By David Smith
First published to uk.rec.models.rail on the 24.2.2004 and used here with the author's permission. My thanks to him :)
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Measure the outside dimensions of the corridor connection and cut a strip of
thin card.
Cut a strip as long as you like with the width the same as the height of the
connector.
Mark off the strip across the width with a set square at intervals equal to
the width you want the connector to finish up with.
Then also mark across the width, half way between each of the first marks. I
use a hard very sharp pencil.
Now fold the strip into a concertina along the ORIGINAL set of marks.
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With a bit of trial and error you will need to find how many folds you need
to bridge to gap between your coaches. Bearing in mind that there will be one
connector on each coach end, thus making two per connection. This works
because they slide side to side against each other.
For my close coupled Bachmann Mk1s I have found that each connector is made
up of 2 sets of 5 'panels' from the folded concertina. (Add your own numbers
of panels where necessary).
So cut the concertina strip into 5 'panel' pieces. Now slit down the
centreline of each panel (using that second set of marks) from top to just
past half way.
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Take two of these pieces and interlock them.
Once they are interlocked and in line, glue a new piece of thicker card, say
180 gr on each end. Now shape the whole thing with a sharp craft knife. I
use a scalpel.
I use PVA all round.
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If you want to restrict the length that the connector expands, for instance
on the end of a rake of coaches, embed black thread under the end pieces as
in the pictures.
If you are into modern stock you may want grey card etc.
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