Modeling Glass Cullet Loads

I think at one point we all come across a prototype freight load that begs to be modeled. In particular I can say there are many that lack a model, but a simple one that has been on my planning board for sometime is recycled glass otherwise known as "cullet". My intended goal will be to share the backstory and creation process so you can bring these loads to your layout. 

What is it? 
In simple enough terms it is crushed recycled glass. This material is used in numerous ways such as fiberglass insulation, glass beads (sandblasting), and road materials to name a few. 

           Potter's Industries north of Brownwood, TX. They make glass ball beads for many different uses. 
                   Photo courtesy of Google Maps. 

How is it transported?
Alot of times glass cullet is crushed and transported locally by truck from the recycling facility to end user, but there are cases where it moves by rail. I do not believe it will be one of those unit train type commodities found often like aggregate or coal, but as a one off load. Every prototype example I have seen or found shows use of dump trucks or open top hoppers, not to say an older covered hopper could be utilized. This is a heavier material as its raw material was sand and soda ash prior to becoming glass, so the car would not be loaded to the brim more around 3/4 full. The cars I have seen are marked EAMX (Everest Railcar Services). Due to the nature of the commodity these are probably in a captive service as cleaning would require something more abrasive then water like sandblasting. 

Besides seeing in person from an overpass, John Danielson over at rrpicturearchives.net has the best photo of these 3 bay hoppers carrying glass cullet at this link: EAMX 328 - John Danielson Collection 

How is is loaded/unloaded?
Loading at the crushing facility is as simple as a front end loader filling its bucket and dumping into the railcar. Unloading is just as easy. In this prototype example a small under track pit allows the transloader to empty from one gate at a time. The pit is shallow but deep enough for a front end loader to get a bucket full, back up, and then load the awaiting truck. The front end loader could also double as a car mover if multiple cars are to be unloaded. 

Photo courtesy Google Maps (Satellite View)

                         Glass cullet rail to truck transload in Brownwood, TX on Texas Rock Crusher Railroad

                                                        Photo courtesy Google Street View 

How is it modeled?
The easiest part about glass cullet is its "replication" on a model level. Sometimes making model loads are complex and require kitbashing or even scratchbuilding. In this case it is about simple cosmetics. Follow along as I walk you through creating a glass cullet load. In as little as a weekend you could have yours complete. 

Step 1: Materials
- Removable type open top hopper load (I used Motrak Models #81728)
       ** Side note the Motrak Models coal load is fantastic as purchased without changes **
- Rustoleum 2x (Gloss White) or any cheap white spray can 
- Dullcote
- Extra fine glitter (I used silver peacock which is blueish-green-silver)
- India Ink / Isopropyl Alcohol mix

Coal type loads work well with the sharp angles to provide a good texture for the paint / glitter to adhere on. 

Step 2: Base 
- Start by giving the drop in loads a generous coat of gloss white (Well ventilated area)
- Spray from all four angles to ensure you get a good coat in all the tight spots

Step 3: Glitter
- Giving the paint just about one minute to setup some then sprinkler your glitter
- Do not worry about being modest you want solid coverage 
- At this point let the load completely dry, do not touch or dump off excess glitter

Step 4: Glitter to Cullet
- Once dry, carefully pickup the load and tip it over to remove excess material.
- You should have good coverage with no load under showing through.
- In a well ventialiated area - spray the load with dull coat and let dry.
- The glitter provides the dull shine that you would find from crushed glass.  

                           This was my test plastic load before making the cullet loads from Motrak load. 

Step 5: Dull 
- Once dullcoat is dry use your fingernail to check around the edges of the load and remove any glitter stuck on the sides. Its important the sides are clear of glitter so it will sit properly in the railcar. 
- Airbrush load with a india ink / alcohol mix to get the desired dirty effect 
- Let dry, then place in railcar.

This technique worked well for plastic and hydrocal casting loads. Materials can be purchased for under $10 at your local craft store. 


I hope you enjoyed this fun post, showing you a quick and inexpensive way to add a one of a kind open top load to your layout. Everyone have a safe and happy Halloween.

GM 

Early July Update

Well June and its significant rainfall is now gone, but the scorching heat and humidity of a Texas July is in full swing. Back earlier this summer I outlined what projects I had planned for June, July, and August in hopes to complete them. I am happy to report that June's sound install project (LHT #02) is complete and both P2K GP38-2s (MCIS 3827 and MCIS 3833) are operating and sounding fantastic. Being able to complete this and have our second child was quite a feat. Thanks to my wife for giving me time in the evenings while the kids were asleep to complete the project. This post we are going to focus on the recent motive power and rolling stock additions, while the Mid-July post will dive into the July project which entails adding scenery to Bay Yard.

MCIS 4052 and CN 6256 lead the M-PHBA-07 through Upper Huron, MI.

Motive Power
Earlier this spring three MCIS motors and one CN motor were sent to VMS in Virginia for sound installation, and other wok. VMS otherwise known as Virginia Midland Shops is work that my friend and fellow modeler Shannon Crabtree completes for me. Just prior to the July 4th holiday VMS completed work on two MCIS EMD SD40-2s and one CN EMD SD40-3 arriving back on property just before the holiday. I happened to be at the right place at the right time to capture two of the motors heading up the M-PHBA-07 through Upper Huron yesterday.

MCIS 4052 (EMD SD40-2) closeup.

CN 6256 (EMD SD40-3) trailing. Last I checked the prototype motor was operating up on CN''s DMIR property.

MCIS 4056 at Bay Yard receiving inspection, ditch light, and air conditioner installation.

Rolling Stock
Trailing behind the power on the M-PHBA-07 were three railcars that are new to the St. Clair Subdivision and also represent new business for the railroad.

Pipe load for Alaska
TR874111 is carrying banded pipe out of Wolverine Steel Products at Marine City heading to the Fairbanks, Alaska via ARR barge at Seattle, WA.

Railcar is Atlas 73' model with custom pipe load created by a local friend and fellow modeler in the Fort Worth area.

A future post will showcase many of the unique and awesome open top loads that his modeler has created.

Closeup of load - meticulous detail with each bundle wrapped individually.

Coke for Sugar Beet Production
CWE 125379 and CWE 125360 from Tom Patterson's Chesapeake, Wheeling & Erie are carrying coke destined to Michigan Sugar at Upper Huron. Once these cars reach Bay Yard at the terminus of the M-PHBA-06 they will then return to Upper Huron on the Port Belle Turn (R-BAPB). This is a great win for the railroad as in the past the coke was being trucked out of Detroit, but with a pooled supply of cars from CWE and MCIS a product pipeline will be in place to deliver anywhere from 2 to 6 cars a week depending on the sugar production needs.

Both railcars are Bowser 100 ton models. 

These modernized 100 ton hoppers were painted, decaled, and weathered by Shannon Crabtree's Virginia Midland Shops before heading to the CWE for loadout. More to follow on these cars in my next foreign railroad equipment post.

Later on this weekend I will be posting my Mid-July update focusing on this months project at Bay Yard.

GM