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Danbury Mint Sinclair Service Station
 
 

Modification with Electric Lights
by Robert Alescio

Brief review
In a review that can be read on the D4C, I had both praise for the service station and suggestions for improvement. Certainly, on the plus side, is the obvious fact that your die-casts can now be displayed in a realistic setting rather than just sitting on a glass shelf. Thus, it lends some welcome life to the cars. Out of the safety of their display case, cars are vulnerable to dust and other nasty bits, so a cover that encompasses the whole of the structure would be in order. I put that off for now to instead tackle another perceived want.

Need for lights
Although both the outside and inside of the Sinclair Service Station are painted white, one might employ a flashlight to see the cleverly decorated interior. Not wanting to leave it at that, I was compelled to illuminate the station in a simple and effective manner. Not knowing anything about dollhouses other than their relative size and vast array of accessories available, I set out to see what I could utilize. Only a brief search on the Internet turned up numerous possibilities. I settled on was Cir-Kit Concepts (http://www.cir-kitconcepts.com/) who offers a complete line of miniature lights, light fixtures, wiring kits, and materials.

Having never performed this kind of work before, I had to make the best guess of just which items to order. Looking over what was available, and considering how I wanted to light the station, I settled on what I hoped would suite my needs. I would employ four ceiling mounted lights. The temptation to get fancy fixtures was tempered by the realization that this is a gas station after all; thus, bare bulbs.

Materials
(See complete list below)
The lights are frosted bulbs that mount in a porcelain base. (Fig. 3) I felt the frosted (vs. clear) would diffuse the light better. These are 12-volt systems, so a transformer is also required. Fortunately, Cir-Kit Concepts has a choice of starter kits (Fig. 1 & 2) that include everything I needed to complete the wiring, from wall plug to lit bulb. Two-conductor tapewire is included and offers a clean, unobtrusive method of running current to the lights. This presented both solutions and challenges in the construction phase. I also ordered a spot light for an idea I am saving for the future. Added to these materials are a sheet of thin balsa wood and some suitable white paint.

Construction
What makes this project possible is a roof section that just sets into place. Had the roof been permanently attached, I would not have even attempted this. Equally important, nothing of the original gets modified, thereby maintaining its integrity and resale value.

  1. Using the roof as a template, trace out two copies on the balsa. This method sandwiches the wiring between the wood hiding it from view.
  2. Both pieces of wood are then sanded to fit easily into the building without being too snug. They are identical except for a notch in the back of the lower one. The location of the lights is chosen to most uniformly illuminate the interior, remain out of direct line of sight, while still being positioned logically.
  3. Read and reread the relevant sections of the supplied Tapewire Instruction Book.
  4. As shown in Fig. 5, one taperun starts at the rear, runs forward, and then intersects the lateral taperun. It is the position of the lateral piece that first has to be determined.
  5. Working with what will be the lower section of wood, measure, then mark the light locations. These are 1 1/2” from the front edge and approximately 1/3 and 2/3 out from the center-dividing wall. This fulfills the need for uniform, hidden light.
  6. After contemplating connecting the tapewire to the transformer lead-in wire, I decided to make the junction splice (Fig. 7) appear to be an unobtrusive ceiling fixture. By mounting this forward slightly, the wire to the transformer can drop straight down rather than protrude unnecessarily.
  7. Cut a 1” x 5/8” notch at the rear of the same piece of balsa. This is aligned with the notch in the back wall of the office.
  8. Drill four 1/8” holes for the light pigtails to pass through. Test fit each bulb and porcelain base to insure flush fit with ceiling.
  9. Draw a line across the wood through the holes almost to the outer edges of the wood. These will aide the alignment of the tapewire.
  10. Sand the wood smooth, clean, and paint the bottom of the lower and the top of the upper pieces of balsa.
  11. The lateral tapewire is laid down first. Cut a strip at least 1 inch longer than the two farthest holes. Using the pencil mark as a centerline, press the adhesive-backed tape into place. The pre-drilled holes will be in line with the non-conductive center of the tapewire. Open holes through the tape center where the balsa was drilled.
  12. Measure, cut, and apply the second tapewire perpendicular to the lateral strip. This strip will wrap around the previously cut notch and extend forward again about an inch. This underside is where the junction splice will be located. Complete the connection of the two tapes by inserting the supplied brass brads. (Fig. 6) Confirm the conductivity with the supplied tester or an ohmmeter. Install the junction splice and test again.
  13. Install the lights. (Fig. 4) First, the pigtails will have to be shortened and the ends striped of insulation. Follow the instruction dealing with light connections in the booklet that accompanies the starter kit. Holding the lights firmly against the balsa, bend the wires over and secure with any good tape. This is to insure against slack in the wires that would allow the lights to droop at an angle. (Mine are tied, not taped. Perhaps both methods together are best.)

Finish
All that remains is to plug the transformer lead-in wire to the junction splice and install the new ceiling and roof sections. (Fig. 8) Plug the transformer in to an outlet, and you are done.

Results
The effect is quite pleasing, as now the station interior really comes alive. All of the furniture, fixtures, accessories, tools, posters, and signs are showcased, whereas before, they were mere background. Place a couple of cars or trucks in the scene and you are one step closer to reality.

   
 
Danbury Mint Sinclair Gas Stations
Figure 9 - Completed Project
   
 

Future Projects

  • As mentioned above, a clear cover is a must. The tall Sinclair sign presents a height problem, unless one foregoes the sign altogether.
  • I ordered a miniature spotlight, thinking of mounting it on the roof and aiming it at the Sinclair sign.
  • Illuminating the gas pumps requires a total remake, but this would really add to the scene.
  • People in the form of mechanics, customers, maybe a guy sleeping in the office would complete your diorama.

List of Materials

From Cir-Kit Concepts:

  • 1 x CK101 Starter Wiring Kit
  • 4 x CK502 Porcelain Kit (with frosted pea bulb)

From local sources:

  • 1 piece, balsa wood (1/8” x 6” x 36”) – more than you will need, but cheap insurance.
  • 1 can, white spray paint

Figures

   
 
CK101
Figure 1 - CK101
   
 
CK101
Figure 2 - CK101
   
 
CK502
Figure 3 - CK502
   
 
Light Installation
Figure 4 - Light Installation
   
 
Lower section wired.
Figure 5 - Lower Section Wired
   
 
Connection Detail
Figure 6 - Connection Detail
   
 
Junction Splice
Figure 7 - Junction Spice - upside down
   
   
 
Installed Lower Section
Figure 8 - Installed Lower Section
   
     
   
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