Western Star 4900 FA plow truck

[BK9300]

Kind of a bonus day - started the morning out looking in my aftermarket parts drawer, and came across a couple sets of CTM, US truck batteries.  Too bad I hadn't remembered that a few days ago!

 

I'm going to go with three of these batteries for the truck - lots of power for those cold starts and the demand from all the lights.  I started in on converting the battery posts to threaded terminals, by removing the existing posts and drilling holes for the small bolt sections I will CA glue in.  Also needed to figure out a hold down mechanism for the batteries. 

 

Saw lots of pics online about ways to hold batteries in place; the method I settled on was just the easiest to achieve.  Built a tray to set the batteries in, added the brass tubing/threaded end, hold down rods and some Scale Model nuts, to bolt the hold down bar in place.  I had previously forgot to cut the openings in the sides of the back of the box, to allow for the cables to pass through, so did that today as well.

 

I will need to paint these boxes, the batteries, tray and hold down bar, before I CA glue the threaded terminal ends in place.  Hope to get to a bit more wiring in the next few days.  Not much today, but moving forward!  Take care.

Edited April 22 by BK9300
Typo

[AmericanMuscleFan]

On 4/20/2025 at 5:11 PM, BK9300 said:

With some (lots!) of difficulty, and a pair of tweezers in each hand, I did get all the nuts snugged up into place.

I understand you Brian, I was lucky enough to buy the socket set for all sizes back in the day before Scalehardware was sold and I don't regret it, they are so useful and effective, especially for the smaller nuts.

As for the rubber clips on the cover, have you thought about small O-rings that would be stretched between 2 pins?  It certainly wouldn't be the same design as the originals but it would be removable much like the real ones.

The result is impressive my friend, no detail is missed ! 👌

[Force]

You blow me away with every detail Brian, top notch.

[Scott Eriksen]

19 hours ago, BK9300 said:

Yes, they are definitely a step up from some kit parts.  I have to go back to your build and see what you used for a fuel tank - I recall that it was a square sided, diamond plate tank in combination with the steps.

Brian,I used Auslowe Mack tanks without the built in step but I cut them down to just fit under the cab   MACK SQUARE FUEL TANKS, MB14 — Sour Krauts Model Trucks

[BK9300]

7 hours ago, AmericanMuscleFan said:

I understand you Brian, I was lucky enough to buy the socket set for all sizes back in the day before Scalehardware was sold and I don't regret it, they are so useful and effective, especially for the smaller nuts.

As for the rubber clips on the cover, have you thought about small O-rings that would be stretched between 2 pins?  It certainly wouldn't be the same design as the originals but it would be removable much like the real ones.

The result is impressive my friend, no detail is missed ! 👌

I wonder if any of those socket sets are available 'out there' - I'll do some checking and see.  I will try the CTM latches, just to see, but always good to have a plan 'B' - I could always make a set of bungee cords to hold the covers down!  Thanks, Francis.

 

6 hours ago, Force said:

You blow me away with every detail Brian, top notch.

Thanks for the generous comment, Håkan - I appreciate it!

 

2 hours ago, Scott Eriksen said:

Brian,I used Auslowe Mack tanks without the built in step but I cut them down to just fit under the cab   MACK SQUARE FUEL TANKS, MB14 — Sour Krauts Model Trucks

Thanks, Scott - the tanks look perfect on the side of your wrecker, for sure.

Edited April 22 by BK9300

[BK9300]

Boxes are out being painted and now waiting till next coat(s) and colour changes.  Did receive a small package of printed items from @Bren today - another bonus!  I had asked him if he would try and print the battery boxes, even though I had designed them with very thin walls.  He certainly gave it a good go and even though he advised me the walls may be too thin, a few turned out with just some slight warping to deal with.  He also did another experimental print for me - a Western Star dash logo.

 

I think, with some work and some straightening effort on my part, the boxes could be made very workable - maybe for an older truck that actually did have bungee cords holding the covers in place!  The covers are still removable, but are not diamond plated - my software program couldn't specify that for Bren to print.  They would still look great with the Auslowe step treads added on -

 

 

I think the logo will look great when peering in from the passenger window.  Bren sent me several prints, so I will try to do some very delicate cleanup on the back, where the print supports attached.

 

More painting to do, so all for now.

Edited Thursday at 03:08 PM by BK9300

[Biggu]

LOVE Bren's emblem ! Looks GREAT !

[BK9300]

1 hour ago, Biggu said:

LOVE Bren's emblem ! Looks GREAT !

I'm happy with it, too - I'm thinking the only thing better would be photo etch - haven't found any this exact size - and I don't think I'm going to learn how to do that at this late stage!

[BK9300]

More paint drying going on, so did a little experimenting with my battery cables.  Again, going with threaded terminals because it makes things a bit easier for me.

This is the type of cable end I need to make -

 

Started with some more Gopher ignition wire, with a bit stripped off one end and a section of 0.8mm brass tube -

 

I shortened the tube length, then crimped one end and CA glued the stripped wire into the other end - 

 

I couldn't hold the small cable end to drill it, so I taped it to a piece of styrene and drilled it out with a 0.6mm bit -

 

Using a Scale Hardware nut, and a bolt with the head cut off, I had the threaded terminal and cable end ready for the battery -

 

A sample cable, half done and not yet glued in place - 

 

I need to make 9 more cable ends and wire sections,  plus add a couple smaller, auxiliary power wire runs.  Then CA glue the batteries in the tray, add the cables and glue the tray into the painted battery box.  More to follow! 

Edited April 23 by BK9300
another typo

[Brenton]

Those cables look amazing!! Great craftsmanship!!

[BK9300]

21 minutes ago, Brenton said:

Those cables look amazing!! Great craftsmanship!!

Thanks a lot, Brenton - appreciate the comment! 

[BK9300]

Still fussing with the battery/tool boxes - I will eventually work on something else!  Today was just a partial reassembly day for them, after painting. 

 

The box covers have been painted with Alclad White Aluminum and very happy with how they turned out.  Not going to use any kind of clear on them, so they literally got the white glove treatment today.  Added the bolts for the step treads as well.  Batteries are CA glued to the tray and the hold down bar and bolts are also glued in place -

 

 

Very hard to make out the battery detail, with the lighting from the desk lamp, but did want to show that paint layers are thin enough to allow the lid(s) to be removable with ease.

 

Will be making cables tomorrow!  Take care.

Edited Friday at 12:46 AM by BK9300

[Jürgen M.]

I showed some of your pics of this build to my wife and her first reaction was: "Why do these guys all have such big workshops at home where a whole truck fits in?"

I tried to convince her that it's not a real truck but a 1/25 scale model! She couldn't believe it!

I can hardly believe it and I knew from the beginning that there are only models built here!

To make this shorter: Amazing job!"

[Scott Eriksen]

Boxes look great Brian,,,I can see a whole lot of applications for those ,,yepper ,,,lol 

[Gary Chastain]

I was kidding when I said “are you wiring in the key switch” now I’m starting to worry Brian….but I bet you could make a set of keys for the dash🤩🤩

[BK9300]

11 hours ago, Jürgen M. said:

I showed some of your pics of this build to my wife and her first reaction was: "Why do these guys all have such big workshops at home where a whole truck fits in?"

I tried to convince her that it's not a real truck but a 1/25 scale model! She couldn't believe it!

I can hardly believe it and I knew from the beginning that there are only models built here!

To make this shorter: Amazing job!"

That's very funny, Jürgen!  Maybe I need to make a scale model shop, too.  Thanks for your generous comments!

 

 

10 hours ago, Scott Eriksen said:

Boxes look great Brian,,,I can see a whole lot of applications for those ,,yepper ,,,lol 

Thanks, Scott - lot's of parts to scratch ones like this, so, would be good if the process could be made a bit easier using some printed ones.  Will need to keep refining the design!

[BK9300]

2 hours ago, Gary Chastain said:

I was kidding when I said “are you wiring in the key switch” now I’m starting to worry Brian….but I bet you could make a set of keys for the dash🤩🤩

Thanks, Gary - I'm trying hard to figure out how to do it, but I don't think I left any room on the firewall for the starter relay!

[BK9300]

Had a good session at the bench today - battery day!

 

The needed bits have been gathered -

 

Started in with cable ends, like with the test piece I did earlier - 

 

Half the ends completed! -

 

I taped around the batteries because I didn't want to wear any paint off the edges while handling.  Threaded posts have been added at this point and about to starting bolting the cables down

 

Had to check my reference pics a few times, but finally settled on this cable arrangement.  I'll have to finish the other ends of the cables once the box is mounted on the frame and I know the lengths to the starter that I will need.  Several of my reference pics showed two or three additional, white power wires, but I chose only to do one, because, well, I just wouldn't know where to terminate them!  The one white wire often powers the ECM (thanks @Scott Eriksen!), so I'll see what I can do with that.

 

Pretty happy with this outcome.  I'll remove the ground wire out the back of the battery box, and attach it to the frame before I glue the boxes to the frame - should be able to thread the ground back into the box and re-attach it later.

Besides the latches, still have one more little detail to add to the battery box cover, but need to make it first!

Thanks again for all the generous comments - much appreciated!

Edited Friday at 11:04 PM by BK9300
typo

[Gary Chastain]

Oh my, those battery boxes and all that detail is a kit within itself

[AmericanMuscleFan]

Absolutely stunning work Brian, the wonder seems to have no end and I have no objection to that! 👌

[BK9300]

On 4/26/2025 at 7:45 AM, Gary Chastain said:

Oh my, those battery boxes and all that detail is a kit within itself

Thanks, Gary - going a little crazy, I guess!
 

 

23 hours ago, AmericanMuscleFan said:

Absolutely stunning work Brian, the wonder seems to have no end and I have no objection to that! 👌

And I appreciate you continuing to check in on things, Francis - thanks!

[cifenet]

Small details never lost here.  Amazingly cool to see how you are constructing components out of nothing. Bravo!