Using dimensions from trams in local museums a full cad model was first drawn up and simulated to go around the tightest bend of 9 meters on the existing railway. Wheels had to be sourced from a mining equipment supplier as our lathe was just not big enough and the cost of machining from solid would have been too much anyway. The electric motors were scanned using 3D digitizing technology and the bogies was then modeled around them. Once the bogies were complete, a temporary chassis was built to mount the battery and electronic drive components on to take for a test drive. The frame also had a height gauge to make sure it cleared all the bridges, one bridge had to be cut to allow the clerestory to pass through. We borrowed a battery from the supplier and established that it was a touch too small, so the next size up was ultimately chosen.
The frame and body were fabricated and being put together in stages small enough for two men to be able to carry the various parts without needing a forklift. Everything was sandblasted and phosphate dipped to make sure the metal is protected from the ocean air where it lives. A test bench was assembled and left in the park over the busy December period to test every backside that passed it to make sure everyone “fits”. To keep the center of gravity low, the battery box was fabricated out of 6mm steel and slung below the frame. The box has external ports where all the different controls plug into, so should a better drive solution arrive one day it can easily be swapped out. A drive motor is mounted in each bogie to supply power to the wheels, a third electric motor runs the air compressor used for the fail safe park brake. Each bogie carries its own little 5-liter air tank that keeps the brakes on even if all power and air supply to them fails. The compressor also comes in handy for cleaning the floor with a quick coupler under the steps to plug in the airgun.
It is drivable from both ends, a master key unlocks the control panel. The controls are dead simple to understand. Ignition on, brakes off, select gear and open the throttle. Notching back to zero will regenerate and slow down the tram without touching the brakes. If you can’t learn to drive it in 5 minutes.
The tram touched down on its new home track on the 1st of July 2023.