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Old 08-21-2018, 02:49 PM   #1 (permalink)
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Default New Project: Scratch Build 737

Hey guys,

As you can see she's well underway. I'm using 3DS Max for the design and will print it on my new Anycubic Photon SLA 3D printer. I'm looking at making it in 1/100 or larger, possibly 1/60. I'll update this thread with progress in the design, printing, assembly and finishing. This should be fun!

Comments and critiques welcome!

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Old 08-21-2018, 04:36 PM   #2 (permalink)
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Default Re: New Project: Scratch Build 737

I am sure it will be awesome. Please keep us updated.
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Old 08-22-2018, 01:35 AM   #3 (permalink)
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Default Re: New Project: Scratch Build 737

Forgive me if i may be ignorant but if you are going through so much hard work to create this model then why choose to make it in such odd 1/60 or undesirable common size such as a 1/100? why not opt for the more desirable 1/48 or 1/50 scale? its not a scale that isn't capable of being displayed due to lack of space.
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Old 08-22-2018, 02:22 AM   #4 (permalink)
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Default Re: New Project: Scratch Build 737

Hi Neil. This sounds an exciting project. Looking forward to following the progress

Neil.
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Old 08-22-2018, 05:32 PM   #5 (permalink)
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Default Re: New Project: Scratch Build 737

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Originally Posted by leoteo View Post
I am sure it will be awesome. Please keep us updated.
Wilco, thanks!

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Originally Posted by stratoliner View Post
Forgive me if i may be ignorant but if you are going through so much hard work to create this model then why choose to make it in such odd 1/60 or undesirable common size such as a 1/100? why not opt for the more desirable 1/48 or 1/50 scale? its not a scale that isn't capable of being displayed due to lack of space.
Good question. Yeah, I'd love to make it in a larger scale but I'm limited by the print volume of 155x115x65 mm. The smallest dimension would barely fit an entire 737 cross section at 1/60, and 1/50 or larger are out of the question unless I want to cut the cross sections in half and do some crazy stuff with the print.

The good thing though is that the 3D mesh model can be made for any scale - 1:1000 or 1:1 and anything in between. The only limitation on smaller scales is resin strength. The insane print resolution and the use of resin can make the most incredibly detailed miniatures.

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Hi Neil. This sounds an exciting project. Looking forward to following the progress

Neil.
Thanks Neil. This project will no doubt take more time than my last one, but it'll be worth the effort!
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Old 08-23-2018, 11:41 AM   #6 (permalink)
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Default Re: New Project: Scratch Build 737

How much is that 3d printer of yours ?
& the supplies ?
What is the material used to build ?
Is your model solid ?
this project sounds very interesting...
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Old 08-23-2018, 04:23 PM   #7 (permalink)
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How much is that 3d printer of yours ?
& the supplies ?
What is the material used to build ?
Is your model solid ?
this project sounds very interesting...
The printer is an Anycubic Photon and it's the most affordable high resolution 3D printer on the market. I bought mine for $480, so if I manage to create 2-3 models it's already paid for itself. This video is one of the things that sold me on this machine, as I had no idea how good 3D printers had become. I can see myself doing a run of 1/200 GSE with it as well.

You can use a few different types of resin with it, but once cured I believe they are all pretty similar to the polyurethane resin used in Pacmin style models. The model mesh can be printed hollow and I will probably do the first one like that to save on the resin as it's pricey. Once I have a good model assembled(it'll be printed in sections), I can simply create a mold and cast as many replicas as I want without having to print again.

There will be a learning curve, but this thing is capable of printing as much detail as you cam pump into a 3D model. Can't wait to proceed!
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Old 08-23-2018, 10:35 PM   #8 (permalink)
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Default Re: New Project: Scratch Build 737

1/72? A hard scale to find the 737-200 as a desktop, but easy to find decals due to model kits being made in that scale.....
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Old 09-05-2018, 07:06 PM   #9 (permalink)
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Default Re: New Project: Scratch Build 737

Quick update guys. The whole fuselage has been redone, especially the nose, which has been more accurately contoured to include the flat spots for the windows. The engines still need interior detail and the flap canoes still need to be done as well. Thought I'd do a progress shot of the wing to body fairings, which are being a huge pain in the rear. You can see how they are shaped using those yellow shapes(splines). I'll update soon showing the result.

Still deciding in whether or not to do a landing gear. I think I will at least design the gear as it'll be fun, but this first one probably won't have gear.

Anyhow, some pics!




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Old 09-05-2018, 07:10 PM   #10 (permalink)
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1/72? A hard scale to find the 737-200 as a desktop, but easy to find decals due to model kits being made in that scale.....

I think it will be done in 1/72, but I won't need a decal sheet as I plan to make those too. Theres a cool feature in the 3D program that will allow me to export shape files for things like cheatline wrap around decals so there will be no guesswork on the decals and they will fit the model perfectly.
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Old 09-28-2018, 10:21 PM   #11 (permalink)
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Default Re: New Project: Scratch Build 737

Been working quite hard at trying to get the nose right and I think its as close as it'll get. I've re-designed the fuselage and nose about four times now. The flap track fairings, wing to body fairings and some detail on the nose and engine inlets now all complete as well. In fact, I'm calling the principal design complete. All thats left will be adding some more detail like flight control cutouts, apu inlet and exhaust, ram air inlets and a bit more on the engines.

Once that's done, it will be time to do the fun part of 3D printing and assembling the prototype.

And of course, some pics...






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Old 09-29-2018, 11:43 AM   #12 (permalink)
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Default Re: New Project: Scratch Build 737

Excellent work she looks great and thank you for sharing.
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Old 09-29-2018, 02:20 PM   #13 (permalink)
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Default Re: New Project: Scratch Build 737

Looking forward to seeing this project.

Neil.
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Old 09-29-2018, 07:11 PM   #14 (permalink)
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Default Re: New Project: Scratch Build 737

Now THATS the shape! Amazing work!
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Old 10-05-2018, 02:09 PM   #15 (permalink)
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Default Re: New Project: Scratch Build 737

Can't wait to see the finished product.

Thanks for posting the pics.

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Old 10-05-2018, 06:02 PM   #16 (permalink)
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Default Re: New Project: Scratch Build 737

Great job Neil!!! For 3D printing it is the rendering that is the hard part. And you obviously have mastered that. Awesome!!


I made a lot of parts with my 3D Flash Forge printer. Then donated it to a local High School. I was getting in over my head with the rendering. Don't have the patience I had when I was 20 years younger.
Here are some of the parts I made over a 2 year period. (The Electra is 1:43. Only the props were printed) Now I need a 1:50th Boeing 737-300 engine made, and I am hoping the kids at school will be able to render and print it for me.

The sound suppressors turned out fantastic. So did the props. A lot of sanding and filling, painting etc.... They don't come out of the printer looking like that.

Al

Last edited by 707boeing; 01-25-2019 at 02:52 PM.
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Old 10-06-2018, 03:10 PM   #17 (permalink)
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Default Re: New Project: Scratch Build 737

Hi Al,

Hope all is well.

The KLM Electra props really came out looking nice. Looks like they came with the airplane from the factory.

The sound suppressors also look great and am sure that it took a good amount of time to work on those.

Great workmanship as always.

Regards, Robert
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Old 10-06-2018, 07:59 PM   #18 (permalink)
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Great job Neil!!! For 3D printing it is the rendering that is the hard part. And you obviously have mastered that. Awesome!!

I made a lot of parts with my 3D Flash Forge printer. Then donated it to a local High School. I was getting in over my head with the rendering. Don't have the patience I had when I was 20 years younger.
Here are some of the parts I made over a 2 year period. (The Electra is 1:43. Only the props were printed) Now I need a 1:50th Boeing 737-300 engine made, and I am hoping the kids at school will be able to render and print it for me.

The sound suppressors turned out fantastic. So did the props. A lot of sanding and filling, painting etc.... They don't come out of the printer looking like that.

Al
Hey Al, man those pieces look fantastic. Love that 1:43 Electra and the interior of your cutaway model. Can't wait to see that when she's done.

I learned autocad many years ago, so there's been a learning curve getting back into it. It does take up a lot of time, especially when you decide that something looks off and you must start over again. Since the last update, I've reworked the pylons now for the third time. I'm hoping projects will go quicker in the future.

The few test prints I've made have been really good so I'm looking to start printing next weekend as I finalize the design.

How detailed are you wanting that 737-300 motor? I plan to do a -300 and -500 after this project so I'll have to make one eventually. Let me know! Sounds fun!

-Neil
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Old 10-07-2018, 12:41 PM   #19 (permalink)
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Good morning Neil and Al you both made my Sunday morning. Those props, the Electra and all those little people just amazing. Meanwhile Neil I wait with bated breadth for your next update. Happy Canada Thanksgiving and thank you both for sharing.
Anthony
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Old 10-10-2018, 06:40 PM   #20 (permalink)
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Default Re: New Project: Scratch Build 737

Hey guys, she's about ready for slicing and printing now. I've fixed a few existing things and added flight control reliefs, some cutouts for various inlets and exhausts, a few hump and bumps, wheel well cutout and tires, and antennae. I changed my mind again on scale and I've decided to do it in 1/100 and 1/60. Wish I could do 1/50 but the largest cross section I can get out of my 3D printer is about 1/57.

Anyhow a few images of the almost finished final 3D model. While I'm printing the fuselage, tail and wings - the engines inlets and exhausts will get a bit more detail. All that's in there now is the "bullet" and inlet guide vanes.














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Old 10-12-2018, 10:33 PM   #21 (permalink)
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Another quick update: Just a little look at how I'm going to make the individual parts for the print and how they will attach to other pieces. I gave the wing some extra meat for insertion into the fuselage, and cut a relief for it with a Boolean operation in 3DS Max. I'm pretty happy with the result, and it should be a perfect fit when it comes time to assemble the printed model. Now to do the other wing, tail, horizontals and engines.


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Old 10-13-2018, 04:54 AM   #22 (permalink)
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Hi Neil. Looks as though things are going very well indeed. I love ‘tuning in’ to see the latest instalment! 1/60 is still a very good scale for the 737. I seem to remember that Pacmin did them in that scale. Thanks for keeping us updated with progress.

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Old 10-13-2018, 02:54 PM   #23 (permalink)
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It does look good! Try to export this to Flight Simulator and I'll take care of the textures!;-)
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Old 10-17-2018, 02:16 AM   #24 (permalink)
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Whew! Finally done with the 3D cad model...at least for now anyways. This thing is all sliced up as to fit all the sections neatly in my 3D printer, and now it's time for the fun part to begin. A liter or so of UV light sensitive green goo will turn this model from a 3D rendering into a physical model.

I've already printed a few test pieces, which turned out surprisingly well. So now I'll print these sections, clean off the residual goo, and start assembly!




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Hi Neil. Looks as though things are going very well indeed. I love ‘tuning in’ to see the latest instalment! 1/60 is still a very good scale for the 737. I seem to remember that Pacmin did them in that scale. Thanks for keeping us updated with progress.

Neil.
Thanks Neil. I never owned an airliner larger than 1/100, so I cant wait to see this thing as 1/60. But first, I'll make in 1/100 and fix any problems before stepping it up so as not to waste any of the UV resin which is quite expensive. Many more updates will be coming fast!

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It does look good! Try to export this to Flight Simulator and I'll take care of the textures!;-)
Ha! No thanks, the shading groups and animation would be a nightmare.
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Old 10-17-2018, 02:54 AM   #25 (permalink)
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Default Re: New Project: Scratch Build 737

‘The fun starts here’ as they say. You must be getting pretty excited by now. Looking forward to the next stage! Here's my slightly larger 1/50 JAT Boeing 737-300, it’s a good scale on the 737.

Neil.
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Old 10-17-2018, 09:36 AM   #26 (permalink)
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Looking fwd to see this one done and ready! ;-)
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Old 10-23-2018, 07:33 PM   #27 (permalink)
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‘The fun starts here’ as they say. You must be getting pretty excited by now. Looking forward to the next stage! Here's my slightly larger 1/50 JAT Boeing 737-300, it’s a good scale on the 737.
Neil.
That's what I'm talking about! Can't wait to have a few of those biguns' in my collection.

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Looking fwd to see this one done and ready! ;-)
It won't much longer! Still no idea what the livery will be, but it'll be something classic!
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Old 10-23-2018, 07:58 PM   #28 (permalink)
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Another update on the project. The fuselage has been printed in three sections and will be assembled into one piece shortly. The wings and tailfin have been printed and won't need any assembly as they are one piece. I've added some detail for the engines as well. I'm not sure how well these details will print at 1/100, but I'll re-design and or simplify as needed.





Some shots of my 3D model exported into the 3D printer software and being readied for printing. The 'scaffolding' is necessary to ensure the parts don't sag or bend. The parts will come out of the printer looking as they do here in the software.




And finally...the model is no longer just a string of 1's and 0's. I was a little worried about some of the details not coming thru, as well as some of the geometry around the cockpit - but I was pleasantly surprised by the result. The only screwup was not enough space from the build platform to the fuselage sections, which made it impossible to neatly join the sections together. A hacksaw was needed to cut the support section from the actual fuselage parts. I will not be repeating that mistake when it comes time to print at 1/60!









The next update, the fuselage will be whole with wings and empennage attached. The parts will need a light sanding to remove the print 'grain', but there will be little, if any, detail lost during sanding.
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Old 10-24-2018, 02:27 AM   #29 (permalink)
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Amazing pictures. This has all the signs of becoming a great model, looking forward to seeing the end result, bet you are too!

Neil.
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Old 11-02-2018, 04:02 AM   #30 (permalink)
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Default Re: New Project: Scratch Build 737

This looks amazing, great work. I have a shed full of about 250 blank resin 737s haha, should have come to me If you ever want a 1/50 though!

Also, how much would it be for you to print me a set of those stabilisers in 1/50 scale? I desperately need a set as all my 1/50s are stab-less!
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Old 11-02-2018, 03:56 PM   #31 (permalink)
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Amazing pictures. This has all the signs of becoming a great model, looking forward to seeing the end result, bet you are too!

Neil.
Thanks Neil. Indeed! I still got no idea what livery to do as well. So many choices.

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This looks amazing, great work. I have a shed full of about 250 blank resin 737s haha, should have come to me If you ever want a 1/50 though!

Also, how much would it be for you to print me a set of those stabilisers in 1/50 scale? I desperately need a set as all my 1/50s are stab-less!
PM sent, thanks. It's sort of my goal to make lots of these, dunno if I'll make 250 though !
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Old 11-02-2018, 07:31 PM   #32 (permalink)
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Default Re: New Project: Scratch Build 737

Fantastic work!!!. All kinds of possibilities. Fans are hard to get a hold of. Parts etc.... Do you have plans for your .stl files ? Sharing ? Selling ? You are obviously a 3D Cad guru. That is where I get stumped and stopped the 3d printing. I do have STL's for 1:50th seats, DFM DC-8 sound suppressors, Hamilton Standard props etc.... Just throwing ideas out there.......Al
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Old 11-02-2018, 09:07 PM   #33 (permalink)
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Fantastic work!!!. All kinds of possibilities. Fans are hard to get a hold of. Parts etc.... Do you have plans for your .stl files ? Sharing ? Selling ? You are obviously a 3D Cad guru. That is where I get stumped and stopped the 3d printing. I do have STL's for 1:50th seats, DFM DC-8 sound suppressors, Hamilton Standard props etc.... Just throwing ideas out there.......Al
Hey Al,

Thanks for the kind words I can definitely see making replacement parts for people as well as making "kits" for sale for modellers. You mentioned a 737-300 motor before, did you have one made yet? I'm doing a -300 and -500 next so I'm going to make it anyhow. lemme know!

With the CAD stuff, it can be super frustrating but keep on with it. Your work is awesome!
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Old 11-03-2018, 03:11 PM   #34 (permalink)
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Default Re: New Project: Scratch Build 737

Neil,


I would certainly be in the market for a couple sets of 1:50th 737-300/400/500 engines with the fans.


al
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Old 11-21-2018, 11:31 AM   #35 (permalink)
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Default Re: New Project: Scratch Build 737

Well, shes starting to resemble an airplane now. I haven't had a lot of time to work on her lately, but I did get the wings, stabilizers and the tailfin printed, as well as some prelim sanding and filling.

A redesign of the wing to body was needed to correct a fit issue, so you'll notice two fuselages there. I went ahead and "practiced" on the first one, joining the three fuselage sub-pieces with the tail as well. Epoxy was used to join the pieces, then after a moderate sanding, putty was applied and then wet sanded to make everything nice and smooth. Primer was then applied to reveal areas that need further work. Happy with the "practice" piece, I then repeated the work on the reworked pieces.







For the next update, i'll finish the sanding, filling and priming which will be the last step before painting and decaling. And then, onto a 1:60 version.
The whole album of this project can be viewed HERE.
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Last edited by neilc777; 11-21-2018 at 11:35 AM.
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Old 11-21-2018, 11:34 AM   #36 (permalink)
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Neil,

I would certainly be in the market for a couple sets of 1:50th 737-300/400/500 engines with the fans.

al

Can do! PM sent.
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Old 11-21-2018, 04:10 PM   #37 (permalink)
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Default Re: New Project: Scratch Build 737

Just unbelievable!! Awesome work.


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Old 11-21-2018, 04:18 PM   #38 (permalink)
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Default Re: New Project: Scratch Build 737

Looking good!

Neil.
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Old 11-21-2018, 04:56 PM   #39 (permalink)
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Just unbelievable!! Awesome work.

al
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Looking good!

Neil.
Thanks boys!

Al, once the 1:60 parts are printed, I'll start the -300 and -500 mod changes and I'll do the engines first so it won't be long until I cant get yours printed in 1:50. Also doing a set of stabilizers in 1:50 for another DAC member.
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Old 11-22-2018, 03:13 AM   #40 (permalink)
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Default Re: New Project: Scratch Build 737

That is just amazing!! What a talent and skill that you have!! Can't wait!!
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Old 11-25-2018, 10:22 PM   #41 (permalink)
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Starting the decaling by creating vector shapes in CAD, which will become the graphics for the decals. This is much easier than using photoshop or PSP, as the use of splines and beziers makes nailing an exact logo or typeface much simpler with the added benefit that the graphics can be used for any scale.

Otherwise not much progress since the last update, just getting all the fuselage joins nice and smooth. Here we have the last bit of priming and filling done giving a uniform primer gray finish. Next the surfaces will be sanded smooth and shot with correct paint for the livery.

In the background, you'll see one of Istari's giant 1:50 stabs.










For the next update, the final paint will be applied with some decalling. I'm using the awesome Alclad II for the polished aluminum surfaces, so I'm hope this thing will be a stunner!
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Last edited by neilc777; 11-25-2018 at 10:26 PM.
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Old 11-25-2018, 10:24 PM   #42 (permalink)
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That is just amazing!! What a talent and skill that you have!! Can't wait!!

Thanks smoothjazz! I have to say I'm no expert but I'm having fun learning some good techniques and tricks when it comes to Cad and 3D printing.
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Old 11-26-2018, 02:15 PM   #43 (permalink)
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Default Re: New Project: Scratch Build 737

Niceeee jobbb
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Old 11-26-2018, 02:32 PM   #44 (permalink)
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Default Re: New Project: Scratch Build 737

Amazing work Neil! Be good to you use the Alclad again, looked great on the MD. The -200 is still my favourite variant. Looking forward to seeing the next stage

Neil.
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Old 11-26-2018, 10:48 PM   #45 (permalink)
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Default Re: New Project: Scratch Build 737

Can't wait to see the decals on it!! Looks very promising!!
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Old 12-23-2018, 09:34 AM   #46 (permalink)
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Default Re: New Project: Scratch Build 737

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Starting the decaling by creating vector shapes in CAD, which will become the graphics for the decals. This is much easier than using photoshop or PSP, as the use of splines and beziers makes nailing an exact logo or typeface much simpler with the added benefit that the graphics can be used for any scale.

Otherwise not much progress since the last update, just getting all the fuselage joins nice and smooth. Here we have the last bit of priming and filling done giving a uniform primer gray finish. Next the surfaces will be sanded smooth and shot with correct paint for the livery.

In the background, you'll see one of Istari's giant 1:50 stabs.










For the next update, the final paint will be applied with some decalling. I'm using the awesome Alclad II for the polished aluminum surfaces, so I'm hope this thing will be a stunner!
WOW Neil! that is a very nice 737-200 you made! Amazing the accuracy of it!
Well done!!
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Old 12-23-2018, 09:56 AM   #47 (permalink)
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Default Re: New Project: Scratch Build 737

Very nice work!

Neil.
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Old 12-24-2018, 03:51 PM   #48 (permalink)
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Can't wait to see the decals on it!! Looks very promising!!
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WOW Neil! that is a very nice 737-200 you made! Amazing the accuracy of it!
Well done!!
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Very nice work!

Neil.
Thanks guys! Most of the painting is done, just a few areas to touch up and I'll start decaling. Update coming soon!
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Old 12-25-2018, 04:27 PM   #49 (permalink)
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Default Re: New Project: Scratch Build 737

Just a quick update. Painting is mostly done, just need some polished aluminum on the leading edge of the horizontal stabs and some touching up where paint bled thru the masking. The cockpit window decal is a test for the final shape. The final version will feature polished metallic frames and a bit of detail, same with the pax windows.

After decalling, I'll make some tweaks and improvements to the base -200 design and then make changes needed for the -100 -300 -400 and -500 models. Molds of all will be made in 1/72 and 1/100 and kits will be available for purchase for the resident modellers. Stay tuned!

Some photos including one with a DACers parts requested for some of his projects.

Merry Christmas guys!





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Old 12-25-2018, 07:46 PM   #50 (permalink)
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Well done Neil. The model is progressing well!
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