r.l...the laser-cut wood parts include many very thin parts; handle carefully. also, three...
TRANSCRIPT
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R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA SCOTIA kit #RLW-1650
© 2021 Republic Locomotive Works 1650 – pg. 1
HISTORY:
From the Sherbrooke Village Museum, Nova Scotia website
( https://historicnovascotia.ca/items/show/224 ):
“The first sawmill in the Sherbrooke area was erected around 1809 by
James Fisher, who came from Truro in 1805. In 1814, another
sawmill and a grist mill were set up by David Archibald III, also from
Truro, at the site of present-day Sherbrooke.
The year 1826 marked a unique development in Sherbrooke’s sawmill
industry. William Thompson Archibald, son of David Archibald III,
and Henry Cumminger entered into an agreement to erect a double
mill at the southern end of the village, now part of the Sherbrooke
Village restoration area. With this agreement, the Archibald mill was
relocated to its new home and a second set of machinery was installed
by Henry Cumminger. To supply power for the water wheels, they also
dug a canal, which ran from Sherbrooke lake to St. Mary’s river and
was approximately 260 metres long, 3 metres wide, and nearly 5
metres deep.
By 1856 ownership of the double mill was acquired by the McDonald
Brothers. By 1900, however, the mill was abandoned and allowed to
fall into ruin. For many years, nothing remained of this once active industry except the hand-dug race, which assumed the character of a
natural outlet from Sherbrooke Lake.
In 1970, when restoration work commenced on a part of the village of Sherbrooke, transforming it into a typical 19th century Nova Scotia
community [https://sherbrookevillage.novascotia.ca/] the decision was made to reconstruct a working replica of a water-powered, up-and-
down sawmill on the site of the former McDonald Brothers’ mill.
The sawmill building is a two storey structure with hand-hewn post and beam
construction and board and batten exterior cladding. The roof is covered
with long board shingles with 40-centimetre exposure to the weather. The
lower storey contains the belt and pulley gear for the mill, and provision is
made for a shingle mill and other woodworking equipment. Upstairs is the
log carriage and up-and-down saw with their simple but ingenious
mechanisms…. With a bountiful supply of water from a chain of five lakes,
the reconstructed McDonald Brothers’ Sawmill is believed to be the only one
of its kind in Nova Scotia capable of full waterpower production.”
The Up-Down sawmill (also called “frame sawmill”, “English gate sawmill”,
“upright saw”, or “sash sawmill”) is a mechanical application of its hand-
powered predecessor, the Pit Saw. A crank driven by the waterwheel moves
the saw frame and single saw blade in an up and down motion, cutting into
the log on each downward stroke. The up-ward motion of the saw is also used
to move the log carriage forward by means of a system of levers and a
ratchet. Several minutes are required for each cut through the length of an
average log.
For additional exterior and interior photos, see: https://www.republiclocomotiveworks.com/show_item.php?ID=1338
GENERAL:
This is a craftsman kit consisting of laser-cut wood and paper, cast urethane resin, white metal, 3D printed acrylic plastic parts, brass wire,
embossed foil, and paper templates. (See “Parts Identification” for images of included parts):
Some resin castings may contain minor flash or small bubble holes. Otherwise, good castings will NOT be rejected for small flaws; it is
assumed the modeler will have the skill to fill these small flaws. Finishing recommendations are included under “WORKING WITH
RESIN CASTINGS” below.
The laser-cut wood parts include many very thin parts; handle carefully. Also, three thicknesses and two types of wood materials are
used for the laser-cut parts: 1/64” (.016”) plywood, 1/32” (.032”) plywood, and 1/16” (.063”) bass wood. The latter is not plywood, and
Reconstructed McDonald Brothers Sawmill, Sherbrooke Village,
Nova Scotia – photo by Marshall Thomson
Interior of reconstructed McDonald Brothers Sawmill,
Sherbrooke Village, Nova Scotia, showing vertical saw and log
carriage – photo by Marshall Thomson
https://historicnovascotia.ca/items/show/224https://sherbrookevillage.novascotia.ca/https://www.republiclocomotiveworks.com/show_item.php?ID=1338
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R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA SCOTIA kit #RLW-1650
© 2021 Republic Locomotive Works 1650 – pg. 2
care must be taken not to break these parts. Finishing recommendations are under “WORKING WITH LASER-CUT WOOD” below.
The 3D printed parts are an acrylic plastic. While strong, these are not as strong nor as flexible as the engineering plastic or styrene you
may be used to working with. Carefully remove parts from attached sprues. Parts should be carefully washed with isopropyl alcohol or
mild dishwashing detergent before painting with acrylic paints.
Every different procedure or method is discussed in detail in the instructions; however, once it has been discussed, it may not be repeated in
detail again.
This kit is not intended for use by novice modelers, or individuals under the age of 18 without the supervision of an adult. Additionally,
the modeler assumes all liability regarding the proper use of this product, or any product suggested. The user must become familiar with
the kit instructions, and instructions on any product used to complete this kit. Please read and follow all safety procedures for all products
used to finish this kit. Details may vary between scales and from the sample model shown.
Follow safety requirements and manufacturer’s requirements as stated on all paint, chemical blackener, and adhesive containers.
WARNING: Pursuant to California Health and Safety Code section 25249.6, the manufacturer and distributor of this product
warns you that this product may contain substances known by the state of California to cause cancer, birth defects and/or
reproductive toxicity.
Tools & Materials:
small drills, including #80, #76, #67 clips for holding parts together – Mueller Electric BU34
flat file - Nicholson 6" Mill Bastard magnification such as Optivisor or Edroy Opticaid
small files - Micro Mark #83180 paint brushes and air-brush
model building knife – Xacto or equal, with #11 blades paints – see detailed instructions
finger-nail clippers or Xuron flush rail cutters Rustall and Weather All (www.rustall.com )
Tweezers and smooth-jawed needle-nose pliers adhesives – 3M 77 Spray Adhesive, CA, 2-part epoxy, Sanding board (make by gluing sandpaper to piece of wood)
Rotary cutter – Olfa, Excel or equal Pliobond, and Titebond wood glue, Pacer Canopy Glue
glues: 3M 77 Spray Adhesive; CA; carpenter’s or “white” glue;
Optional:
Water Wheel and Sound Animation kit (RLW #1651)
logs – Details N Scale
outhouse(s) (RLW-211N – includes parts for two outhouses)
figures
horse-drawn wagons – Musket Miniatures, Langley, Republic Locomotive Works, Preiser
miscellaneous details: tools, etc. – Republic Locomotive Works
miscellaneous scenery materials to complete scene
Order of Assembly
The instructions are arranged as follows:
• Water Wheel & Motor Mount
• Laminations
• Base and Basement Level
• Upper Stories
• Water Wheel Flume
• Roof
• Interior Details
• Ancillary Structures: Drying Shed, East and West Bridges; Sawdust Bin and Conveyor; Sawn Lumber Conveyor
• Finishes (this section will be referenced in above sections as appropriate to assembly sequence.)
• Site: Dam, Bridge Abutments, Log Dump (with terrain suggestions) (NOTE: Instructions for assembly of Water Wheel Animation, and Sound Animation add-on kits are included with those add-on
kits; important aspects of interfacing these add-on kits with the base kit are included in the sections above.)
Orientation
Throughout the instructions reference will be made to the cardinal reference points of the site: north, south east and west. These
references will be included in parts identification on the laser-cut sheets and in the parts list, and are also scribed on part B.39, the
Sawmill Base.
http://www.rustall.com/
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R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA SCOTIA kit #RLW-1650
© 2021 Republic Locomotive Works 1650 – pg. 3
Parts Identification
A Parts List is included as a separate document in the kit box. The following diagrams and images are provided to aid in visually
identifying parts.
Laser-Cut Parts Frets: Parts are organized by material and thicknesses, with a letter code designating material and thickness, followed by the part number. The different materials and thicknesses can be identified by the following codes:
A.## 1/16” Basswood C.## 1/64” Plywood E.-## Peel-and-Stick Paper Trim B.## 1/32” Plywood D.## 1/64” Laser Board F.-## Clear Glazing Material
The following images of each of the laser-cut sheets can be used as a way to identify part locations; it does not represent the order of
assembly, and the sizes shown herein are not necessarily reflective of the relative sizes of the actual sheets.
SHEET 1 – 1/16” BASSWOOD
SHEET 2 – 1/32” PLYWOOD
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R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA SCOTIA kit #RLW-1650
© 2021 Republic Locomotive Works 1650 – pg. 4
SHEET 3 – 1/32” PLYWOOD
SHEET 4 – 1/32” PLYWOOD
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R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA SCOTIA kit #RLW-1650
© 2021 Republic Locomotive Works 1650 – pg. 5
SHEET 5 – 1/32” PLYWOOD
SHEET 6 – 1/64” PLYWOOD
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R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA SCOTIA kit #RLW-1650
© 2021 Republic Locomotive Works 1650 – pg. 6
SHEET 7 – 1/64” PLYWOOD
SHEET 8 – LASER BOARD
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R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA SCOTIA kit #RLW-1650
© 2021 Republic Locomotive Works 1650 – pg. 7
SHEET 9 – PEEL & STICK PAPER SHEET 10 – CLEAR GLAZING MATERIAL
Resin Castings:
3d Printed Parts: (Note:3D printed parts are supplied joined together as one piece and must be carefully cut apart with a razor saw or
jeweler’s saw.)
Other
Also included are:
0-80 flat-head screws (2 each) Laser-cut roof shingle material
1-72 screws, nuts and washers (2 each) Ladder stock
Brass wire Misc. SS Etched Logging & Sawmill Tools
Cut Lumber Misc. White Metal Detail Castings
Working With Laser-Cut Wood
The laser-cut sheets may look like pieces are missing, but these holes are intentional. The opening for windows, doors, etc., are removed
by the laser to make building this kit easier. These waste pieces, called drop-outs, may still be clinging to the sheet, and fall out when
touched. Save them for use as clutter and scraps when doing the final detailing.
The laser-cut wood parts include many very thin parts - handle carefully. Three thicknesses and two types of wood materials are used for
the laser-cut parts: 1/64” (.016”) plywood, 1/32” (.032”) plywood, and 1/16” (.063”) bass wood. The latter is not plywood, and care
Dam & Spillway Log Dump West Bridge East Bridge Abutment Abutment
Water Wheel
Water Wheel Mount*
(Use if NOT installing motor.)
Water Wheel End Support
Carriage
Winch
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R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA SCOTIA kit #RLW-1650
© 2021 Republic Locomotive Works 1650 – pg. 8
must be taken not to break these parts. Remove the pieces from the carrier sheets with a sharp hobby knife as they are needed, and lightly
sand off the remainder of the tabs. On the thicker pieces, there is a slight draft angle caused by the laser. This angle can be removed with a
pass or two of a fine sanding block. Identify all the parts, checking them against the parts list and sheet diagrams. Most wood parts have
a number either on them or nearby. Do not remove the parts from the carrier prior to actually using them in the construction of the model.
Wood and paper products are effectively live materials on which humidity and temperature changes will change the size of parts slightly.
Our climate is moist so you may find minor changes in the proportion of the parts when moved to a dryer climate, so test-fit parts and
adjust if required.
In many cases, assembly requires the lamination of layers of laser-cut wood or laser board. It is important this be done with 3m 77 Spray
Adhesive. After lamination of the batten sheet to the underlying wall sheet, excess material is to be trimmed away using a rotary cutter
such as those made by Olfa, Fisker or Excel. Do NOT use a model knife or similar blade for this as it will displace the battens.
The prototype structure is unpainted wood with the exception of the window sash, frames and trim. It is recommended the model be
assembled first, then airbrushed a base coast of gray followed by dry-brushing to create a weathered wood effect. (See “FINISHES” for
details on finishing.)
Working With Metal Castings
All the metal parts should be handled with care as denting and breakage may occur if they are dropped.. After you have completed the
initial cleanup of parting lines, sprues and flash, wash all the castings in isopropyl alcohol, and allow them to dry. Handle these after
washing by wearing gloves to avoid getting them contaminated with the oils from your hands.
Painting the castings can be accomplished with a brush or airbrush. A good base coat will be created by airbrushing your castings with
Vallejo Acrylico Air NATO Black or Microlux Engine Black (same paint – different packaging.) Choose relatively dull colors for your
castings. Models tend to look more realistic using shades such as Mud, Grimy Black, etc. by Floquil, or similar dull shades. Rarely
should you consider using bright colors in model scenes.
Working With Resin Castings
Some resin castings may contain minor flash or small bubble holes. There may be small bubbles inside recesses. Otherwise good castings
will NOT be rejected for small flaws; it is assumed the modeler will have the skill to fix these small flaws. Wash resin castings with soap
and water or isopropyl alcohol prior to painting. Glue resin castings to laser-cut ply base with CA adhesive or two-part epoxy. Urethane
parts may be sanded and filed easily, but the dust should not be inhaled! Urethane resin parts may be airbrushed with acrylic paints. It
is recommended that all the resin castings be sprayed with an undercoat of flat black acrylic modeler’s paint ( Vallejo NATO Black.)
Working With 3d Printed Parts
The 3D printed parts are an acrylic plastic. While strong, these are not as strong nor as flexible as the engineering plastic or styrene you
may be used to working with. Carefully remove parts from attached sprues. Parts should be carefully washed with isopropyl alcohol
before painting. For fragile parts such as the log carriage lightly coat the thinnest parts of the 3D printed part with a low viscosity CA
adhesive to strengthen the part. Examine the drawings, and drill holes where required. Glue 3D printed parts together with CA adhesive.
It is recommended that all the 3D parts be sprayed with an undercoat of flat black acrylic modeler’s paint such as Vallejo NATO Black.
These parts can have undercuts and recesses, so be sure the spray penetrates all areas. Working With Peel-and-Stick Materials Included in the kit are sheets of laser-cut peel-and-stick material for roofing shingles and window trim. Window trim should only be
applied after the exterior painting and weathering has thoroughly dried. The small window trim pieces are best lifted from the carrier
sheet and transferred to the model with the tip of a modeling knife before being burnished to the model surface. Working With Site And Building Bases
The kit is designed to facilitate the assembly of the separate structures on a wood base prior to installing on the layout. This base is thin
laser-cut plywood. Plan the location of the sawmill in advance, and – if desired – add mounting flanges or framing to bottom of laser-cut
plywood base to facilitate incorporating the model into the layout. ALSO, the laser-cut base only extends the width of the exposed face of
the dam and does NOT extend to the limits required for the drying shed on the west, the bank and stairs up from the bridge to the east, nor
the log pond on the north. A SITE PLAN is included in the “SITE” Section. You may wish to mount the laser-cut base on a larger sub-
base to incorporate additional “terrain” to support these features or add them to the scene after the main sawmill and dam are incorporated
into your layout.
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© 2021 Republic Locomotive Works 1650 – pg. 9
R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA SCOTIA kit #RLW-1650
ASSEMBLY INSTRUCTIONS
WATER WHEEL & MOTOR MOUNT
Assemble parts A.01.3, A.01.4, and A.01.5(2) as shown below using Titebond glue or “carpenter’s glue”. If NOT installing the
motorized water wheel animation kit, install the Water Wheel Mount after washing with isopropyl alcohol (see WORKING WITH 3D
PRINTED PARTS) and taping for 0-80 screws using the two 0-80 flat-head screws provided.
Assure hole in Water Wheel is clean – if necessary, swab out with isopropyl alcohol
with a pipe cleaner. Test fit water wheel to mount. DO NOT FORCE WHEEL
ONTO SHAFT OR YOU WILL BREAK SHAFT OF WHEEL. If necessary,
carefully scrape out any residue from the printing process inside the shaft hole and
try again, repeating if necessary. Fit should be a smooth slip fit. Slip Water Wheel
onto shaft but do not glue in place.
Glue part A.01.1 to
base B.39 aligned
with the guidelines
on B.39 using
spray adhesive or Titebond glue. (If using Titebond glue, place a flat
weight on top and allow to dry overnight.) Place 1-72 nuts in the
hexagonal holes in part A.01.1, and glue part A.01.2 on top aligning
the holes with the nuts visually or using a round toothpick; do not get
glue into the threads of the nuts.
Test fit Water Wheel & Motor Mount to base with two 1-72 screws
and washers through slots into nuts in base. If glue has gotten into
threads, chase with a 1-72 tap. Check to see if screws protrude from
bottom of base, and file if necessary.
If installing the motorized Water Wheel and Sound Animation add-on
kit (RLW #1651) follow the instructions included with the geared motor for installing the water wheel, motor and wiring.
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© 2021 Republic Locomotive Works 1650 – pg. 10
R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA SCOTIA kit #RLW-1650
LAMINATIONS
The building exterior walls and roof are of laminated construction. The walls consist of an outer layer of battens over a layer of siding with exterior scribing and
upper window sash, an interior layer of siding including the interior board scribing,
and a layer of interior post-and-beam framing (not installed as part of this step.). The main sawmill roof pieces include an interior face with planking scribing, and
an exterior face with scribed guidelines for the installation of the peel-and-stick roofing shingles.
Tabs with holes are included at the top corners of the different wall layers to
facilitate the alignment of these different layers. Using a piece of pine or other soft
wood and one each of the long (east and west) and short (north and south) walls,
press straight pins through the two tabs at the top corners of the wall and cut the
heads off the pins. This will allow the accurate alignment of layers as laminated.
Remove part C.01 from the Sheet 6 fret and using a sharp modeling knife cut the
tabs and remove any remaining window and door drop-outs. Place C.01 over the
pins. Remove battens D.01 from Sheet 8 and remove any remaining hanging drop-
outs. Holding batten sheet D.01 by one of the corners using tweezers or other
clamping device, spray the back uniformly with 3M 77 Spray Adhesive (suggest
using a disposable carboard sheet or cardboard box in an area with ventilation) then
drop D.01 onto C.01 using the pins for alignment. Press D.01 into C.01; a small
roller such as used for linoleum block printing or even a small cylindrical glass
bottle such as a paint bottle is useful for this. If battens at the corners drop off
either during this operation or later during assembly, extra battens are provided
which can be installed after the walls
are assembled to each other.
OPTIONAL: Turn wall assembly
over and glue interior wall surface in
place with 3M 77 Spray Adhesive.
Otherwise, install after trimming
battens aligning window openings.
(See parts numbers for interior sides
to be laminated to exterior parts in
following paragraphs.)
Remove laminated wall assembly
and trim excess batten layer away
with rotary cutter. (Do not use
modeling knife across battens or you
will displace the battens.) Repeat,
laminating part D.02 onto part C.02;
part D.03 onto part C.03; part D.04
onto part C.04; part D.05 onto part
B.01; part D.06 onto part B.04.
Interior side: using spray adhesive,
laminate part C.02 to part C.05; part
C.06 to part C.01; C.07 to part C.0;
and part C.08 to part C.04.
Using spray adhesive, laminate roof
parts B.34 to part B.37 and part B.36
to part B.35.
Alignment jig for laminating wall layers: top,
exterior wall placed over alignment pins; bottom,
exterior battens applied using spray adhesive and
pressure.
Trimming excess batten layer: trim tabs with
alignment holes with modeling knife, then trim
excess battens layer with rotary cutter (do not use
modeling knife on battens).
Laminating interior wall surface to exterior; can be done with alignment pins or trim off
tabs and align using widow openings as a
guide.
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© 2021 Republic Locomotive Works 1650 – pg. 11
R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA SCOTIA kit #RLW-1650
BASE AND BASEMENT LEVEL
Use Titebond glue to glue parts B.01 (east), B.02 (west), B.03 (north) and B.04 (south) to base B.39, fitting tabs into slots in base. Use
clamps to hold walls square to each other if required.
After glue sets, add interior (core) basement walls A.03 (east), A.04 (west), A.05 (north) and A.06 (south). Use clips to hold these core
walls tight to exterior walls while the glue cures. If installing the Water Wheel and Sound Animation kit (RLW #1651), insert one speaker
behind holes in east basement wall, then glue part A.02 to back of north wall to act as stop for holding speaker in place.
Glue parts A.10 and A.11 in place to inside of basement walls and add part B.39, the partial basement floor , to the south end of the
basement interior, with the walkway extending through the doorway.
UPPER STORIES
Use Titebond glue to glue the second floor, part B.10 to the west wall laminate (parts C.02 + C.05) using a square to assure the parts
are perpendicular. (Photos next page.) After glue dries, add north, south and east wall laminates to the floor. Use clamps to hold
walls square to each other if required. After assembly, check corner battens and if any have been lost during assembly, add new
battens from parts provided. Test fit upper part of building to basement and base.
Left: basement walls fitted to base; center – interior “core” walls glued in place to inside face of basement exterior walls (back of
water wheel flume being test-fitted in right image.); right - Partial basement floor and supports.
Left - West exterior wall laminate fitted to second floor; center and right – test fitting upper floors to basement level.
Install East and West interior post-and-beam
framing (parts B.17 and B.18) with Titebond glue
– hold tight to outer walls with clips as necessary.
After glue dries, install North and South interior
post-and-beam framing (parts B.19 and B.20)
then tie beams B.21.
Bevel top and bottom edges of part B.09.02 and
install as shown along with B.09.3.
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© 2021 Republic Locomotive Works 1650 – pg. 12
R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA SCOTIA kit #RLW-1650
Glue part A.07 to the inside of the west wall tight to the floor above to act as a stop
when the upper floors are placed over the basement level.
Glue parts A.08 and A.09 on the exterior under doors #6 and #7 as ledgers for supporting
the bridges.
Doors & Windows:
The doors are composed of a scribed siding component or left (L) and right (R) components on Sheet 6 and a cross brace component
(B) on Sheet 8. Each door opening and each door is numbered on both the laser-cut fret and on page 5 of these instructions, and the
opening number is linked to a door and bracing number as follows:
Opening no. Door part no. Brace part no.
1 C.10.L/C.10.R C.13.LB/C.13.RB
2 C.11.L/C.11.R C.14.LB/C.14.RB
3 C.12.L/C.12.R C.15.LB/C.15.RB
4 C.13 C.16.B
5 C.14 C.17.B
6 C.15 C.18.B
Glue the appropriate brace to the corresponding door, then glue the door in place using Pliobond for a flexible joint along the hinged
edge, leaving door in the open position. See finished model photos for doors opening out vs. doors opening inward.
Window painting, glazing & installation is covered in the “FINISHES” section.
Door #6 Door #5 Door #2 Door #3 Doors #1 & #4
(Note braces C.18 & C.19)
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© 2021 Republic Locomotive Works 1650 – pg. 13
R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA SCOTIA kit #RLW-1650
WATER WHEEL FLUME or RACEWAY (also called a PENSTOCK)
Assemble the west side of the Water Wheel Flume (B.05 – Raceway West) to the bypass part B.09.1 while test-fitting to the east wall (A
below). Then add the south end frame B.06.2 (B below). Glue in place to the base and the east wall of the sawmill. Laminate t he Flume
Framing (B.08) to the Raceway East (C.18) then glue to the base and the installed Raceway West (D below). Add raceway framing
C.06.1 through C.06.10 and raceway side B.07 (E below). Note that the raceway necks down at the outlet where B.07 is located. Finally,
add decking C.20 to the top of the raceway (F below).
After installing the water wheel flume/raceway, removal and
reinstallation of the upper portion of the building must be done
on a slight angle; see picture at right.
Water wheel flume/raceway assembly sequence.
It is recommended that at this point the exterior of the sawmill
as well as the water wheel flume be painted and receive initial
weathering; see “FINISHES” section of these instructions.
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© 2021 Republic Locomotive Works 1650 – pg. 14
R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA SCOTIA kit #RLW-1650
SAWMILL ROOF
The Sawmill Roof is composed of laminated top (B.36 and B.37) and bottom (B.34 and B.35) pieces to be then assembled on the roof
rafters/trusses (B.22). The top and bottom for the west side and east side are identified on the laser-cut fret. The ridge (top edge) is also
identified and notched to mate with the opposite side. Use spray adhesive for laminating the top and bottom sheets. After assembly, use
a modeling knife to cut a bevel in the “downhill” side of the locating slots. (See photo sequence below.)
When roof is assembled, apply peel-and-stick roof shingles. The top of the laser-cut roof panels is scribed with guidelines. THESE ARE
NOT FOR SPACING THE SHINGLE STRIPS – they are to help keep each strip parallel to the ridge of the roof. Use the notches in the
shingle strip defining each shingle as a guide to the overlap (or “exposure”) of each shingle strip. (See image below.) With shingles in
place, add eave and rake trim (D.09 and D.10)
The section on “FINISHES” will cover the painting weathering of the roof shingles.
INTERIOR DETAILS
The following items are included for the interior of the sawmill second floor:
• Log Carriage (3D print)
• Log Carriage support (part B.26) • Winch - sometimes called a “Pull Wheel” - (3D print)
• Log Deck, comprised of parts B.33 and deck C.20 • Saw Frame, comprised of parts B.24, B.25 and B.25.1
• Saw blade on Sheet 10
• Misc. logs, white metal castings and etched tools
This section will cover the components above which are fixed to the structure (as
noted in the image to the right); the modeler can determine the extent to which the
miscellaneous items are used and where they are placed to complete the simulation of
an operating sawmill.
Upper and lower surfaces east roof Gluing roof trusses and end locators in place Cutting bevel in roof locating slots
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© 2021 Republic Locomotive Works 1650 – pg. 15
R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA SCOTIA kit #RLW-1650
The log carriage and winch are 3D printed plastic. Carefully wash these parts
as described in “Working With 3d Printed Parts”. Chase holes as required
and glue in .010” brass wire for the control levers and the shaft for the blocks
as shown at right. Airbrush or brush paint these parts with your choice of
color – the current color at the Museum is red.
When dry, cut two .010” wide
by 2” long strips of typing
paper, paint the paper on both
sides Vallejo Air 71.027 Light
Brown and wrap a strip around
the pulley on both the saw
carriage and winch securing
with some CA adhesive and
gluing the free ends of the strips
together.
Test fit the log carriage in place between the vertical legs of B.25 and with the pulley and belt
sticking down through the opening in the floor. If necessary, trim material away from the
opening. When satisfied with the placement, secure with a drop of CA applied with a pin to the
joint between the carriage and the carriage support frame.
Glue the carriage support frame for the saw carriage (B.26) in place on the second floor, aligning the slot for the saw in the floor with the
slot in the support frame. Glue the frame supporting the log deck (B.33) in place aligned with Door #1 and opposite the northern half of the
carriage support frame. Glue the log deck (C.20) to the top of this frame. Locate the winch with the pulley and belt sticking down through
the opening in the floor and glue in place.
Add parts B.24, B.25 (“Fender Posts”) and B.25.1 (“Saw Gate”) as
shown on previous page, gluing B.24 to the bottom of the previously
installed tie beams (B.21) making sure the slot in the Saw Gate (B.25.1)
is above the slot in the floor and the carriage support frame. Remove the
laser-cut saw blade from Sheet 10, paint silver or aluminum, and – when
dry -slide down through the slots in the Saw Gate, the carriage support
frame and the floor before gluing with a small drop of glue where it fits
into the Saw Gate (B25.1) (Optional: use one of the etched stainless steel
two-man saws from the tools fret.)
Several pieces of 12” – 18” diameter logs (typical sizes for this sawmill)
are included in the kit. Cut to about 20’ lengths and add to the log deck
and the ramp from the millpond. Using a modeling knife or razor say,
slice one of the logs lengthwise and place on the log carriage. Optional: if
desired, fabricate dogs from brass wire to simulate the dogs that would
hold the log against the blocks (holes are provided in the blocks for
these).
Additional detailing: Paint and add white metal castings as desired. Add
sawdust and strip-wood simulating cut lumber.
For additional equipment (Edger, Cutoff Saw, etc.) you wish to install at
this level, see:
https://www.republiclocomotiveworks.com/showPage.php?page=1
https://www.republiclocomotiveworks.com/showPage.php?page=1
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© 2021 Republic Locomotive Works 1650 – pg. 16
R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA SCOTIA kit #RLW-1650
ANCILLARY STRUCTURES
Besides the main sawmill structure, the complex has the following structures which are included in this kit:
• Drying Shed
• West Bridge
• East Bridge
• Sawdust Bin
• Sawdust Conveyor
• Sawn Lumber Conveyor (Not included is the modern ADA-accessible restroom building.)
Drying Shed:
Glue siding C.27 and C.28 to the two (2) B.29 post-and-beam/rafter
parts. Glue post-and-beam/rafter parts B.29 into holes at left and right
ends of the Drying Shed base B.40 then glue four (4) parts B.30 into
intermediate holes in B.40. Glue two (2) parts B.32 across long sides
of the drying shed keyed into the notches at the top edges of the B.29
and B.30 parts. Glue siding C.29 across back wall. After glue dries,
glue four (4) B.31 girts between posts along back wall at the base of
the siding. At this point, it is recommended basic painting and
weathering be performed before installing roof panels. (See
“FINISHES”) When basic painting and weathering is completed, glue
two (2) roof parts B.38, then add peel-and-stick shingles and rake and
eave trim parts D.11 and D.12.
East Bridge:
Glue truss B.11.1 to C.22.N and truss B.11.2 to C.22.S noting the orientation of the railing parts with respect to the building. Add cross beams
B.12, making sure the two pieces not including a vertical element are centered on the truss. Glue the decking to one half of the bridge at a
time using clips to hold everything solidly together, then trim ends of railing parts back to scribed line.
Installing post-and-beam framing on base Installing siding on rear wall; hold with clips Girts B.31 installed along base of rear wall
Finished Drying Shed after painting and weathering. (See “FINISHES”)
Primary trusses and cross framing to railings Gluing one side to deck; hold with clips Completed bridge (See “FINISHES” for painting)
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© 2021 Republic Locomotive Works 1650 – pg. 17
R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA SCOTIA kit #RLW-1650
West Bridge:
Glue beams B.13.1 and B.13.2 to C.23, using West Bridge Abutment resin casting to
check spacing; tabs on bottom of beams fit into slots on the top of the abutment. Glue
railings C.24 to either side of the bridge between the tab that engages the abutment and
the east end of the bridge deck (see image to right). Do not glue bridge to either abutment
or building.
Sawdust Bin:
Glue the post-and-beam
frames B.27 (2) to base B.41,
with scribing at knee braces
facing inwards, then add
siding pieces C.16 (2) and
C.17 (2). Glue top conveyor
support B.28 to top.
Sawdust Conveyor The sawdust conveyor runs from the square opening on the
west side of the lower level up to the top of the sawdust bin. The final length of the conveyor and the location
along the length of the conveyor of the support legs is dependent upon how the modeler constructs the slope and
the flat area where the bin is located. Glue parts C.25 (2) to the conveyor B.15 flaring the sides out about 20-30̊ Turn
over and glue parts B-16 in place; these have extended legs which need to be cut to fit your final slope. See “SITE” for
locating and installing this structure.
Roller Conveyor
NOTE: The roller conveyor runs from Door #4 opening on the west side of the upper level to the adjacent flat area. The final length of the
conveyor and the location is dependent upon how the modeler constructs the slope and the flat area where it ends. (The horizontal parts are extra length and an extra frame (B.14.4) is provided for long installations.) Ream holes then install brass wire, using B.14.1 to space the frames. Glue
with CA then trim flush. Assemble the remaining parts using Titebond glue. Support using B.14.5 (and B.14.6 if required.)
Finished West Bridge after painting and
weathering. (See “FINISHES”)
Sawdust Bin
NOTE: The Sawdust Conveyor & Roller Conveyor fit between
the west wall of the sawmill and top of the adjacent bank. It is
recommended you NOT assemble these until you have
completed the basic terrain (see “Site”) then build to suit the
length required.
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© 2021 Republic Locomotive Works 1650 – pg. 18
R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA SCOTIA kit #RLW-1650
FINISHES
Building walls:
Airbrush exterior walls, bridge framing, sawdust bin, and conveyors with a base
coat of light gray (Vallejo Air Light Gray 71.050) then drybrush with an assortment
of colors to simulate weathered unpainted wood; recommended paints:
• Vallejo Air NATO Black 71.251
• Vallejo Air Mud Brown 71.037
• Vallejo Air Light Brown 71.027
• Vallejo Air Sand 71.075
Windows:
After weathering the exterior walls paint windows sash Vallejo Air
Aged White 71.132 inside and out, and also paint the window frame
(opening edges.) Paint the lower sash included on Sheet 8 with
Vallejo Air Aged White 71.132 on both sides. Add glazing using
one of two options: (1) laser-cut clear plastic is provided which can
be glued to pre-painted sash with Pacer Canopy Glue; (2) use
Microscale Micro Krystal Klear or Pacer Canopy Glue liquid to
form thin film glazing. When glazing has dried, glue lower sash in
the window openings from the interior in closed, open or partially
open positions to suit.
Roofs:
After shingles have been applied, airbrush with Vallejo NATO
Black, and when dry, drybrush with:
• Vallejo Air Light Gray 71.050
• Vallejo Air Light Brown 71.027
• Vallejo Air Aged White 71.132
• Vallejo Air Mud Brown 71.037
Bridge Abutments:
After washing and drying resin castings, airbrush with a basecoat
of Vallejo NATO Black, and when dry, drybrush with Vallejo
Air Light Gray 71.050. When dry, use a fine brush to pick out
individual stones with:
• Vallejo Air Light Brown 71.027
• Vallejo Air Mud Brown 71.037
• Vallejo Air Sand 71.132
Log Dump and Dam:
After washing and drying resin castings, airbrush with a basecoat of Vallejo NATO Black,
and when dry, drybrush with Vallejo Air Mud Brown 71.037 followed by dry brushing
highlights of:
• Vallejo Air Light Brown 71.027
• Vallejo Air Aged White 71.132
• Vallejo Air Mud Brown 71.037
• Vallejo Air Sand 71.132 Drybrush sloping wood top of dam with Vallejo Air Light Gray 71.050.
Water Wheel:
After washing and drying resin castings, airbrush with a basecoat of Vallejo NATO Black, and when dry, drybrush with Vallejo Air Mud
Brown 71.037. (Wheel stays relatively dark because it is always wet.)
Wood siding weathered with acrylic paints; left –
window sash and painted window frame interior; right –
white peel-and-stick window trim burnished in place.
Window glazing: left - applying Microscale Micro Krystal Klear to back of
lower sash by swiping across the fret with a toothpick dipped in glazing
liquid; right – glue lower sash in place from inside structure.
Finished peel-and-stick roofing shingles: left – Vallejo Air NATO Black
undercoat; right – after dry-brushing with various colors.
Water Wheel with base coat of NATO Black
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© 2021 Republic Locomotive Works 1650 – pg. 19
R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA SCOTIA kit #RLW-1650
SITE
The McDonald Brothers Sawmill is located on a cove along the St. Mary’s River in Nova Scotia (see satellite image on left, below.) The site
plan on the right below shows the prototype arrangement of the historic sawmill structures included in this model, with an outline of part B.39.
Dam & Spillway
The dam is a resin casting. Wash
the casting with isopropyl alcohol
(see “Working with Resin
Castings”.) Airbrush the casting
with a base coat of Vallejo Air
NATO Black. When dry, drybrush
with various browns and grays to
simulate weathered logs and
planking (See “FINISHES”.)
When paint has dried epoxy the
dam in place on the base B.39
taking care as sliding the casting in
place under the water wheel flume.
Bridge Abutments
After washing East and West Bridge
Abutment resin castings (see “Working with
Resin Castings”) airbrush with Vallejo
NATO Black, followed by stonework finish
coats (see “FINISHES) then epoxy in place
on base B.39.
Log Dump
After washing the Log Dump resin casting (see “Working with Resin Castings”) airbrush with
Vallejo NATO Black, then paint and dry brush to simulate logs and loose bark on dirt. (See
Finishes”.) Suggestions on how to blend the resin base around the logs into the adjacent scenery are
in the “Terrain” portion of this section.
Left- paint and lightly weather dam before installation; right – slip dam under flume and epoxy to base B.39.
Left- painted bridge abutments; center & right – abutments glued in place.
The existing McDonald Brothers Sawmill reconstruction site (minus the modern ADA-accessible restrooms)
McDonald Brothers Sawmill reconstruction is located at Sherbrooke Village Museum 4037
Sonora Rd, Sherbrooke, NS B0J 3C0, Canada
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© 2021 Republic Locomotive Works 1650 – pg. 20
R.L.W. McDONALD BROTHERS SAWMILL, SHERBROOKE VILLAGE, NOVA SCOTIA kit #RLW-1650
Terrain
The prototype sawmill building is located in a swale below the dam on the outlet stream
or “race” which connects to Mill Cove. The bridges and conveyors connect the different
levels of the building to the tops of the adjacent slopes of the swales. The flat site at the
top of the west slope (left in the photo) includes the Drying Shed and Sawdust Bin as
well as access to the Log Dump, Roller Conveyor and the West Bridge. The modeler
will need an area larger than base B.39 to model these features. It is recommended the
base be glued to a larger piece of plywood, MDF or hardboard for this purpose, the size
of which will be determined by the available space on the layout. It is recommended a
minimum space of 10” x 12” be allocated for this. Note that if rail access is to be
included, this size should be adjusted accordingly, as should the orientation of the Log
Dump and the Drying Shed which could potentially be served by the same track.
The photos below show construction of adjacent terrain using polystyrene insulation board and tinted spackle, the placement of structures, water
simulation and the addition of landscape elements - static grass, shrubs and trees. After terrain surface is faired in, test fit Sawdust Conveyor and
Roller Conveyor and cut supporting timbers to length.
For assistance in assembly or interpretation of instructions, contact:
For all other enquiries: Republic Locomotive Works
16 Little Cape Horn, Cathlamet, WA. 98612
360-577-6479
21.02.05
South side of sawmill showing swale with outlet from mill pond on right and slope up to Sawdust Bin
and Drying Shed on left.
Terrain roughed in with 1” foam insulation Terrain faired in with pre-tinted spackle; Scenery using static grass, foliage, rocks, gloss
Cut to fit around bridge abutments and dam; bases for Log Dump, Sawdust Bin, Drying gel medium (figures not included in kit.)
1/8” hardboard mill pond surface Shed cut into spackle surface then glued down
mailto:[email protected]