Jim's Woodworking Shop

Latest Project

Stagecoach

Last year I started building a model Stagecoach from scratch.
I never knew that a Stage had so many parts. They are quite the work of art.
The first thing to do is find out just how a stagecoach is constructed. I went online and found many drawings and pictures. It seems there are many models of stagecoaches, so, I integrated them into one plan I felt wouldn't be too difficult to construct.
The first object, to manufacture the wheels.
I had some experience making wheels, so after a couple false starts, I came up with a plan for the wheels.
There are 12 spokes in each wheel, so that works out for each section to have a 15 Deg. angle.
The progress of the wheels is shown below. It took some thought to decide how to drill holes for the spokes, and I finally decided I needed a fixture. It worked fairly well.

Wheels

Angle set at 15 Deg.	Cutting Segments	Drilling Hub spoke holes
Drilling Spoke Holes	Dry Fit	Initial Glueup
Front Wheel Glueup	Rear Wheel Glueup	Rough Wheel
Finished Wheel

I discovered one of Gracie's dog bowls was just about the right size for 2 of the wheels.   The others I used 3 long hose clamps end to end. It worked well.  It took some adjustment to get the spokes just the right length so everything fit right. But, after a couple false starts, the wheels were done.

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Chassis

The next item was the chassis to hold the wheels. Again, I looked at the way several coaches were designed and finally settled on one that didn't look too hard to copy.
The front axle is held onto the main chassis by a pin. The joint pivots on a sub axle that has a small amount of crown to it.

Front Axle Detail	Chassis Glue up	Chassis

Below are pictures of the brake bar and shoes. On a real coach, there are two metal rods that connect to the brake lever. I decided to use some wood rods I just happened to have.

Chassis	Chassis detail	Brake Bar
Brake Shoe	Strap Fitting(4 ea)	Strap on Fitting
Brake Rods	Brake Mechanics	Brake Levers

I discovered the coach is slung on what looks to be leather straps. (Strap fittings and strap on fitting) pictures. There is a fitting fore and aft on each side and the strap is fastened between them. There appears to be 3 or 4 layers of straps. Sort of like a big leaf spring only made out of leather. There are 2 fittings on each side of the underside of the coach, that slip over the leather straps. It must have been a strange ride compared with what we're used to with our modern autos.

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Coach

The design of the coach took the same path as the frame. I compared several plans and chose the one that looked best to copy. I made a drawing, and transfered it to cardboard. Then cut out 2 sides from some 3/32 plywood.

Next I decided how wide to make the coach, and cut a framework from 1/4 pine to join the two sides.

Some of the framework can be seen in the picture of the Baggage Braces. You can see how the side patterns were edged with 1/4 wood frame, with stringers running from each side to set the width of the coach. I traced the curve of the side panels onto the 1/4 stock and cut them out on the bandsaw and the scrollsaw. The roof panel has a small amount of curve on the sides, and is also curved on the roof slightly.
The baggage rack is made so it can be folded up. (I haven't a clue why) and is held with a chain on each side, and wall made of a piece of leather on each side.

Baggage Frame	Baggage Holder Glueup

The Doors and Trim.

The doors were made from a tracing of the door opening on a piece of the thin plywood held up on the outside of the coach and a pencil going in the opposite door. The window opening was drawn, and cut out on the scroll saw.

Doors with Hinges	Finished Doors

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Put it all together

The straps I wanted to use were just black fabric, and I discovered when I tried to install them that they weren't strong enough. On to plan "B". Actually, I had no plan "B". Just that if the fabric didn't work, I'd have to find something else. The something else turned out to be a roll of stainless wire I'd had forever. (Picture "1"). I cut 2 lengths for each side, and it worked very well. (Picture "2".

Picture "3" is the coach with the trim on the sides. It is the same material as I used for the walls of the coach. When it is painted Red and the walls stained Early American, there is a pleasing contrast. A Little can be seen in picture "2".

Once the trim was installed, I set about making the wire luggage rails that are on top of the coach. The first attempt looked out of proportion. It was too large. So, I went with just a very simple rail. My first soldering attempt looked bad also. I was taking the two wire pieces and just sticking them close together with solder holding them. It worked far better to make a small loop on the end of the wire, and hooking it onto the joining piece. After the rail was complete, I carefully marked the mounting places on the roof and drilled small holes. I was careful that the holes were located over the inner framework, and that I didn't drill through. The holes are about 1/4" deep.
That completed the coach. Pictures "1" below.