HST 125 unit ditch and tail lights

 

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You back already. The device in the picture is what is needed for the power units. Basically it consists of a piece of a LED lighting strip cut from the extra ones I bought. After trial and tribulation I found out that these things appear to be connected in sets of three LEDs in series with a resistor. You will notice that there is a scissor mark in the middle of the unit. I choose this section because I know that the two LEDs are not connected to each other. Therefore they can be treated as discrete units. Take a closer look at the unit. Clicking on the picture will give you a close up view. Notice the positive rail marked (+) is closest. The 1000 Ohm resistor has one lead connected to both white LEDs at the anodes. It is then trimmed off. The lead on the top is bent over and cut short. I used the remainder of this pig-tail to connect the two cathodes together. This forms the basics of the circuit. The tail lights are connected directly to the wire joining the two anodes of the white LEDs. Another piece of tinned copper wire was obtained from the rubbish before it got to the bin. It was also a cut off pig-tail. This was soldered between the two cathodes of the red LEDs.

Fig. 1
Fig. 1

How did it all get there? Read on. First I tinned one leg of the 1k resistor. Soldered it between the two white LEDs at the anodes. Then I bent the resistor leads into the shape you see and trimmed off the excess from both the furthest LED and the opposite end of the resistor. The longest pig-tail removed was long enough to use as the connection between the two cathodes of the white LEDs. Note the small extension past one end. It is to facilitate connection of the white wire. Next using super glue applied to the base of one the gull-wing LEDs stick it in place on the surface of the unit up against the anode wire with its black line closest to you. Do the same with the other gull-wing LED.

Using a flux pen wipe flux over the two places where the gull-wing LEDs touch the wire. Then solder these. Be careful while doing this. These devices won’t take much heat. Place another piece of pig-tail under the other two gull-wings. It should fit pretty slug. Using the flux pen apply flux to these joints and solder them in the same fashion. Note the length of this pig-tail. It should have a bit of an extension for the yellow wire. Once this is done solder the coloured wires on as per photograph.

Now we need to test the device before sticking it to the power unit. With a 15 volt power supply connect the blue wire to the (+) positive of the power supply. If everything is all right the white wire touched to the (-) negative terminal should light the white lights. Doing the same with the yellow wire should light the red lights. To the loco or power unit as they are called.

Remove the body of the unit. At the front remove the bulb and its wiring. This article assumes that you have already converted the unit to DCC. Behind the bulb there is a black plastic panel. The unit should be trimmed to fit this. Make sure that there is no oil, dust or dirt on the plastic panel. Test fit the device we created on to the panel. Once you are satisfied with the fit take the cover strip from the back of the device and stick it in place. The white LEDs should be at the top and the red ones at the bottom of the power unit. The wires will be to your left as you look at the front of the unit. You shouldn’t have any trouble working out where to connect the wires. After all they are colour coded the same as the DCC chip’s wires.

Place the power unit on a short piece of track. Connect up your DCC controller to the track. Select your power unit. Switch on the head light. If you are in forward gear the white lights should light up. Change to reverse. The lights will change to red. Put the body back on the unit. You are done. Note you may have to advance the throttle a little to get the chip to change direction. There is one more unit to do. I choose to use a second chip in the rear unit to operate the lights on the rear. It does seem to be a bit of a waste though. There is a little trick to remember when wiring the rear unit. Connect the white wire to the yellow one and vice versa otherwise you will have white at both ends in forward and both ends red in reverse. The Hornby “Select” controler doesn’t like two chips with the same address on the layout. It will complain.

Tools used on two projects shown in photo bellow. There are three items missing from the photo. They are a white out pen, a pair of scissors and a roll of electrical insulation tape.

 

Tools used
Tools used

Lighting a Hornby Inter City 125

I have a Hornby Inter City 125. It is quite old, may be one of the first ones out. Recently it was updated to DCC operation. I was thinking it would look much better if it was lighted. The decision was made. The parts were ordered from YouChoos. (http://www.youchoos.co.uk/)

What was used? Parts List:-.

  • 5 x 12 Led stick on strip lights.
  • 5 x 680 ohm 1/8th watt resistors.
  • 5 x 2 pin plugs and sockets. YouChoos provided the plugs and sockets pre-wired.
  • Some 0.5 mm insulated wire in green, blue and black.
  • The lead and trailing units require coloured wire as well. Colors will be blue, white and green.
  • I purchased some extra strip lighting to obtain the LEDs for the forward ditch lights and tiny gull-wing SMD red LEDs for tail lights.
HST Coach with lighting strip in position
HST Coach with lighting strip in position

To start, remove the frame from the body of the coaches. It is not too difficult. The parts are held together by little clips in the end doors. Lay this aside. Take one of the lighting strips. Lay it on the table in front of you with the + sign further away from you. Take one 680 ohm 1/8th watt resistor. With wire cutters trim the pig tails to about 5 mm in length. Using resin core solder and a soldering iron tin both pig tails. Don’t hold the resistor in your fingers during soldering or the heat will burn them. Now solder one end of the resistor to the left side of the (+) rail of the lighting strip. This will be the front of the coach. Solder a piece of blue 0.5 mm insulated wire to the other end of the resistor. On the (-) rail of the lighting strip to the left solder a piece of green 0.5 mm insulated wire. These wires should be about 20 cm long.

Having prepared the lighting strip, take the coach body. Make sure it is clean and free of oil and dust. Peal the cover strip from the back of the lighting strip and stick the strip in the coach body with the wires towards the front marked thus. (*). Note for the Inter City 125 there is no orientation mark. The lighting strip should be in the centre of the roof of the coach as per the photo. Make sure that the strip is pressed down firmly for its entire length. For the purpose of this article the front end of the coach is to the left.

Rear view of HST coach
Rear view of HST coach

Next we need to mark out on the rear door of the coach a rectangle that is 2 mm x 4 mm. set it so the bottom of the plug will be 8 mm from the floor of the coach. Using a pin vise with a No. 61 bit fitted. Drill a row of three holes in the rectangle along the bottom edge. Stay inside the rectangle. Use the bit to join the holes up to make a slit. With a small file you need to file out the rectangle so the socket fits snugly. I used a file from a set designed for hobbyists. Mine is square sided to file the 2mm ends and has a pointed flat bit to file the 4mm sides. The file I have is a little bit larger than the slot, but with a bit of care and patience it will make the slot large enough for the file to enter.

Once you have the hole completed insert the socket. With the back of the coach to your right and the body upside down the blue wire should be furthest from you. Leave about 1 mm of the plug sticking out of the coach. Using super glue or hobbyist’s plastic glue fastens the plug to the coach. Take care not to use too much glue. It should be glued on the inside so as not to distract from the external appearance of the coach. These glues seep between the joint to form their bond. Make sure the socket is straight before the glue dries. Otherwise it will be permanently crooked. You will have about 20 seconds to get it right before the glue dries. If you take a close look at the photo of the back of the coach you will notice that I used too much glue. It spoiled the pristine look. That was the second attempt to stick it together.

Front view of the coach with the wire and plug fitted.
Front view of the coach with the wire and plug fitted.

Now we go to the front of the coach. The plug has two black wires attached. Measure 3 cm from the face to the plug. (That bit that touches the socket when attached) Mark this position on the wires. I used white out pen so the line could be seen. In the middle of the front door drill two holes with the No. 61 bit. These should be about 2 mm from the floor of the coach and about 1 mm between them. Using the drill bit join these holes together. Pass the ends of the black wires that are attached to the plug through this slot from the outside. You need to tie a knot in these wires. Take the two wires and tie a single knot. Adjust this knot so that the white mark is in line with the outside of the slot. This length will allow you to get your fingers in-between the coaches to attach the plugs.

It is time to wire everything up. First go to the picture of the coach above. It is the one that shows the completed wiring. Now click on the picture. This will give you an enlarged view. You can see how the wires are installed in the roof of the coach. Once you have had a good look click the browser <- back button. You need scissors and some electrical insulation tape. Cut off a small piece and fasten the wires from the socket to the roof of the coach as shown in the photo. Tweezers will help to place the tape. There should be enough of the wires loose to allow you to have the ends sticking up out of the coach by about 3 cm. This allows for soldering.

Strip about 10 mm of the insulation off the ends of these wires. The next step requires that you adjust the length of the remaining wires so that the knot is hard up against the front door of the coach. The wires go to the roof and are threaded in a small piece of heat shrink tubing along with the blue and green ones from the lighting strip. These wires go along the roof to the ones from the rear. Curve them up to meet the rear ones. Allow about 3 cm of wire length sticking out of the coach once more. With the wire cutters, trim them to length. We need to strip about 10 mm of the insulation off the remaining wires. I used a pair of wire cutters. However there is a chance you might cut the wire short.

Twirl ends of the two green wires together. Twirl ends of the two blue wires together. Twirl the end of one black wire to the green ones. Twirl the end of the other black wire to the blue ones. With a soldering iron and resin core solder, solder the ends. You should end up with two joins. One joint has two greens and a black wire. The other joint has two blues and a black wire. If you wish, trim a little bit off the length of the soldered joints. Cut 2 short pieces of heat shrink tube and place one over each of the joints. Here is where it gets a bit tricky. We want to shrink the tube in place over the joints to keep them electrically separated. No burning of wires allowed. No burning of coach body allowed. No burning of fingers allowed. If you don’t feel confident with this you might consider getting help here or find another way to fasten the tubing in place. What is required is that you have one of those little burners that run on lighter gas. They work like a lighter but the flame is different. Just feather the blue tip of the flame over the heat shrink tube for 0.5 to 1 second. This should be enough. Do one joint at a time. Finish off by fastening the wires in the roof as shown.

That completes the soldering. Leave the coach in two pieces. The next job is to fit the people in the coach. You will have to use the wire cutters to cut off the legs of the figures. If you don’t they won’t fit. Just glue them in place one at a time using super glue. Once this task is finished, you will need to test things. If you already have a loco with an outlet for the coach lighting power use this to test the lights. Notice we did not orientate the black wires when we soldered them. We are doing this now. Just using the coach body plug it into the loco and turn the locos DCC F1 on. If there is light you have it plugged in the correct way around. Don’t unplug it just yet. If there is no light you will have to unplug the coach and reverse the connection. This time the coach should light up. With the coach lighted take a white out pen and make a small white dot across the socket and plug at the back of the loco. Now you have the plug marked so you know which way around to plug it in next time. The white dot on the socket will serve to help you locate the socket to plug it in next time.

All being, well put the coach back together again. Take care that there are no arms or shoulders in the way. What’s that? It didn’t work. Are well you are up for some fault-finding. Note. You can use a 15 v DC power supply to test the coach also. The blue wire should be positive. Check your solder joints as well. Check what I said above about the structure of the connections. That is blue, blue and black joint and green, green and black joint. If you got it wrong it will cause trouble at the next coach. Oh! That’s right you have four more coaches to do. When you get back we will have a look at the power units.

Tools used
Tools used

I decided to split it into two here as this is getting a bit long. The next instalment is called “HST 125 unit ditch and tail lights”