Hi friends,
I developed unique load inserts – imitation of molten iron and slag for two types of Märklin Z scale metallurgical cars, ladle and slag ones offered in 86210, 86211, 86212, 86213 and 86214 sets. It was quite difficult to find a suitable method for implementation of such idea, but after numerous experiments, I came to the desired results.
3 mm black polystyrene precisely cut on CNC machine is used as a base for these loads. It was a bit difficult to do a “reverse-engineering” of these unusual cars due to a conical shape of the ladles (one of which has also an irregular oval shape when viewed from the top), but after a number of precise measurements, I got perfect results – without any visible gaps.
The next challenge was to figure out how to simulate a lava-like surface – which should not be too flat and too rough at the same time. Realistic coloring was also a big question. Once again, after some tryouts, I found a combined solution.
First, the base was covered with a thin layer of fine grade orange sand stabilized with thinned glue. Then I decided to use an unusual approach I never used in my load inserts before – to print a full-color image of molten iron directly onto the surface using UV-printing technology, as it was very difficult to achieve any realistic results manually.
Some years ago, I was on a tour at a metallurgical plant for the purpose of a photo report, where I managed to take a big number of unique pictures of crude iron in many different conditions. Among them, there was a photo of molten iron loaded into the ladle car – taken almost directly from above. I remember that it was rather dangerous task – surely, not because of the risk of falling down, but because of the very high temperature around the car, which did not even allow you to get anywhere close to it. I was able to make only few steps forward and stay there for not more than 3-4 seconds, taking a serial shooting with my camera, after which I quickly jumped back away. Here is one of these pictures:
I decided to use some pictures from this series for imitation of crude iron and slag in my load inserts. First test printouts already exceeded expectations – it was obvious to me that it would be impossible to do anything close to it manually. Very fine 1440 x 1200 dpi printing did not show any visible dots at all. Additionally, UV inks added some glossiness to the areas printed with maximal density, which increased realism further.
I used six different variants of pictures for each load insert, so it is likely that in most cases, customers will receive all loads with different images when ordering several of them together.
At the end, I airbrushed the load inserts using a semi-gloss clear lacquer for even better look and stabilization. Taking an opportunity of using UV-printer even more, I also printed text labels directly to the bottom side of the loads instead of applying stickers:
The loads are already available at 1zu220-shop.de at the following links:
ZM-MRK-SW-001 – Load insert for 4-axle crude iron ladle car (oval type), suitable for 86210, 86211, and 86213 sets:
https://www.1zu220-shop.de/Zmodell/Lade ... 43713.html
ZM-MRK-SW-002 – Load insert for 4-axle slag car (round type), suitable for 86210, 86212, and 86214 sets:
https://www.1zu220-shop.de/Zmodell/Lade ... 43714.html
Some tips on installation and removal:
To install: Carefully adjust the load insert in the horizontal position with hand or tweezers if needed. Don’t push the load insert inside too strongly, otherwise it can get stuck in the ladle.
To remove: Release the load insert by gentle shaking the ladle upside down, either with a help of a needle or sharp tweezers.
I noticed that the first batch was already sold out at the time of posting this report. Nevertheless, anyone interested can place pre-orders; I will produce the next batch as quick as I can.
Greetings,
Alex
Joachim
I am happy to see, that you are producing nice things again. And what a luck that I can buy them at Jörgs shop.