points of the site: north, south east and west.
These
references will be included in parts identification on the
laser-cut sheets and in the parts list, and are also scribed on
part B.39, the
Sawmill Base.
http://www.rustall.com/
-
R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA
SCOTIA kit #RLW-1650
© 2021 Republic Locomotive Works 1650 – pg. 3
Parts Identification
A Parts List is included as a separate document in the kit box.
The following diagrams and images are provided to aid in
visually
identifying parts.
Laser-Cut Parts Frets: Parts are organized by material and
thicknesses, with a letter code designating material and thickness,
followed by the part number. The different materials and
thicknesses can be identified by the following codes:
A.## 1/16” Basswood C.## 1/64” Plywood E.-## Peel-and-Stick
Paper Trim B.## 1/32” Plywood D.## 1/64” Laser Board F.-## Clear
Glazing Material
The following images of each of the laser-cut sheets can be used
as a way to identify part locations; it does not represent the
order of
assembly, and the sizes shown herein are not necessarily
reflective of the relative sizes of the actual sheets.
SHEET 1 – 1/16” BASSWOOD
SHEET 2 – 1/32” PLYWOOD
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R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA
SCOTIA kit #RLW-1650
© 2021 Republic Locomotive Works 1650 – pg. 4
SHEET 3 – 1/32” PLYWOOD
SHEET 4 – 1/32” PLYWOOD
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R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA
SCOTIA kit #RLW-1650
© 2021 Republic Locomotive Works 1650 – pg. 5
SHEET 5 – 1/32” PLYWOOD
SHEET 6 – 1/64” PLYWOOD
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R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA
SCOTIA kit #RLW-1650
© 2021 Republic Locomotive Works 1650 – pg. 6
SHEET 7 – 1/64” PLYWOOD
SHEET 8 – LASER BOARD
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R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA
SCOTIA kit #RLW-1650
© 2021 Republic Locomotive Works 1650 – pg. 7
SHEET 9 – PEEL & STICK PAPER SHEET 10 – CLEAR GLAZING
MATERIAL
Resin Castings:
3d Printed Parts: (Note:3D printed parts are supplied joined
together as one piece and must be carefully cut apart with a razor
saw or
jeweler’s saw.)
Other
Also included are:
0-80 flat-head screws (2 each) Laser-cut roof shingle
material
1-72 screws, nuts and washers (2 each) Ladder stock
Brass wire Misc. SS Etched Logging & Sawmill Tools
Cut Lumber Misc. White Metal Detail Castings
Working With Laser-Cut Wood
The laser-cut sheets may look like pieces are missing, but these
holes are intentional. The opening for windows, doors, etc., are
removed
by the laser to make building this kit easier. These waste
pieces, called drop-outs, may still be clinging to the sheet, and
fall out when
touched. Save them for use as clutter and scraps when doing the
final detailing.
The laser-cut wood parts include many very thin parts - handle
carefully. Three thicknesses and two types of wood materials are
used for
the laser-cut parts: 1/64” (.016”) plywood, 1/32” (.032”)
plywood, and 1/16” (.063”) bass wood. The latter is not plywood,
and care
Dam & Spillway Log Dump West Bridge East Bridge Abutment
Abutment
Water Wheel
Water Wheel Mount*
(Use if NOT installing motor.)
Water Wheel End Support
Carriage
Winch
-
R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA
SCOTIA kit #RLW-1650
© 2021 Republic Locomotive Works 1650 – pg. 8
must be taken not to break these parts. Remove the pieces from
the carrier sheets with a sharp hobby knife as they are needed, and
lightly
sand off the remainder of the tabs. On the thicker pieces, there
is a slight draft angle caused by the laser. This angle can be
removed with a
pass or two of a fine sanding block. Identify all the parts,
checking them against the parts list and sheet diagrams. Most wood
parts have
a number either on them or nearby. Do not remove the parts from
the carrier prior to actually using them in the construction of the
model.
Wood and paper products are effectively live materials on which
humidity and temperature changes will change the size of parts
slightly.
Our climate is moist so you may find minor changes in the
proportion of the parts when moved to a dryer climate, so test-fit
parts and
adjust if required.
In many cases, assembly requires the lamination of layers of
laser-cut wood or laser board. It is important this be done with 3m
77 Spray
Adhesive. After lamination of the batten sheet to the underlying
wall sheet, excess material is to be trimmed away using a rotary
cutter
such as those made by Olfa, Fisker or Excel. Do NOT use a model
knife or similar blade for this as it will displace the
battens.
The prototype structure is unpainted wood with the exception of
the window sash, frames and trim. It is recommended the model
be
assembled first, then airbrushed a base coast of gray followed
by dry-brushing to create a weathered wood effect. (See “FINISHES”
for
details on finishing.)
Working With Metal Castings
All the metal parts should be handled with care as denting and
breakage may occur if they are dropped.. After you have completed
the
initial cleanup of parting lines, sprues and flash, wash all the
castings in isopropyl alcohol, and allow them to dry. Handle these
after
washing by wearing gloves to avoid getting them contaminated
with the oils from your hands.
Painting the castings can be accomplished with a brush or
airbrush. A good base coat will be created by airbrushing your
castings with
Vallejo Acrylico Air NATO Black or Microlux Engine Black (same
paint – different packaging.) Choose relatively dull colors for
your
castings. Models tend to look more realistic using shades such
as Mud, Grimy Black, etc. by Floquil, or similar dull shades.
Rarely
should you consider using bright colors in model scenes.
Working With Resin Castings
Some resin castings may contain minor flash or small bubble
holes. There may be small bubbles inside recesses. Otherwise good
castings
will NOT be rejected for small flaws; it is assumed the modeler
will have the skill to fix these small flaws. Wash resin castings
with soap
and water or isopropyl alcohol prior to painting. Glue resin
castings to laser-cut ply base with CA adhesive or two-part epoxy.
Urethane
parts may be sanded and filed easily, but the dust should not be
inhaled! Urethane resin parts may be airbrushed with acrylic
paints. It
is recommended that all the resin castings be sprayed with an
undercoat of flat black acrylic modeler’s paint ( Vallejo NATO
Black.)
Working With 3d Printed Parts
The 3D printed parts are an acrylic plastic. While strong, these
are not as strong nor as flexible as the engineering plastic or
styrene you
may be used to working with. Carefully remove parts from
attached sprues. Parts should be carefully washed with isopropyl
alcohol
before painting. For fragile parts such as the log carriage
lightly coat the thinnest parts of the 3D printed part with a low
viscosity CA
adhesive to strengthen the part. Examine the drawings, and drill
holes where required. Glue 3D printed parts together with CA
adhesive.
It is recommended that all the 3D parts be sprayed with an
undercoat of flat black acrylic modeler’s paint such as Vallejo
NATO Black.
These parts can have undercuts and recesses, so be sure the
spray penetrates all areas. Working With Peel-and-Stick Materials
Included in the kit are sheets of laser-cut peel-and-stick material
for roofing shingles and window trim. Window trim should only
be
applied after the exterior painting and weathering has
thoroughly dried. The small window trim pieces are best lifted from
the carrier
sheet and transferred to the model with the tip of a modeling
knife before being burnished to the model surface. Working With
Site And Building Bases
The kit is designed to facilitate the assembly of the separate
structures on a wood base prior to installing on the layout. This
base is thin
laser-cut plywood. Plan the location of the sawmill in advance,
and – if desired – add mounting flanges or framing to bottom of
laser-cut
plywood base to facilitate incorporating the model into the
layout. ALSO, the laser-cut base only extends the width of the
exposed face of
the dam and does NOT extend to the limits required for the
drying shed on the west, the bank and stairs up from the bridge to
the east, nor
the log pond on the north. A SITE PLAN is included in the “SITE”
Section. You may wish to mount the laser-cut base on a larger
sub-
base to incorporate additional “terrain” to support these
features or add them to the scene after the main sawmill and dam
are incorporated
into your layout.
-
© 2021 Republic Locomotive Works 1650 – pg. 9
R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA
SCOTIA kit #RLW-1650
ASSEMBLY INSTRUCTIONS
WATER WHEEL & MOTOR MOUNT
Assemble parts A.01.3, A.01.4, and A.01.5(2) as shown below
using Titebond glue or “carpenter’s glue”. If NOT installing
the
motorized water wheel animation kit, install the Water Wheel
Mount after washing with isopropyl alcohol (see WORKING WITH 3D
PRINTED PARTS) and taping for 0-80 screws using the two 0-80
flat-head screws provided.
Assure hole in Water Wheel is clean – if necessary, swab out
with isopropyl alcohol
with a pipe cleaner. Test fit water wheel to mount. DO NOT FORCE
WHEEL
ONTO SHAFT OR YOU WILL BREAK SHAFT OF WHEEL. If necessary,
carefully scrape out any residue from the printing process
inside the shaft hole and
try again, repeating if necessary. Fit should be a smooth slip
fit. Slip Water Wheel
onto shaft but do not glue in place.
Glue part A.01.1 to
base B.39 aligned
with the guidelines
on B.39 using
spray adhesive or Titebond glue. (If using Titebond glue, place
a flat
weight on top and allow to dry overnight.) Place 1-72 nuts in
the
hexagonal holes in part A.01.1, and glue part A.01.2 on top
aligning
the holes with the nuts visually or using a round toothpick; do
not get
glue into the threads of the nuts.
Test fit Water Wheel & Motor Mount to base with two 1-72
screws
and washers through slots into nuts in base. If glue has gotten
into
threads, chase with a 1-72 tap. Check to see if screws protrude
from
bottom of base, and file if necessary.
If installing the motorized Water Wheel and Sound Animation
add-on
kit (RLW #1651) follow the instructions included with the geared
motor for installing the water wheel, motor and wiring.
-
© 2021 Republic Locomotive Works 1650 – pg. 10
R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA
SCOTIA kit #RLW-1650
LAMINATIONS
The building exterior walls and roof are of laminated
construction. The walls consist of an outer layer of battens over a
layer of siding with exterior scribing and
upper window sash, an interior layer of siding including the
interior board scribing,
and a layer of interior post-and-beam framing (not installed as
part of this step.). The main sawmill roof pieces include an
interior face with planking scribing, and
an exterior face with scribed guidelines for the installation of
the peel-and-stick roofing shingles.
Tabs with holes are included at the top corners of the different
wall layers to
facilitate the alignment of these different layers. Using a
piece of pine or other soft
wood and one each of the long (east and west) and short (north
and south) walls,
press straight pins through the two tabs at the top corners of
the wall and cut the
heads off the pins. This will allow the accurate alignment of
layers as laminated.
Remove part C.01 from the Sheet 6 fret and using a sharp
modeling knife cut the
tabs and remove any remaining window and door drop-outs. Place
C.01 over the
pins. Remove battens D.01 from Sheet 8 and remove any remaining
hanging drop-
outs. Holding batten sheet D.01 by one of the corners using
tweezers or other
clamping device, spray the back uniformly with 3M 77 Spray
Adhesive (suggest
using a disposable carboard sheet or cardboard box in an area
with ventilation) then
drop D.01 onto C.01 using the pins for alignment. Press D.01
into C.01; a small
roller such as used for linoleum block printing or even a small
cylindrical glass
bottle such as a paint bottle is useful for this. If battens at
the corners drop off
either during this operation or later during assembly, extra
battens are provided
which can be installed after the walls
are assembled to each other.
OPTIONAL: Turn wall assembly
over and glue interior wall surface in
place with 3M 77 Spray Adhesive.
Otherwise, install after trimming
battens aligning window openings.
(See parts numbers for interior sides
to be laminated to exterior parts in
following paragraphs.)
Remove laminated wall assembly
and trim excess batten layer away
with rotary cutter. (Do not use
modeling knife across battens or you
will displace the battens.) Repeat,
laminating part D.02 onto part C.02;
part D.03 onto part C.03; part D.04
onto part C.04; part D.05 onto part
B.01; part D.06 onto part B.04.
Interior side: using spray adhesive,
laminate part C.02 to part C.05; part
C.06 to part C.01; C.07 to part C.0;
and part C.08 to part C.04.
Using spray adhesive, laminate roof
parts B.34 to part B.37 and part B.36
to part B.35.
Alignment jig for laminating wall layers: top,
exterior wall placed over alignment pins; bottom,
exterior battens applied using spray adhesive and
pressure.
Trimming excess batten layer: trim tabs with
alignment holes with modeling knife, then trim
excess battens layer with rotary cutter (do not use
modeling knife on battens).
Laminating interior wall surface to exterior; can be done with
alignment pins or trim off
tabs and align using widow openings as a
guide.
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© 2021 Republic Locomotive Works 1650 – pg. 11
R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA
SCOTIA kit #RLW-1650
BASE AND BASEMENT LEVEL
Use Titebond glue to glue parts B.01 (east), B.02 (west), B.03
(north) and B.04 (south) to base B.39, fitting tabs into slots in
base. Use
clamps to hold walls square to each other if required.
After glue sets, add interior (core) basement walls A.03 (east),
A.04 (west), A.05 (north) and A.06 (south). Use clips to hold these
core
walls tight to exterior walls while the glue cures. If
installing the Water Wheel and Sound Animation kit (RLW #1651),
insert one speaker
behind holes in east basement wall, then glue part A.02 to back
of north wall to act as stop for holding speaker in place.
Glue parts A.10 and A.11 in place to inside of basement walls
and add part B.39, the partial basement floor , to the south end of
the
basement interior, with the walkway extending through the
doorway.
UPPER STORIES
Use Titebond glue to glue the second floor, part B.10 to the
west wall laminate (parts C.02 + C.05) using a square to assure the
parts
are perpendicular. (Photos next page.) After glue dries, add
north, south and east wall laminates to the floor. Use clamps to
hold
walls square to each other if required. After assembly, check
corner battens and if any have been lost during assembly, add
new
battens from parts provided. Test fit upper part of building to
basement and base.
Left: basement walls fitted to base; center – interior “core”
walls glued in place to inside face of basement exterior walls
(back of
water wheel flume being test-fitted in right image.); right -
Partial basement floor and supports.
Left - West exterior wall laminate fitted to second floor;
center and right – test fitting upper floors to basement level.
Install East and West interior post-and-beam
framing (parts B.17 and B.18) with Titebond glue
– hold tight to outer walls with clips as necessary.
After glue dries, install North and South interior
post-and-beam framing (parts B.19 and B.20)
then tie beams B.21.
Bevel top and bottom edges of part B.09.02 and
install as shown along with B.09.3.
-
© 2021 Republic Locomotive Works 1650 – pg. 12
R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA
SCOTIA kit #RLW-1650
Glue part A.07 to the inside of the west wall tight to the floor
above to act as a stop
when the upper floors are placed over the basement level.
Glue parts A.08 and A.09 on the exterior under doors #6 and #7
as ledgers for supporting
the bridges.
Doors & Windows:
The doors are composed of a scribed siding component or left (L)
and right (R) components on Sheet 6 and a cross brace component
(B) on Sheet 8. Each door opening and each door is numbered on
both the laser-cut fret and on page 5 of these instructions, and
the
opening number is linked to a door and bracing number as
follows:
Opening no. Door part no. Brace part no.
1 C.10.L/C.10.R C.13.LB/C.13.RB
2 C.11.L/C.11.R C.14.LB/C.14.RB
3 C.12.L/C.12.R C.15.LB/C.15.RB
4 C.13 C.16.B
5 C.14 C.17.B
6 C.15 C.18.B
Glue the appropriate brace to the corresponding door, then glue
the door in place using Pliobond for a flexible joint along the
hinged
edge, leaving door in the open position. See finished model
photos for doors opening out vs. doors opening inward.
Window painting, glazing & installation is covered in the
“FINISHES” section.
Door #6 Door #5 Door #2 Door #3 Doors #1 & #4
(Note braces C.18 & C.19)
-
© 2021 Republic Locomotive Works 1650 – pg. 13
R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA
SCOTIA kit #RLW-1650
WATER WHEEL FLUME or RACEWAY (also called a PENSTOCK)
Assemble the west side of the Water Wheel Flume (B.05 – Raceway
West) to the bypass part B.09.1 while test-fitting to the east wall
(A
below). Then add the south end frame B.06.2 (B below). Glue in
place to the base and the east wall of the sawmill. Laminate t he
Flume
Framing (B.08) to the Raceway East (C.18) then glue to the base
and the installed Raceway West (D below). Add raceway framing
C.06.1 through C.06.10 and raceway side B.07 (E below). Note
that the raceway necks down at the outlet where B.07 is located.
Finally,
add decking C.20 to the top of the raceway (F below).
After installing the water wheel flume/raceway, removal and
reinstallation of the upper portion of the building must be
done
on a slight angle; see picture at right.
Water wheel flume/raceway assembly sequence.
It is recommended that at this point the exterior of the
sawmill
as well as the water wheel flume be painted and receive
initial
weathering; see “FINISHES” section of these instructions.
-
© 2021 Republic Locomotive Works 1650 – pg. 14
R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA
SCOTIA kit #RLW-1650
SAWMILL ROOF
The Sawmill Roof is composed of laminated top (B.36 and B.37)
and bottom (B.34 and B.35) pieces to be then assembled on the
roof
rafters/trusses (B.22). The top and bottom for the west side and
east side are identified on the laser-cut fret. The ridge (top
edge) is also
identified and notched to mate with the opposite side. Use spray
adhesive for laminating the top and bottom sheets. After assembly,
use
a modeling knife to cut a bevel in the “downhill” side of the
locating slots. (See photo sequence below.)
When roof is assembled, apply peel-and-stick roof shingles. The
top of the laser-cut roof panels is scribed with guidelines. THESE
ARE
NOT FOR SPACING THE SHINGLE STRIPS – they are to help keep each
strip parallel to the ridge of the roof. Use the notches in the
shingle strip defining each shingle as a guide to the overlap
(or “exposure”) of each shingle strip. (See image below.) With
shingles in
place, add eave and rake trim (D.09 and D.10)
The section on “FINISHES” will cover the painting weathering of
the roof shingles.
INTERIOR DETAILS
The following items are included for the interior of the sawmill
second floor:
• Log Carriage (3D print)
• Log Carriage support (part B.26) • Winch - sometimes called a
“Pull Wheel” - (3D print)
• Log Deck, comprised of parts B.33 and deck C.20 • Saw Frame,
comprised of parts B.24, B.25 and B.25.1
• Saw blade on Sheet 10
• Misc. logs, white metal castings and etched tools
This section will cover the components above which are fixed to
the structure (as
noted in the image to the right); the modeler can determine the
extent to which the
miscellaneous items are used and where they are placed to
complete the simulation of
an operating sawmill.
Upper and lower surfaces east roof Gluing roof trusses and end
locators in place Cutting bevel in roof locating slots
-
© 2021 Republic Locomotive Works 1650 – pg. 15
R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA
SCOTIA kit #RLW-1650
The log carriage and winch are 3D printed plastic. Carefully
wash these parts
as described in “Working With 3d Printed Parts”. Chase holes as
required
and glue in .010” brass wire for the control levers and the
shaft for the blocks
as shown at right. Airbrush or brush paint these parts with your
choice of
color – the current color at the Museum is red.
When dry, cut two .010” wide
by 2” long strips of typing
paper, paint the paper on both
sides Vallejo Air 71.027 Light
Brown and wrap a strip around
the pulley on both the saw
carriage and winch securing
with some CA adhesive and
gluing the free ends of the strips
together.
Test fit the log carriage in place between the vertical legs of
B.25 and with the pulley and belt
sticking down through the opening in the floor. If necessary,
trim material away from the
opening. When satisfied with the placement, secure with a drop
of CA applied with a pin to the
joint between the carriage and the carriage support frame.
Glue the carriage support frame for the saw carriage (B.26) in
place on the second floor, aligning the slot for the saw in the
floor with the
slot in the support frame. Glue the frame supporting the log
deck (B.33) in place aligned with Door #1 and opposite the northern
half of the
carriage support frame. Glue the log deck (C.20) to the top of
this frame. Locate the winch with the pulley and belt sticking down
through
the opening in the floor and glue in place.
Add parts B.24, B.25 (“Fender Posts”) and B.25.1 (“Saw Gate”)
as
shown on previous page, gluing B.24 to the bottom of the
previously
installed tie beams (B.21) making sure the slot in the Saw Gate
(B.25.1)
is above the slot in the floor and the carriage support frame.
Remove the
laser-cut saw blade from Sheet 10, paint silver or aluminum, and
– when
dry -slide down through the slots in the Saw Gate, the carriage
support
frame and the floor before gluing with a small drop of glue
where it fits
into the Saw Gate (B25.1) (Optional: use one of the etched
stainless steel
two-man saws from the tools fret.)
Several pieces of 12” – 18” diameter logs (typical sizes for
this sawmill)
are included in the kit. Cut to about 20’ lengths and add to the
log deck
and the ramp from the millpond. Using a modeling knife or razor
say,
slice one of the logs lengthwise and place on the log carriage.
Optional: if
desired, fabricate dogs from brass wire to simulate the dogs
that would
hold the log against the blocks (holes are provided in the
blocks for
these).
Additional detailing: Paint and add white metal castings as
desired. Add
sawdust and strip-wood simulating cut lumber.
For additional equipment (Edger, Cutoff Saw, etc.) you wish to
install at
this level, see:
https://www.republiclocomotiveworks.com/showPage.php?page=1
https://www.republiclocomotiveworks.com/showPage.php?page=1
-
© 2021 Republic Locomotive Works 1650 – pg. 16
R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA
SCOTIA kit #RLW-1650
ANCILLARY STRUCTURES
Besides the main sawmill structure, the complex has the
following structures which are included in this kit:
• Drying Shed
• West Bridge
• East Bridge
• Sawdust Bin
• Sawdust Conveyor
• Sawn Lumber Conveyor (Not included is the modern
ADA-accessible restroom building.)
Drying Shed:
Glue siding C.27 and C.28 to the two (2) B.29
post-and-beam/rafter
parts. Glue post-and-beam/rafter parts B.29 into holes at left
and right
ends of the Drying Shed base B.40 then glue four (4) parts B.30
into
intermediate holes in B.40. Glue two (2) parts B.32 across long
sides
of the drying shed keyed into the notches at the top edges of
the B.29
and B.30 parts. Glue siding C.29 across back wall. After glue
dries,
glue four (4) B.31 girts between posts along back wall at the
base of
the siding. At this point, it is recommended basic painting
and
weathering be performed before installing roof panels. (See
“FINISHES”) When basic painting and weathering is completed,
glue
two (2) roof parts B.38, then add peel-and-stick shingles and
rake and
eave trim parts D.11 and D.12.
East Bridge:
Glue truss B.11.1 to C.22.N and truss B.11.2 to C.22.S noting
the orientation of the railing parts with respect to the building.
Add cross beams
B.12, making sure the two pieces not including a vertical
element are centered on the truss. Glue the decking to one half of
the bridge at a
time using clips to hold everything solidly together, then trim
ends of railing parts back to scribed line.
Installing post-and-beam framing on base Installing siding on
rear wall; hold with clips Girts B.31 installed along base of rear
wall
Finished Drying Shed after painting and weathering. (See
“FINISHES”)
Primary trusses and cross framing to railings Gluing one side to
deck; hold with clips Completed bridge (See “FINISHES” for
painting)
-
© 2021 Republic Locomotive Works 1650 – pg. 17
R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA
SCOTIA kit #RLW-1650
West Bridge:
Glue beams B.13.1 and B.13.2 to C.23, using West Bridge Abutment
resin casting to
check spacing; tabs on bottom of beams fit into slots on the top
of the abutment. Glue
railings C.24 to either side of the bridge between the tab that
engages the abutment and
the east end of the bridge deck (see image to right). Do not
glue bridge to either abutment
or building.
Sawdust Bin:
Glue the post-and-beam
frames B.27 (2) to base B.41,
with scribing at knee braces
facing inwards, then add
siding pieces C.16 (2) and
C.17 (2). Glue top conveyor
support B.28 to top.
Sawdust Conveyor The sawdust conveyor runs from the square
opening on the
west side of the lower level up to the top of the sawdust bin.
The final length of the conveyor and the location
along the length of the conveyor of the support legs is
dependent upon how the modeler constructs the slope and
the flat area where the bin is located. Glue parts C.25 (2) to
the conveyor B.15 flaring the sides out about 20-30̊ Turn
over and glue parts B-16 in place; these have extended legs
which need to be cut to fit your final slope. See “SITE” for
locating and installing this structure.
Roller Conveyor
NOTE: The roller conveyor runs from Door #4 opening on the west
side of the upper level to the adjacent flat area. The final length
of the
conveyor and the location is dependent upon how the modeler
constructs the slope and the flat area where it ends. (The
horizontal parts are extra length and an extra frame (B.14.4) is
provided for long installations.) Ream holes then install brass
wire, using B.14.1 to space the frames. Glue
with CA then trim flush. Assemble the remaining parts using
Titebond glue. Support using B.14.5 (and B.14.6 if required.)
Finished West Bridge after painting and
weathering. (See “FINISHES”)
Sawdust Bin
NOTE: The Sawdust Conveyor & Roller Conveyor fit between
the west wall of the sawmill and top of the adjacent bank. It
is
recommended you NOT assemble these until you have
completed the basic terrain (see “Site”) then build to suit
the
length required.
-
© 2021 Republic Locomotive Works 1650 – pg. 18
R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA
SCOTIA kit #RLW-1650
FINISHES
Building walls:
Airbrush exterior walls, bridge framing, sawdust bin, and
conveyors with a base
coat of light gray (Vallejo Air Light Gray 71.050) then drybrush
with an assortment
of colors to simulate weathered unpainted wood; recommended
paints:
• Vallejo Air NATO Black 71.251
• Vallejo Air Mud Brown 71.037
• Vallejo Air Light Brown 71.027
• Vallejo Air Sand 71.075
Windows:
After weathering the exterior walls paint windows sash Vallejo
Air
Aged White 71.132 inside and out, and also paint the window
frame
(opening edges.) Paint the lower sash included on Sheet 8
with
Vallejo Air Aged White 71.132 on both sides. Add glazing
using
one of two options: (1) laser-cut clear plastic is provided
which can
be glued to pre-painted sash with Pacer Canopy Glue; (2) use
Microscale Micro Krystal Klear or Pacer Canopy Glue liquid
to
form thin film glazing. When glazing has dried, glue lower sash
in
the window openings from the interior in closed, open or
partially
open positions to suit.
Roofs:
After shingles have been applied, airbrush with Vallejo NATO
Black, and when dry, drybrush with:
• Vallejo Air Light Gray 71.050
• Vallejo Air Light Brown 71.027
• Vallejo Air Aged White 71.132
• Vallejo Air Mud Brown 71.037
Bridge Abutments:
After washing and drying resin castings, airbrush with a
basecoat
of Vallejo NATO Black, and when dry, drybrush with Vallejo
Air Light Gray 71.050. When dry, use a fine brush to pick
out
individual stones with:
• Vallejo Air Light Brown 71.027
• Vallejo Air Mud Brown 71.037
• Vallejo Air Sand 71.132
Log Dump and Dam:
After washing and drying resin castings, airbrush with a
basecoat of Vallejo NATO Black,
and when dry, drybrush with Vallejo Air Mud Brown 71.037
followed by dry brushing
highlights of:
• Vallejo Air Light Brown 71.027
• Vallejo Air Aged White 71.132
• Vallejo Air Mud Brown 71.037
• Vallejo Air Sand 71.132 Drybrush sloping wood top of dam with
Vallejo Air Light Gray 71.050.
Water Wheel:
After washing and drying resin castings, airbrush with a
basecoat of Vallejo NATO Black, and when dry, drybrush with Vallejo
Air Mud
Brown 71.037. (Wheel stays relatively dark because it is always
wet.)
Wood siding weathered with acrylic paints; left –
window sash and painted window frame interior; right –
white peel-and-stick window trim burnished in place.
Window glazing: left - applying Microscale Micro Krystal Klear
to back of
lower sash by swiping across the fret with a toothpick dipped in
glazing
liquid; right – glue lower sash in place from inside
structure.
Finished peel-and-stick roofing shingles: left – Vallejo Air
NATO Black
undercoat; right – after dry-brushing with various colors.
Water Wheel with base coat of NATO Black
-
© 2021 Republic Locomotive Works 1650 – pg. 19
R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA
SCOTIA kit #RLW-1650
SITE
The McDonald Brothers Sawmill is located on a cove along the St.
Mary’s River in Nova Scotia (see satellite image on left, below.)
The site
plan on the right below shows the prototype arrangement of the
historic sawmill structures included in this model, with an outline
of part B.39.
Dam & Spillway
The dam is a resin casting. Wash
the casting with isopropyl alcohol
(see “Working with Resin
Castings”.) Airbrush the casting
with a base coat of Vallejo Air
NATO Black. When dry, drybrush
with various browns and grays to
simulate weathered logs and
planking (See “FINISHES”.)
When paint has dried epoxy the
dam in place on the base B.39
taking care as sliding the casting in
place under the water wheel flume.
Bridge Abutments
After washing East and West Bridge
Abutment resin castings (see “Working with
Resin Castings”) airbrush with Vallejo
NATO Black, followed by stonework finish
coats (see “FINISHES) then epoxy in place
on base B.39.
Log Dump
After washing the Log Dump resin casting (see “Working with
Resin Castings”) airbrush with
Vallejo NATO Black, then paint and dry brush to simulate logs
and loose bark on dirt. (See
Finishes”.) Suggestions on how to blend the resin base around
the logs into the adjacent scenery are
in the “Terrain” portion of this section.
Left- paint and lightly weather dam before installation; right –
slip dam under flume and epoxy to base B.39.
Left- painted bridge abutments; center & right – abutments
glued in place.
The existing McDonald Brothers Sawmill reconstruction site
(minus the modern ADA-accessible restrooms)
McDonald Brothers Sawmill reconstruction is located at
Sherbrooke Village Museum 4037
Sonora Rd, Sherbrooke, NS B0J 3C0, Canada
-
© 2021 Republic Locomotive Works 1650 – pg. 20
R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA
SCOTIA kit #RLW-1650
Terrain
The prototype sawmill building is located in a swale below the
dam on the outlet stream
or “race” which connects to Mill Cove. The bridges and conveyors
connect the different
levels of the building to the tops of the adjacent slopes of the
swales. The flat site at the
top of the west slope (left in the photo) includes the Drying
Shed and Sawdust Bin as
well as access to the Log Dump, Roller Conveyor and the West
Bridge. The modeler
will need an area larger than base B.39 to model these features.
It is recommended the
base be glued to a larger piece of plywood, MDF or hardboard for
this purpose, the size
of which will be determined by the available space on the
layout. It is recommended a
minimum space of 10” x 12” be allocated for this. Note that if
rail access is to be
included, this size should be adjusted accordingly, as should
the orientation of the Log
Dump and the Drying Shed which could potentially be served by
the same track.
The photos below show construction of adjacent terrain using
polystyrene insulation board and tinted spackle, the placement of
structures, water
simulation and the addition of landscape elements - static
grass, shrubs and trees. After terrain surface is faired in, test
fit Sawdust Conveyor and
Roller Conveyor and cut supporting timbers to length.
For assistance in assembly or interpretation of instructions,
contact:
[email protected]
For all other enquiries: Republic Locomotive Works
16 Little Cape Horn, Cathlamet, WA. 98612
360-577-6479
21.02.05
South side of sawmill showing swale with outlet from mill pond
on right and slope up to Sawdust Bin
and Drying Shed on left.
Terrain roughed in with 1” foam insulation Terrain faired in
with pre-tinted spackle; Scenery using static grass, foliage,
rocks, gloss
Cut to fit around bridge abutments and dam; bases for Log Dump,
Sawdust Bin, Drying gel medium (figures not included in kit.)
1/8” hardboard mill pond surface Shed cut into spackle surface
then glued down
mailto:[email protected]