Railflyer Updates

[railflyermodel]

GenSet,

If there is an outstanding order, it is best to send an email with your name and order number so we can looking into it because I have no idea who you are. Like Tim said, sign your name to your posts, it makes it easier for us to know who you are.

Guys,

We got some major progress this weekend.

The main disconnect was added and 8/3 BX run up to a void space. We got 60' done last night. The void space was very lucky. There was just enough room in a service conduit to run TECH cable and add two junction boxes on each side. The scary part would have been drilling through the concrete walls and trying to feed conduit for the twenty feet without any means of getting inside the area except knocking down the wall enough to crawl through. Today, we ran the 8/3 BX from the junction in the first unit all the way to ours. Another 70 feet. We just have to connect one junction box and add more anchors and the work is done to our transformer. The issue was we only had 4 hours do to this work today in the other units. All that is left now is 1" EMT from our meter to our panel which is a short distance then its just straight wiring in inside the shop to all the equipment.

Evan and I talked tonight and we're going to transition to them doing order fulfillment which is something I just don't have the time to manage effectively. Right now the shop is completely torn up from the wiring and we're having issues keeping things neat and doing machining at the same time. The two just don't mix well.

So after the wiring is done, we're going reorganize the company a bit to get better at what we do. In all its just growing pains. We've creating completely different company doing the manufacturing in house and yes, it is a complete cluster f$%k right now.

However in a few weeks when we cut our first mould which we're saving a crap load of money on versus doing in China and we have our DCC/dWiDCC done, you start seeing some very good results, while we did loose the tooling, there have been a lot of other things going on behind the scenes to make all of this happen.

We also have our 3D CAD going into skins for ultra realistic mods. This should be live very soon. The test shots look awesome.

Keep up the support, at this point a lot of stuff just needs money thrown at it to wrap up.

All the best,

Christopher Howard, Railflyer Model Prototypes Inc.
www.railflyermodel.com

 

[railflyermodel]

Paint Images

Guys,

Our first MADE IN CANADA injection mould design is done. With this contractor (he did our GMDD Wide Cab), we are being aided through the first few mould designs while we learn the design aspects.

We are able to modify this design for new products using the two part moulds such as the fans, additional doors, hood components, etc.

If we can finish the shop rewiring this weekend, we can have it inspected on Wednesday and restart operations next weekend by reorganizing the shop (its a complete disaster from the electrical work) and running some test files on the CNC.

We have all of the cutters on hand to do this initial mould, the only missing part is the inserts which we needed the 3D files to order, they are about a two week turn.

It's been a tough year but we're now able to do our own tooling which rocks!

The DCC/dWiDCC is going into pre-production once we get our space parts wire. This pays for enough prototypes to conduct programming and layout testing.

While in Bolivia this week, I picked up two designers for the Android and Wireless aspects of the project so with the basic "wired" firmware in place, they are ready to start work.

When this is going on, we're going to wrapping up the lost tooling which is holding up the truck release.

Over the next three months we will have frames, electronics, drives, trucks, and fuel tanks for the following units available:

GP7/9/20
GP35
GP38/39/40
GP38-2/39-2/40-2/50/60
SD38/39/40/45
SD38-2/40-2/45-2/50/60

We will focus in on specific units for the plastic tooling as we get back on our feet. All of these units use the current drive and truck designs we have in place.

Here is a sample of our Acrylic Resin Paint on a SD60F painted by Bob Merriam.

Here is a link to the paint.

http://www.railflyermodel.com/collections/acrylic-resin-paint

This paint is non-toxic, water clean up, sprays like a lacquer without the associated headache. Thin with Windex for the best results.

In stock Colours:

Black (Seen in the model images)
BN Green
CN Grey #17 (Seen in the model images)
CN Red #10 (Seen in the model images)
CPR Action Red
CPR Bright Red
CR Blue
EMD Primer Grey
Interior Beige
Interior Brown
Interior Grey/Green
Machine Grey
Non-Reflective Black
Red Oxide Primer
Silver
Soo Red (Also used on current CPR repaints)
White

We have an additional nine paint matched and ready go to.

Also seen on Bob's model is our SMD 402 LED's, Ditch Lights, Pyle Headlight, Drop Grabs, Ladder Grabs, and Dog Leg Grabs.

Once the electrical work is done, we have the ability to again do OEM machining and tooling. We will start restocking and bringing in held up projects as things go back to normal with sales and we get reorganized. Essentially we went from outsourcing our production to being able to do it here in Canada so, yes it has been a little screwed up but we got it done.

Christopher Howard, Railflyer Model Prototypes Inc.
www.railflyermodel.com

 

[blackz28]

wow that is some beautful work !!!!!!!

 

[railflyermodel]

Guys,

I survived my first trip after being off flying for 9 months. Here is some video, I am a Pilot in Command of a Falcon 20F-5.

Take-off from MRPV (Pavos, Costa Rica) to SEGU (Guayaquil, Ecuador)

http://youtu.be/mPprMXxkc-4

Landing in Cochabamba, Bolivia, last Monday

http://youtu.be/kWu4UseRLpk

We now have a Android/C++ developer on staff, we’re restarting the Android application and also creating infrastructure to support our 12V (single motor) and 5V (traction motor) DCC/dWiDCC.

With this push, May looks completely realistic for the full release of both Sound/Non-Sound and Wireless versions of the system.

Tablet Throttle Interface - Test

http://i1192.photobucket.com/albums/aa329/RFMP_2005/throttle_test_zps3fd1200b.png

The PCB design was wrapped up two months ago. We were able to compress the Processor and Power PCB’s to 16MM x 35MM. They are accompanied by two Truck PCB’s that contain solder pads for the LED lighting system and in the 5V system, pick up contacts for track power and the motors. A few locomotives have been recorded and production testing of the design has begun at the developers.

All the best,

Christopher Howard, Railflyer Model Prototypes Inc.
www.railflyermodel.com

 

[blackz28]

nice with the android app !!/ c++ will not hurt , good we need to b able to run throttle/phone

 

[railflyermodel]

WiFi based throttles work by sending a signal to a PC, to the command station, then to the locomotive through the rails.

it really isn't completely wireless, you still need to wire your track to make it work.

with us, you don't need a PC, Command Station, Booster, Juicer, track wiring, and even signal blocks.

the tablet interfaces with your layout nodes (locomotives, signals, turn outs) directly. you can have wooden track!

all hardware development is done!

Christopher Howard, Railflyer Model Prototypes Inc.
www.railflyermodel.com

 

[railflyermodel]

what's going on - part 1

What’s Going On

We’re scheduling an inspection for our shop wiring next week. This will put our Datron M7HP, Air Dryer/Compressor, and Vacuum System in full productivity after a false start last July.

We had the equipment delivered and installed by Datron Dynamics, within two weeks we reported issues and experienced driver and processor PBC failures. We also had motors fail and unexplainable crashes or drive cut outs during operation such as tool length measurements or changes. The only thing we were able to do with the CNC is do few minor projects and training. It has been completely dead since November. In January we did have a service technician arrive and diagnose electrical fluctuations in our shop. We repaired and certified the CNC to 19 micron accuracy over 3 meters. The machine is accurate to 0.0005” and capable of tooling both steel and aluminium inserts for injection mould tooling but without a clean and consistent power supply it is merely a very expensive paperweight.

This investment was the largest amount of money we’ve put into the company since we started, it shows our commitment to getting the tooling done and it also puts us into a very good strategic position. While the combination of down time and direct online attacks on our business have hurt, the metrics associated and the flexibility of having complete control on your tooling will make all of the past year worth the work.

Keep in mind; we got this close with 20 moulds, so this hasn’t been intentional to hold up releases. I can ship garbage or I can ship what is done to my standards.

Foba G5 30 Watt Fibre Laser

We’ve been working on this purchase since January. We ran some tests on aluminum to simulate an injection mould tool. See the results. While the CNC is best at some things, teaming it up with the laser can result in very rapid and precise tooling when the laser is used for surfacing and squaring up pockets or fine details. We can also completely replace our photo-etched products with the laser as well which we intend to do. These samples were completely done with a laser.

The funding has been approved however we need to raise deposits.

Injection Mould Design

We’ve been hitting the mould design and have two moulds ready to cut. Another is being done this week to finish up the hood doors. We’re going to start with the hood doors because they will go fast, and it’s a great starting point to get or processes in place. It’s also needed for our locomotives so it’s a win/win. After the hood doors, we’re prepping the fans and truck details.

While the armchair “business owner” might say we’ve been worthy of jail time, the investment in the in house tooling is going to result of faster delivery and with direct tooling costs now ¼ of what we were paying previously, it’s going to give us a lot more bang for the buck.

A healthy business model and more product options for prototype modeller’s; what’s the problem?

Also note that tooling the previous moulds in house is also cheaper than reordering additional production with our suppliers. Without the compromises we had to make so the plastic bases were generic enough to amortize the costs over more products, we can now simplify assembly by adding more detail in the parts.

The hoods cover the GP/SD 38/39/40/45 up to the Dash Two series. Both EMD/GMDD options are included and they are intended to work with our hood bases.

Motor Control/Layout Control

A traction motor based drive has been done for a while now. With the Datron up, we can machine the additional wheel variations that are posted.

Using the traction motors has a lot of benefits.
• We can use scale width and see through trucks.
• We can use scale draft gear.
• Pull is greater than traditional drives.
• Current draw is ½ or less than current drives.

With the motorization part of the drive being contained in the truck and the low amperage draw it gives us the flexibility to offer wireless operation by including a battery in the locomotive hood.

The difference between our system and others is that you get the DCC/dWiDCC in one package. Most other wireless platforms require both a decoder and wireless module purchase.

We also put all of the LED components and programming in our package so LED lighting is simply soldering the correct lead to the correct pad. We have 46 LED outputs, 23 on each end of the locomotive for multiple effects and light options.

The PCB’s for all versions posted on the web-site are done.

The tablet development is also done.

All that remains now is software which is currently in progress. The system is up-datable with an internet connection. As the capabilities evolve, rest assured that the hardware design is now “frozen” and all of our locomotive motor control can be reused in all of our future releases no matter if its GE or Alco.

Excellent Tooling, Excellent Motor Control, and Excellent Layout Control are all important for model railway locomotives. Thus why we are combining the three into one package optimised for the prototype modeller and prototype operator.

The tablet is your “Command Station”, the PCB’s in the locomotives and associated software is the brains. In the wireless system, no track based signal is used, however the PCB’s of all variations are able to run with existing stations using track wiring.

 

[railflyermodel]

Paint

Do not forget about our paint. It is an acrylic resin which gives the finish of a lacquer but the ease of water clean-up. Use Windex for thinning. The paint is concentrated so a little goes a long way.
17 colours are in stock, 9 more are ready to ship once things return to normal.

Here is an example of our CN Red #10, CN Grey #17, and Black.

New Speakers

Our new speakers are ready to ship from the supplier, they have been held up by the rewiring and slow sales; however they can be here in a week. The new versions are smaller which enable more placement options. The new layout for the locomotive kits will have two. The PCB’s support outputs for two speakers.

Photo-etch

We have a lot of photo-etch in stock. Anything out of stock is either going to be reordered or replaced with the laser as we see fit. Some DP 6631 photo-etch is inbound and we also ordered DP 6612 but there is a delay on this due the new supplier having layering issues.

Quite frankly, the laser is going to do a better job on the photo-etched products and we can right size our inventory so just please be patient, once sales return to normal, we’ll get your order shipped.

Revisions and New Kits

As stated, with the lost tooling it will be replaced and guys caught up on the locomotive kits once we have enough to justify shipment.
One thing I have been working on is new frames and fuel tanks.
The issue with the previous releases is that trying to make the plastic as generic as possible increases assembly time. With the new revision we are trying to meld numerous components into one or two parts. The new configuration also takes into account wiring and enables the running of leads through the frame to areas such as the steps and truck area. Yes, our system is prototypical so you get real lighting such as safety and walkway lights. So the result is a metal frame that is machined with a top that is likely going to be also machined or MIM (metal injection moulded). Currently over the next few weeks we’ll machine GP9, GP35, G38/39/40, GP38/39/40-2, GP40-2L, GP50, GP60, SD38/39/40/45, SD38/39/40/45-2, and SD50/60 frames. Essentially anything that can run on our three announced drives. We’re also going to machine samples of matching fuel tanks.

Anybody with locomotive kit “Pre-Orders” will be reset with the latest revisions.

Again our “Pre-Orders” are crowd funding which is not the same as a dealer asking for money upfront such as Canadian Model Trains (CMT).

Closing

Thank you for the support the past year. Yes it’s been tough on everybody but we now have the ability to manufacture on site which we didn't do previously.

I have been completely upfront on “Pre-Orders”, they depend on sales to expedite shipments. Whether or not you agree with our business practices, “crowd funding” is not illegal and the on-line attempts to put us under just result in the 600+ open orders being pushed back further for delivery. We have done all we can do this past year to deliver by bringing in the equipment and software to do injection mould tooling and machining in house.

The “hard” parts of our projects are done; we’re just waiting on a normalisation of our sales to fund the releases.

Unfortunately as you see more and more, small business is not supported by the “traditional” financial services system even though we shoulder the burden in job growth and creation. We could purchase and lease $300,000 worth of equipment and software but I couldn't get a $5000 loan to rewire and get it working from a “traditional” bank.

The same goes for inventory, they won’t touch it, thus we need the discounted “Pre-Orders” to release the projects or sales on the products we've already done to reorder inventory that goes out of stock. A healthy cash flow enables us to expedite order fulfilment or improve our infrastructure.

After seven years in business, we've released a lot, we have a lot more in the works, and our core business is design and manufacturing.

Dealers and Distributors core business is fast shipping and up to date inventory management but they don’t really cater to the prototype modeller as we do, thus when we lose support it makes things appear a lot worse than they really are.

You can’t approach us with the same mentality as your local hobby store. They don’t make the parts you buy. So don’t waste your time bashing us, you’re just screwing those who are supporting us because whether you like to admit it or not, having small companies around whom do their homework force the larger companies to up the game. Most products for the “prototype” modeller were tooled in the 1980’s and 1990’s and are starting to wear or become irrelevant with current releases. From day one, my approach on the locomotive project was to release the full kit from the rails up to a new standard. While our product overlaps some detail products, it is intended for the release of full kits and later on, painted and assembled models.

I am trying my best to get this done quickly, but at the same time, it is also going to be done right so it lasts. Being 30 years younger than most of my competitors, we’re going to be around for a while yet.
All the best,

Christopher Howard, Railflyer Model Prototypes Inc.
www.railflyermodel.com

 

[blackz28]

Wow nice looks you guys are moving in the right direction

 

[railflyermodel]

because of some awesome support today, the designer fees for the new PCB's are more than half paid off. a good weekend is all that stands between having the physical hardware in hand - so I can show you how it works and release the drive.

all the PCB components will work in every locomotive we ever release, this covers wired , wireless, sound and no sound versions. all are done the design phase.

software and programming is scheduled to be done in 4 - 6 weeks!

we have lots of LEDs going out next week and other items because the shop is going to be back together, so if you can support us, doing so now is going to show progress very quickly.

CJH

 

[railflyermodel]

wiring is done, it was a very long week getting it all finished. inspection again tomorrow, hopefully energizing Thursday.

 

[railflyermodel]

the wiring passed this week, the Datron needed a bunch of modifications to pass the ESA evaluation but they are now done, playing phone tag with the inspector to get it passed. we'll be cutting metal again this week.

 

[blackz28]

aint progress nice , cant wait till you get producing