Demag TC 500 truck crane in scale 1/24
 

Demag TC 500 truck crane in scale 1/24

Now that the LTM1800 is more or less finished it is time for a new project. I have been thinking about which crane to built for quite a while and I actually started with some parts a few months ago. Before deciding to actually build this crane. It is a German built Demag crane on a Faun carrier and was produced in the late 70’s. There are still some around, one at Inland Crane hire in in Idaho.
On this page you can see the TC500 ready for action: http://www.heavyequipmentforums.com/...dge-replacment
Van Seumeren also had a few: https://www.flickr.com/photos/73498813@N02/6641955839/

The Demag TC500 is the successor of the TC400 and is basically the same crane, just a few reinforcements and more counterweight and is rated at 125 metric tons capacity.
Here two pictures, one from the back of a leaflet and the other taken by myself. I will build the version with the very low-line carrier cab.
https://farm8.staticflickr.com/7020/...3b6096c0_b.jpg
https://farm9.staticflickr.com/8281/...11fc6700_b.jpg

Here are two pictures of the rims:
https://farm8.staticflickr.com/7430/...33d8a7ca_b.jpg
https://farm6.staticflickr.com/5488/...fc70e3a7_b.jpg
The tires come again from the All American Toy Company.

At the moment I am working on the drive axles, which is a challenge, because space is very limited. I decided to completely build the axles myself. Pictures will follow.


Kerst

Re: Demag TC 500 truck crane in scale 1/24
 

Got the popcorn going! Another cool crane build :bounce::bounce::cool::cool:

Re: Demag TC 500 truck crane in scale 1/24
 

What tires are those?

Re: Demag TC 500 truck crane in scale 1/24
 

They are from here:
http://www.allamericantoyco.com/kwkit.html
Scroll down the page, it is part # 34
They are very nice tires for this purpose.

Kerst

Re: Demag TC 500 truck crane in scale 1/24
 

At the moment I am working on the drive axles, which is a challenge, because space is very limited. I decided to completely build the axles myself.
Here are some pictures:
https://farm6.staticflickr.com/5572/...b67fcde7_b.jpg
https://farm6.staticflickr.com/5529/...985d18af_b.jpg


Kerst

Re: Demag TC 500 truck crane in scale 1/24
 

Wow:D double reduction, just like what Mack Truck's build's! I like them:jaw:
Cheer's, Neil.

Re: Demag TC 500 truck crane in scale 1/24
 

I am steadily working on the rear axles of the Faun carrier. When I last posted I had everything figured out, so now it is a matter of realizing it all and it is coming together nicely. I am pretty happy with the result. The axles are functional and hardly to scale, but they won’t be visible at all once they are in place. I put all the parts together in a mock-up to see how it will look.
https://farm4.staticflickr.com/3917/...83209009_b.jpg
https://farm4.staticflickr.com/3894/...7637b510_b.jpg
https://farm3.staticflickr.com/2917/...08ba48cd_b.jpg

Kerst

Re: Demag TC 500 truck crane in scale 1/24
 

Those are looking strong, I think they'll pretty much move anything!:jaw::jaw:

Re: Demag TC 500 truck crane in scale 1/24
 

Thank you.
These axles need to be strong. The real ones are rated (static) at around 90,000 lbs each.

kerst

Re: Demag TC 500 truck crane in scale 1/24
 

Wow, that's a very nice bit of brass fabrication there. Mine work has solder slopped everywhere. Looking forward to seeing more!

Re: Demag TC 500 truck crane in scale 1/24
 

I made the drive shaft between the two axles. This was tricky, because they are very close together.
https://farm6.staticflickr.com/5577/...2483b88f_b.jpgAxles FAUN by kerstdejong, on Flickr

Kerst

Re: Demag TC 500 truck crane in scale 1/24
 

The summer has been busy with all kind of activities, including making a Board room table to fit 22 people for our new office.
But I picked up again in the Fall and got a good start. I finished the tandem axles, started on the frame and just now started making the wheels for the other three axles.

Tandem axles:
https://farm6.staticflickr.com/5616/...920b521a_b.jpg
https://farm6.staticflickr.com/5603/...03cd1556_b.jpg

Frame:
https://farm8.staticflickr.com/7546/...925e19c1_b.jpg

Soldering the parts together for the front wheels:
https://farm9.staticflickr.com/8600/...9bbbfa1d_b.jpg
Front wheels in the making:
https://farm8.staticflickr.com/7548/...7f437f3d_b.jpg

Kerst

Re: Demag TC 500 truck crane in scale 1/24
 

I made some progress with the wheels. The tandem axles are done and I have been working on the other wheels. These are the three axles with single tires and one of the three axles is driven. For these I used brass, because it is so easy to solder and machine. I will focus on the driven axle next. It is very similar to the rear axles.
The picture shows all the front wheel parts in various stages of assembly. The bearings are 14 x 8 x 4. I got a whole lot of them for very little money:
https://farm9.staticflickr.com/8668/...5d328f58_b.jpg

The tandem axles with walking beam suspension:
https://farm9.staticflickr.com/8663/...774f5106_b.jpg

Here is the frame, made of AL:
https://farm8.staticflickr.com/7546/...925e19c1_b.jpg

Kerst

Re: Demag TC 500 truck crane in scale 1/24
 

Very nice work on the wheels. Good attention to details!

Re: Demag TC 500 truck crane in scale 1/24
 

I made some progress with the Faun carrier. The suspension of the two front axles was quite a challenge, mainly due to little room. The first axle is a driven one and the second non-driven. I also had to keep as much room as possible for the motor, which will be mounted above the front axles.
https://farm8.staticflickr.com/7463/...be02b906_b.jpg
https://farm9.staticflickr.com/8623/...f59c929e_b.jpg
https://farm8.staticflickr.com/7517/...3fdf4523_b.jpg
https://farm9.staticflickr.com/8598/...3db66c18_b.jpg

Kerst

Re: Demag TC 500 truck crane in scale 1/24
 

Looking great

Re: Demag TC 500 truck crane in scale 1/24
 

Hey, Kerst, I just caught up with this one. Again, another knock-out! I love the herkiness of your builds, and that everything is metal. Super work on those hubs and wheels, they look great. And another great crane in 1/24 scale, to boot! I'll be following.

Re: Demag TC 500 truck crane in scale 1/24
 

I made some nice progress, although things are not as finished as they seem. Today I made good progress on the third axle. I still have to finish the suspension and the steering.
https://farm9.staticflickr.com/8669/...2c482bc7_b.jpg

kerst

Re: Demag TC 500 truck crane in scale 1/24
 

thats looking great!! have you ever thought about doing
a crane in 1/14 or 16 scale?

Re: Demag TC 500 truck crane in scale 1/24
 

I find those scales too big. It would open up a lot of new possibilities, but I like 1/24. It is easy to handle and fits my spaces. And when fully rigged it will still be over 10' high.

Thanks,

Kerst

Re: Demag TC 500 truck crane in scale 1/24
 

Excellent machining on the wheels and frame work. Question for you- how are you fastening the wheel centers to the rims on the front 3 axles? Are the center bolts and nuts gripping on the rim?

Re: Demag TC 500 truck crane in scale 1/24
 

That is right, it works like the real thing.

Kerst

Re: Demag TC 500 truck crane in scale 1/24
 

The beginnings of the cab are here:
https://farm6.staticflickr.com/5331/...235a6211_b.jpg
I also started on the outrigger boxes. They are pretty straightforward. I decided on Steel and I brazed them together. Now they are definitely strong enough. The second picture shows some parts added using solder. They need to be cleaned up a bit and they are ready. Next are the outrigger beams.
https://farm1.staticflickr.com/542/1...a432c010_b.jpg
https://farm1.staticflickr.com/375/1...f1d63e2c_b.jpg

Kerst

Re: Demag TC 500 truck crane in scale 1/24
 

Faun carrier

The outrigger boxes are ready and bolted to the carrier. Next will be the outrigger beams. I am also thinking how to build the gearbox and transfer case and which motor to use. There is not a lot of space, so they need to be designed carefully.

https://farm1.staticflickr.com/562/1...f8010499_b.jpg

https://farm1.staticflickr.com/461/1...c42d6105_b.jpg


Note: The third axle is missing.

Kerst

Re: Demag TC 500 truck crane in scale 1/24
 

if this is anything like you had at cabinfever it will be amazing

Re: Demag TC 500 truck crane in scale 1/24
 

Transfer box

In the last couple of weeks I have been experimenting with a planetary reduction, which I got from a small geared motor. A lot of trial and error! The outside diameter is 22 mm and all the gears are steel.
The trick was to incorporate it in the transfer box. I tried a lot of different setups, but I think I found a setup that works. The transfer box will have two speeds (direct and very low) and front wheel drive can be engaged or disengaged. The real one has an inter-axle diff, between the rear axles and the front axle, but I couldn’t find the right planetaries to accomplish that. It would need a 1:2 ratio.
It turned out nice and compact. But it hasn’t been tested yet.
https://farm6.staticflickr.com/5669/...37927e55_b.jpg

Kerst

Re: Demag TC 500 truck crane in scale 1/24
 

Love to see gearing!!

Re: Demag TC 500 truck crane in scale 1/24
 

Kerst,

Very nice build. I hope to learn more about building small controllable transmission like this. Have you done any experimentation with electromagnetic clutches or other types of clutch set ups in any of your work? I have been thinking about how a clutch could be used to precisely control a hoist.

Re: Demag TC 500 truck crane in scale 1/24
 

Thank you!
I haven't worked with any type of remote controlled clutches yet. I have thought about it, including using pneumatics or servos.
This gearbox will have a simple lever.

Kerst

Re: Demag TC 500 truck crane in scale 1/24
 

During the past couple of weeks I worked on the universal joints. I always make them myself, mainly because they need to be very specific in size, but also because good quality universal joints are very expensive. The final assembly of the joints is always tricky, because I solder the pins (1/16" diameter) in from the center and the solder easily flows in the wrong spaces. It needs to be heated just enough for the solder to flow, but not too long. I had a cup of water handy to cool it down quick once I thought it was done.

In the pictures the motor is directly connected to the transfer box, but I might add a 2-speed gearbox. I want to first try out the speeds and see if this is the right motor, etc.

https://farm6.staticflickr.com/5711/...4acb6e87_b.jpg
https://farm1.staticflickr.com/755/2...f05558f1_b.jpg

Kerst

Re: Demag TC 500 truck crane in scale 1/24
 

The transfer box is finished:
https://farm6.staticflickr.com/5730/...1dc74a08_b.jpg
https://farm1.staticflickr.com/593/2...f639e545_b.jpg
https://farm6.staticflickr.com/5761/...047e6b9e_b.jpg

Kerst

Re: Demag TC 500 truck crane in scale 1/24
 

Nice work in a tight space. Very nice build you have started.

Re: Demag TC 500 truck crane in scale 1/24
 

That looks like it should handle a pretty good load. Those U-joints are beautiful! Did you use ball bearings or bushings?

Re: Demag TC 500 truck crane in scale 1/24
 

I've really enjoyed following this build and am very interested in your u-joint fabrication. Would you post a bit more detail on how you make them?

Thanks!

Ken

Re: Demag TC 500 truck crane in scale 1/24
 

Very impressive home made parts! Nice job.:cool:

Re: Demag TC 500 truck crane in scale 1/24
 

Mr. Kerst Sir you are are very impressive cant wait to see the final build and here I thought the last crane you built was amazing this will be a masterpiece

Re: Demag TC 500 truck crane in scale 1/24
 

I did some work on the cab. I added the doors with homemade hinges. They still look clunky, but this was the best I could do.
https://c2.staticflickr.com/6/5757/2...fb5b40b9_b.jpg
https://c1.staticflickr.com/1/603/22...c7c03695_b.jpg

I also installed the motor and a separate small gear motor to lift the counterweights. This needed a bit of thinking, since room was very limited. The 2 pictures show it both in lowered as in in raised position.
https://c1.staticflickr.com/1/569/22...ec9a5938_b.jpg
https://c1.staticflickr.com/1/658/21...2fba56b9_b.jpg

Kerst

Re: Demag TC 500 truck crane in scale 1/24
 

In the past couple of months I did all kinds of little things, including optimizing the steering, working on the space in front of the third axle, the levers of the gearbox and some other details.
https://c1.staticflickr.com/1/646/23...d30aefff_b.jpg
https://c1.staticflickr.com/1/707/23...50c62a4c_b.jpg
https://c1.staticflickr.com/1/642/23...f5fe382a_b.jpg


Here is a short video of the steering in action: https://youtu.be/ObYaSMiSlfU

I also made a box for the crane with space for the crane itself and the boom sections.
https://c2.staticflickr.com/6/5727/2...3ce6abc0_b.jpg
https://c2.staticflickr.com/2/1597/2...88bf795e_b.jpg


I wish you all a Happy New year and see you at the Cabin Fever Expo!
Kerst

Re: Demag TC 500 truck crane in scale 1/24
 

This is a super build! With limited space you have still figured ways to make things work. Love all the mechanisms that make this crane tick and the detail.
Ken

Re: Demag TC 500 truck crane in scale 1/24
 

I started work on the outriggers. here you can see the structural parts of the outriggers, steel, brazed together. I will use hand operated screw jacks for the vertical movement. there is too little space for a motor.
https://c2.staticflickr.com/2/1491/2...8121c8c4_b.jpg

kerst