PDK D15 User manual

D15 Assembly Instructions
Chassis Assembly
Take the frames (1) and solder in the axle bushes (2), making one frame L/H and one R/H.
Choose either the ‘OO’ or ‘EM’ frame s acers (3) as required, bend as shown on the diagram,
and solder the frames to the s acers making sure everything is assembled square and flat.
Solder an 8BA nut (4) over the hole in the main s acer halfway between the axles, and
another over the hole in the smallest s acer to which the bogie link will be attached. If fitting a
D11 motor screw the motor to the mounting late (5) using two washers (6) under the screw
head. Put an axle and the Romford gear in the chassis to check the gear mesh, adjust if
necessary, and then fix the mounting late in lace. The D11 motor can be fixed in lace
ermanently after ainting and fitting the wheels. If fitting a Portesca 1219 motor this late will
not be necessary.
Solder ieces of the 22 wire through the holes in the frames to form the brake gear su orts
(7). Now take the brake hangers (15) and solder the brake blocks (16) to them, making L/H
and R/H airs, then solder the assembled brakes to the su ort wires (7). Using a driving
wheel and axle make sure they do not touch the wheels. Now fit the brake tie bars (17) and
ull rods (18). Fit the ash an sides (19) to the underside of the chassis.
Now is the best time to aint the chassis. S raying with a cellulose rimer and then with
cellulose satin or matt black is recommended. Clean out the axle holes with a rat tail file.
Next fit the wheels, axles, gear and crank ins to the chassis, using the four axle washers (8) to
take u any side lay. Fit the airs of cou ling rod halves (9) together, lace the rods on the
crank ins and check that the wheels revolve freely, and then fit the four small washers (10) to
retain the cou ling rods. Put a er between the cou ling rods and the washers when fixing to
avoid soldering the rods to the crank ins, and then remove the a er afterwards. Screw the
collector tag (11) to the main s acer using one of the 8BA screws (12) and the two fibre
washers (13). Check that the tag is not electrically live to the chassis, then form current
icku s using some of the 26g handrail wire (14) soldered to the tag.
Turn now to the bogie (21) and fold down the sides at right angles to the centre stretcher, then
solder the two strengthening lates (22) between the frames below each edge of the stretcher.
These two ieces may require slight trimming to fit. Now fix the two large washers (23) on the
underside of the bogie centre. Next fix the dummy equalizing beams (24) to the bogie frames,
so that the axle holes line u . If working in ‘OO’ the beams should be s aced off the frames
with one axle washer (25) er axle hole. If working in ‘EM’ two washers between the beams
and the frames should be used. Next fit ieces of 22 wire through the small holes at the front
and back of the bogie to form the tie bars (26). Now take the bogie link and its washer (27),
solder the washer over the smaller end of the link and ta the hole 8BA. Screw the link to the
bogie leaving a small amount of lay and shorten the screw so that its end is flush with the to
surface of the link. Paint the bogie and then fit the wheels to the bogie. The bogie can now be
screwed to the chassis using an 8BA screw and the cast ivot (28).
The drawbar (29) and drawbar ivot (30) are fixed to the chassis with the same screw used to
attach the rear end of the chassis to the su erstructure.

Superstructure Assembly
Take the foot late (1), lay it u side down on a flat surface (the hole for the vacuum i e should
be to the L/H side of the loco), and solder the drag beam (2) to it, slightly in from the front
edge. Next solder the valances (3) to the foot late, 0.5mm in from each edge, then solder the
bufferbeam (4) in lace, followed by the bufferbeam overlay (5). Solder the ste lates (6)
behind the valances with their centre lines 35mm back from the front edge of the foot late.
Bend u the ends of the ste s (7) and fix into the slots in the ste lates and valances. Solder
two 8BA nuts (8) over the holes on the foot late centre line to screw the chassis to, and then
fix the frame ieces (9) into the slots in the foot late, checking against the chassis that they
come midway between the bogie wheels. Then fix the other frame ieces (10 & 11) to the
underside of the foot late, in front of and behind ieces (9), checking the bogie wheel
clearances before continuing.
Next take the cab/s lasher sides (12) and the cab front/s lasher to s (13) and carefully curve
the s lasher to s to match the s lashers, and then fix the arts together. Note that the cab
front/s lasher to s fit between the sides, and not on the to edges of the sides. The cab and
s lasher assembly can be fitted to the foot late, checking that everything is flat and square
before finally fixing, and filing the ends of the s lasher to s as necessary to ensure a good fit
to the foot late.
Next fit the cab window surrounds (14) to the cab windows, then fit the u er frame ieces (15)
to the foot late, and make the grab handles (16) from the handrail wire. Bend the cab floor
su ort (17) and fix to the foot late, only slightly in from the foot late edge, and with its ends
against the inside faces of the cab sides, then fix the cab floor (18) to it. Bend the two cab
s lasher sides (19) along the etched fold lines and solder them to the cab floor with their rear
faces almost level with the rear edges of the cab sides, then fix the to s (20) to them. Now
take the regulator handle (21) and fix it to the backhead (22), then fix the backhead in lace in
the cab.
Curve the cab roof (23) to match the curves of the cab front, bend u the side edges along the
fold lines, and then solder it to the cab. Then fix the rainstri s (24) into the half-etched lines in
the roof. The to rainstri on the etching sheet is slightly longer than the other two to allow for
the curve of the rear edge of the cab roof. The cab side beadings (25) can now be fitted,
bending them during fitting to match the sha e of the cab side cut-outs. The beading should be
continued along the underside of the cab roof and the ends trimmed flush with the rear edge of
the roof. Now make the cab handrails (26) from the handrail wire, threading the wire through
the holes in the ends of the beading and the holes in the foot late either side of the cab floor.
Turn now to the boiler, and roll the boiler/firebox unit (27), bend out the lower art of the firebox
sides, and solder along the boiler seam. Next form the smokebox inner (28), straightening the
saddle sides out so that they fit between the u er frame ieces, and fit it to the boiler unit.
Solder the smokebox front (29) in lace, then form the smokebox outer (30) and fit to the
smokebox so that it overla s the edge of the front (29). Now solder the saddle front (31) and
rear (32) to the saddle, checking at the same time the fit of the saddle between the u er
frame ieces, and the alignment of the tag on saddle front with the slot in the foot late. Check
at the same time the fit of the boiler unit to the foot late and cab, then fit the three boiler bands
(33) in lace. The assembled boiler can now be fitted to the foot late/cab checking before
finally fixing that the boiler is straight and level, and that its to centre line lines u with the

centre of the cab. Once fitted the boiler handrail can be made from the 26 wire (34) and
handrail knobs (35). The chimney (36), dome (37), and clacks can now be fitted, and then the
clack i es (39) can be formed from the 22 wire and fixed into the clacks at one end. 0.75mm
holes will need to be drilled in the s lasher to s, behind the front s lashers and close to the
firebox sides for the other end of the i es. Fit the two i e covers (40) to the firebox sides,
and then fit the whistle (41) in lace. Form the two injector i es (42) either side of the firebox,
bending the u er ends to fit into the holes in the firebox to either side of the whistle. 0.75mm
holes will need to be drilled in the s lasher to s between the s lashers for the other end of
these i es, in line with the holes in the firebox to and 1.5mm out from the sides. These and
the holes for the clack i es were not etched out , as any variation in the curving of the
s lasher to s would have ut the holes in the wrong osition. Now fit the three smaller i es
from the whistle and injector i es to the cab using handrail wire (43).
Turn to the smokebox and fit the u er lam brackets (44) and the front ste (45) to the
smokebox front. Fit the smokebox door handles (46) and the two lam brackets (47) to the
smokebox door (48) and fit the door to the smokebox. Fix the buffers (49) into the holes in the
bufferbeam, and fit the cylinder cover (50) to the front of the smokebox saddle between the
frame ieces. Fix the three lam brackets (51) and the vacuum i e (52) into the holes in the
front edge of the foot late.
Now turn back to the cab, take the fall late (53) and curve it slightly, make a hinge from the
handrail wire and s lit ins (54) and fix it into the holes in the cab floor, making sure that it
ivots freely. Lastly fit the two ejectors (55) below the foot late, behind the cab ste s.
Tender Assembly
Take the chassis (1) and bend down the sides at 90˚ to the centre. Solder an axle washer (2)
over each axle hole, and then clean out the holes with a 2mm drill. Solder 22 wire through
the three holes in each frame to form the brake gear su orts (3). Fit the wheels to chassis
using axle washer to take u the side lay, but leaving a small amount of side lay in the centre
axle. Take the brake hangers (4) and solder the brake blocks (5) to them, making three L/H
and three R/H, then solder the hangers to the wire su orts, making sure the brakes do not
touch the wheels. Take the ull rods (6) and thread 22 wire (7) through these and the holes in
the lower ends of the hangers. Solder in lace when assembled and trim the ends of the wire
after assembly.
Turn now to the body, take the foot late (8) and solder the bufferbeam (9) to it, 0.5mm in from
the back edge of the foot late. Next fit the valances (10) to the foot late, also 0.5mm in from
each edge, then fix the drag beam (11) in lace. Bend u the ends of the four ste s (12) and fit
these into the slots in the valances. Take the frames (13) and fix into the slots in the foot late,
and then fit the buffer bodies (14) to the bufferbeam. Solder an 8BA nut (15) over each hole in
the foot late, for screwing the chassis to the body. Now take the tender body (16) and bend
the corners to 2mm radius. This must be done accurately and squarely to ensure the correct fit
of the body to the foot late, and to ensure the accurate fit of the other body arts. The to of
the sides and back should be flared outwards at 60˚ to the horizontal. The front corners of the
sides must also be curved at 2mm radius for a full 90˚. Once the tender body is correctly
formed it can then be slotted into the foot late and soldered in lace. Take the front late (17)
next, bend over the two to ieces at 90˚, and then fix the late into the slot in the foot late. It
should fit between and level with the front edges of the tender body. Bend the five lam

brackets (18) and fit into the slots in the back of the body, then bend the floor su ort (19) and
fit to the foot late only very slightly in from the front foot late edge, then slot the floor iece
(20) into the front late and fix it to the floor su ort.
Now take the long lower co ing stri (21) and starting at one end of the front of the body, fix
the stri all the way round the body with its to edge against the bend of the flared co ing.
Next take one of the two overlays for the flared co ing (22) and curve this to fit the flared to of
the body. Fix in lace, and then re eat with the other overlay. The two ieces join at the back
of the tender.
Bend the coal late (23) next and fit into the body. The main section should be level with the
etched fold line for the flared to , and the front edge should be level with the bottom edge of
the coal hole in the front late. Solder the coal rails (24) to the flared tender to s with an equal
amount of body at either end. Fit the draught lates (25) into the slots in the foot late either
side of the floor, then bend the sandbox bodies (26) and fix these into the slots in the floor.
Bend the sandbox to s (27) at an angle to match the body sides, then fix in lace. Fix the two
short beading stri s (28) to the to edges of the draught lates, then make the two handrails
(29) from some of the 26 wire, with the to of the wire through the holes in the beading ends,
and the bottom end through the holes in the foot late. Put the drawbar in (30) through the
hole in the foot late and solder it to the back of the drag beam, then bend the guard irons (31)
to sha e and solder them to the frames. Form the vacuum i ing (32) that runs along the
valances on both sides of the tender, with the ends through the holes in the frames, and then
fit the axleboxes (33) into the holes in the frames. The brake column (34) fits against the front
late on to of the R/H sandbox. Finally fit the u er toolboxes (35), tank filler (36), Vacuum
i es (37) and buffer heads (38). The com leted body and chassis can be fitted together using
the two 8BA screws (39).
Chassis Parts List
1. Frames.
2. Axle Bearings.
3. Frame S acers.
4. 8BA Nuts.
5. D11 Motor Mounting Plate.
6. Washers for D11 Motor Screws.
7. Brake Gear Su orts, 22g Wire.
8. Driving Wheel Axle Washers.
9. Cou ling Rods.
10.Crank in Washers.
11.Collector Tag.
12.8BA Screws.
13.
14.Picku Wire.
15.Brake Hangers.
16.Brake Blocks.
17.Brake Tie Bars.
18.Brake Pull Rods.
19.Ash an Sides.
20.
21.Bogie.
22.Centre Strengtheners.
23.Centre Washers.
24.Equalizing Beams.
25.Bogie Axle Washers.
26.Tie Bars, 22g Wire.
27.Bogie Link and Washer.
28.Bogie Pivot.
29.Drawbar.
30.Drawbar Pivot.

Superstructure Parts List
1. Foot late.
2. Drag Beam.
3. Valances.
4. Bufferbeam.
5. Bufferbeam Overlay.
6. Ste Plates.
7. Ste s - 4 Long, 4 Medium.
8. 8BA Nuts.
9. Frame Pieces above Bogie.
10. Frame Pieces In Front Of Bogie.
11. Frame Pieces behind Bogie.
12. Cab/S lasher Sides.
13. Cab Front/S lasher To s.
14. Cab Window Surrounds.
15. U er Frame Pieces.
16. Grab Handles.
17. Cab Floor Su ort.
18. Cab Floor.
19. Cab S lasher Sides.
20. Cab S lasher To s.
21. Regulator Handle.
22. Backhead.
23. Cab Roof.
24. Cab Roof Rainstri s.
25. Cab Side Beading, L/H & R/H.
26. Cab Handrails.
27. Boiler/Firebox/Smokebox.
28. Smokebox Inner.
29. Smokebox Front.
30. Smokebox Outer.
31. Saddle Front.
32. Saddle Rear.
33. Boiler Bands.
34. Handrail Wire, 26g.
35. Handrail Knobs.
36. Chimney.
37. Dome.
38. Clack Valves.
39. Clack Pi es, 22g Wire.
40. Pi e Covers.
41. Whistle.
42. Injector Pi es, 22g Wire.
43. 3 Pi es to Cab Front, 22g Wire.
44. Smokebox Lam Bracket.
45. Smokebox Front Ste .
46. Smokebox Door Handle.
47. Smokebox Door Lam Brackets.
48. Smokebox Door.
49. Buffers.
50. Front Cylinder Cover.
51. Lam Brackets.
52. Vacuum Pi e.
53. Cab Fall late.
54. Wire and S lit Pins for Fall late Hinge.
55. Ejectors.
Tender Parts List
1. Chassis.
2. Axle Washers.
3. Brake Gear Su orts.
4. Brake Hangers.
5. Brake Blocks.
6. Brake Rods.
7. Tie Bars, 22g Wire.
8. Foot late.
9. Bufferbeam.
10. Valances.
11. Drag Beam.
12. Ste s.
13. Frames.
14.Buffer Bodies.
15.8BA Nuts.
16.Tender Body.
17.Front Plate.
18.Lam Brackets.
19.Floor Su ort.
20.Floor.
21.Lower Co ing Stri .
22.U er Co ing Stri s.
23.Coal Plate.
24.Coal Rails.
25.Draught Plates.
26.Sandbox Bodies.
27. Sandbox To s.
28. Beading, L/H & R/H.
29. Handrails, 26g Wire.
30. Drawbar Pin.
31. Guard Irons.
32. Vacuum Pi ing.
33. Axleboxes.
34. Brake Column.
35. U er Toolboxes.
36. Tank Filler.
37. Vacuum Pi e.
38. Buffer Heads.
39. 8BA Screws.

P. D. K. MODELS.
HILLTOP BUNGALOW
CARNKIE
HELSTON
TR13 0DZ
Mobile [phone]
E-Mail: [email protected]
www.pdkmodels.co.uk