How to Build a Railway Handcar

Building a railroad handcar is based on simple principles for locomotion (hand pumping) but still requires skills in welding, mechanics, wood working, metal fabricating and construction. The actual construction is too involved to describe in detail here. I will instead give the basics of how a handcar is constructed and leave the rest to the builder.

Difficulty: Challenging

Instructions

Things You'll Need:

• two sets of railroad car trucks
• access to a machine shop or metal working tools
• oak lumber
• woodworking tools
• rails and ties
• workshop
• paint

1. 
   how a handcar works, diagram #1

   Railroad handcars are propelled by use of a fly wheel operated by the up and down motion of a cross bar. See Diagram #1. The bar goes up and down making a pinned bar push a large drive wheel which intern engages the rear truck directly at a sprocket. Pushing the railcar forward before mounting moves the bar into the proper position and begins the cross bar moving up and down, making continued pumping and movement forward easier for the operator(s).

2. 
   Diagram #2

   The most difficult part of building a railroad handcar is locating the trucks, the wheels) for the handcar. The trucks must be the right size for the rail line you intend to run the car on. Permission must be given if you operate on an active railway .
   Once the trucks are located a metal frame must be welded together large enough to support two operators. Approximately six foot long and four foot wide, depending on track width. Wooden flooring should be of oak. All machined parts; the flywheel, gears , pump handle supports and braces should be of iron or steel.
   One set of trucks must have a gear welded to it that meshes to the flywheel with little play.
   Heavy lifting equipment is needed for working on a handcar. The estimated weight of a full size handcar is between 700 and 900 lbs.

3. 
   Diagram #3

   The railcar breaking system is a simple rod held by a spring, that when depressed by the operators foot engages two bars pinned at its center that sends a steel brake against the front and rear truck wheel face. See diagram #3.

Tips & Warnings

• Local rail fan clubs, the national railroad museum and railroad hobbyist groups can give more detailed information.
• Running personal equipment on an active railway without permission is illegal and dangerous.
• Active railways are private property and all rail stock are subject to the state and federal railroad commission regulations.
• Railcars can be dangerous, may pick up excessive speed on steep grades and are subject to turning over if the brakes are applied improperly.