How to make Rusty Metal Roofing for your Model Railroad

Today we are working on our 1/20.3 scale Chama coaling tower, making rusty steel corrugated roofing panels from aluminum craft foil. This system also works in "O" scale and perhaps smaller scales.
The process involves running 36 gauge aluminum "craft foil" through a paint tube squeezer, a device normally used for squeezing every drop of paint out of a tube of artist paints. Running the craft foil through it produces a great-looking 3-inch scale corrugated steel panel that can be used on a large scale (1/2" to 1/20 scale) roof or siding, even a fence!
In smaller scales, it requires building a jig by perhaps soldering or gluing brass rods onto a brass plate or perhaps gluing plastic rods to a plastic base. The foil is then pressed onto the jig and burnished into form with a flexible tool, something like a stiff chisel-shaped pencil eraser. It may be possible to use a finer foil in the smaller scales, but boy would that be fragile! Keep in mind that cooking foil is also available in heavier and lighter gauges as well.
On to weathering! In this case, we are adding rust and rust damage with ferric chloride copper etchant solution, the stuff they use to etch circuit boards. It's TOXIC! So we used it outdoors, with eye protection a smock, and rubber gloves. The panels were removed from the acid with tongs, in this case, tweezers. It was placed in a disposable plastic tray. A batch of "soda water" was also placed in a plastic tray. This too should be disposable as the acid will destroy it as well. And finally a large bowl of water. To rinse and hold finished panels. This bowl will not be damaged by the acid. (In theory)
The panels were placed in the acid bath to etch. Depending on the temperature of the acid this can go very fast! If the acid is room temperature it may take one to two minutes to get the reaction you want. Be sure to "agitate" the pannel with your tongs to break bubbles and speed the reaction. If the acid is even a bit warm it will "go off" in seconds. The reaction builds heat, so each panel will etch faster than the last. If you stay too long in the acid, you may dissolve the entire panel! One trick I used was to stand the panel in the acid after etching the entire panel, letting the end of the panel totally dissolve. Looks great! If what you are after is a totally rusted out panel.
The panel is then dunked in the soda water. This stops the reaction, but not instantly! The interaction between the acid and soda creates a new reaction, which seems to strip some of the surface aluminum which remains in the soda turning it to a gray paste over time. The soda also stains the panel dark gray, however, over time much of the gray color diminishes leaving the "rust" color from the iron in the ferric chloride. The soda also tends to cling to the panel leaving a texture that may be something you like. Or not. I removed it on most of the panels with a toothbrush. And boy did that brush taste nasty for a while! THAT'S A JOKE PEOPLE! DON'T DO THAT! Anyway leave some, remove some, mess with it!
After the panels are removed from the rinse water they are all dark grey but as they dry the red color comes out. Over the next hour or so they really change.
Ferric chloride:
www.amazon.com/gp/product/B00...
Tube Squeezer
www.amazon.com/gp/product/B01...
36 gauge aluminum Foil
www.amazon.com/gp/product/B00...

[@w.rustylane5650]

For HO scale corrugated metal I got a piece of plastic .040 corrugated metal and use it as a mold. Put a drop or 2 of dish detergent and add a little water (to release the surface tension). Then add a generous amount of Elmer's glue (PVA) and wait for it to dry. Then add another layer on top and wait for it to dry. Then CAREFULLY peel off the glue layer and paint it as you would any corrugated metal. For O scale corrugated metal I got me one of those toothpaste squeezers from Amazon (only $9.99) and save every beer can after I drink it, cut it up with my tin snips and run it through the toothpaste squeezer. Now I've got more O scale corrugated metal than I know what to do with. I guess from now on all my scratch built O scale buildings will have corrugated siding and corrugated roofs, LOL! Cheers from eastern TN

[@ToyManTelevision]

Also for HO you can roll the aluminum over a screw. Or sometimes two screws pinched together.

[@SaintCoemgen]

Lately it seems Sundays and Tuesdays are two days of the week I look forward to the most.

[@lackawannarailfan5206]

Wow those look great! Good job!!

[@brandongeorgeanthonymcquil7192]

I was thinking the same exact thing while I watched this.

[@ToyManTelevision]

Thanks!!!!!

[@robertnelson2719]

I need corrugated roofing for a scratch built O scale warehouse. Went to Michael’s and found the perfect stuff in the scrap booking aisle. It’s paper that holds up to spray paint and glue very well. Cuts with a scissor!

[@jamesrosado2929]

The end result of the corrugated roofing weathering is absolutely amazing and realistic! I’m Going to try that technique

[@ronniedavis3713]

Dale, I've done the same thing using an Aluminum can and a paper crinkler from Hobby Lobby from the craft department.

[@ToyManTelevision]

Him... paper crinkled? Looking.

[@ToyManTelevision]

Hum.. can’t find it. Not made anymore?

[@ToyManTelevision]

I think I found it on Amazon!

[@GrumpSkull]

@@ToyManTelevision Try looking up 'Fiskars' brand who make garden saws. Their paper crimper is good quality plastic frame with metal rollers and does 6 2/3" long sheets about the right scale. I gently run them through a few times so I don't stress the plastic tool too much.

[@JimJepson]

@@ToyManTelevision - Have you tried this with a soda can? Makes sense to save money and cut up the vanilla coke can. I just bought the machine you're using. I'm going to use them for bird houses too.

[@stevemellin5806]

Looks fantastic 😃 thank you. Have a great Sunday

[@ToyManTelevision]

Thanks

[@PlayNowWorkLater]

Was directed to this video from another KZbin channel. smol world workshop. Great stuff! Awesome technique.

[@ToyManTelevision]

Cool, thanks!

[@jasonsnyder3948]

Thanks TM. I just ordered the aluminum and tube squeezer! $20 total on amazon.

[@ToyManTelevision]

Will be picking that up a week from Sunday again. We’re making rotted panels as fence patches

[@charlesmcclure5994]

Looks awesome, isn't it great when a plan comes together 👍👍

[@jeffeastin1982]

Been looking for the ferric chloride method for weeks! Thanks!

[@trainroomgary]

Cool 😎 Well done demo & Cheers from The Detroit & Mackinac Railway 🚂

[@ToyManTelevision]

Hi!! More to come...

[@unclemarksdiyauto]

Dale, so realistic looking!

[@kipter]

I use cut up soda cans for this. Its much cheaper and the material is thicker and holds its shape better

[@ToyManTelevision]

Great idea! I need to try that

[@MrRusty-fm4gb]

I thought I was the only one that figured this out when I came across a “tube wringer” at goodwill. And when I did, only a few years after I bought it when I learned what y was real my for. 😎

[@ToyManTelevision]

Just love these panels.

[@devinrogers6877]

Nice ! Looks like a blast watching them turn rusty

[@ToyManTelevision]

Stinks!!!!! But the results are so worth the effort.

[@edhorst7212]

Corrugated can be used for fencing as well, junk yard, scrap metal business, etc are examples.. thanks for this info

[@ToyManTelevision]

Using it for that in the switching yard

[@georgebottarini1788]

Very authentic. Great work.

[@wwskydvr]

Excellent video. I always learn something from your posts. Thanks.

[@valeriebassett3107]

As always you are amazing! Love your videos. Keep them coming and please keep safe and healthy!!!

[@johnrettig1880]

I've got some 200 aluminum cans and wound up with two of those crimper tools . I'm out in the desert of Nevada along with high winds , so I have to go with the even thicker aluminum and tack them down with short brads . I've also made my own wood stain with White Vinegar and steel wool . It gives a Reddish Brown and will look great on both my HO / HOn 3 and my 1 : 20 : 3 . I will need to finish the wood for outdoors in a Anti U V flat clear . This place looks fantastic in my head . I've been offered help with both of the layouts . Yea until I tell them what needs to be done just to start . Also . If I remember right corrugated sheet metal was made out of tin . I've seen workshops and garages at old gas stations made of wood frames and corrugation sheets and not more than that , except for the windows .

[@rohnerw]

Excellent video! Excellent how-to, step-by-step process instruction. I thoroughly enjoyed watching this and the learning/knowledge relayed! Thank-you!

[@farmcentralohio]

Some people spend a lifetime trying to keep their stuff/equipment/vehicles from rusting and you all get to figure out how to make rust lol Good video, Looks great

[@Fourwheeljive]

Thanks for the great idea and work!

[@MakeItWithCalvin]

This is great! I never liked the plastic stuff very much!

[@ToyManTelevision]

This is only for this large scale but it can be done smaller

[@MrBillCNW]

Fantastic work. You guys really do a good job and weathering

[@samfuller6273]

Very cool!

[@riochcogan8913]

My friend peeled back the top off of the insert of box of chocolates leaving a perfect, paper corrugated effect. Some red and brown spray paint for weathering and , caboom, a rusty old corrugated shed roof 😀

[@lindamayer1577]

Great tutorial. I have watched several other tutorials that show how to use paint for simulating old rusty metal roofs but chemical aging is way more authentic and random. I've purchased the etching solution and a crimper and I can't wait to try it. I also have some old metal trophy topper figures that I'll be aging for use in some artwork. Thank you!

[@ToyManTelevision]

It’s great 👍. But be careful. Not to dangerous but avoid the fumes.

[@robertdavies5501]

Nice work keep it up...need to see more of your talent 👀👀👀👀❤️❤️❤️❤️👍👍👍❤️👍👏👏👏👏👏👏

[@N-Scale]

Nice work again and love the detail. Mike

[@ToyManTelevision]

Hi mike. Thanks!!!

[@shilohgardner]

I’m totally doing this thanks!

[@ToyManTelevision]

It’s fun. Stinky fun. Stay safe. Do it outside

[@HyggeState]

This has been phenomenally helpful!

[@ToyManTelevision]

It’s FUN!! But be careful! Ventilation! Gloves!

[@vernwall374]

I did similar roves for ho. Works perfect

[@sierrapassrr2440]

Wonderful video. Makes me wish I had the space for large scale.

[@aoac1]

good stuff!! thanks !

[@ToyManTelevision]

Thanks!

[@billtimmons7071]

Been saving wine and champagne cork foil. Seems to be a bit stiffer than normal kitchen foil. Can't make large roof panels (HO) but is good for smaller details like straps, bands, smaller roof panels. I'm going to start drinking more wine to get more hobby materials :) This is great hobby video. Thank you for taking us through process.

[@Brianrockrailfan]

Great video 👍

[@ToyManTelevision]

Hi. And as always thanks!!

[@clashofminiatures]

I just got my tube roller today, doing On30 it might be a tad big but it's fine for use, enjoyed your video subscribed off to watch more

[@stevechilders2425]

Ordered toothpaste roller, thanks for the great vid.

[@ToyManTelevision]

You will love it!

[@caseyvillemodelrailroad3877]

Great vidio, the planels came out perfect, do a little test roof outside ta see the effects of real weathering...

[@joelvale3887]

There is a place where you can buy HO corrugated roof sheets made out of paper. It is called KC's Workshop they look great.

[@ToyManTelevision]

Seen those! Really great!

[@joesask857]

nice

[@laragreen4824]

I'm going to try this..

[@ToyManTelevision]

It’s fun. Be careful. Toxic fumes. But oh my! It’s great.

[@jasonsnyder3948]

FECl3 was a little expensive at $18 but still affordable. Awesome walkthrough TM

[@jimkammerer8028]

FANTASTIC RESULTS FROM YOU BOTH ALWAYS HAVE YOUR PROTECTION ON BE SURE YOU ARE BOTH FINE. I APPRECIATE IT THIS PROCESS AND YOUR INFORMATION AND COMMENTS THANK YOU AGAIN JIM KAMMERER OF PHILADELPHIA PA.

[@ToyManTelevision]

Hi Jim!! Thanks again for watching. More coming as always

[@royreynolds108]

Many mines used corrugated metal for roofs and walls from around 1890 on.

[@artr8285]

Thanks for the weathering tips! Check out the engine house in Madrid, NM. Made entirely with corrugated tin.

[@w.rustylane5650]

I wonder how the ferric chloride would react with aluminum from a beer or soda can. Why not put your ridge cap in the ferric chloride to weather it? Cheers - TN

[@ToyManTelevision]

Same thing. I’ve tried it.

[@uscgtankerwhitmore8777]

brunel models corrugated iron maker works great for smaller scales. I use it on my HO scale model roofs.

[@ToyManTelevision]

Looking!

[@ToyManTelevision]

Can’t find it. Looked for Brunel. Large scale trains. Didn’t see this product darn it.

[@uscgtankerwhitmore8777]

@@ToyManTelevision www.brunelmodels.net/corrugated-iron-makers found them for yea. they have one type in gauge 1 more in ho n and o scales

[@GrumpSkull]

Fiskars who make garden saws make a paper crimper that is about the right scale for corrugated iron. It will do sheets 6 2/3" long. It's OK for light weight aluminium like you find in pie trays etc. if you go lightly and run them through a few times.

[@ToyManTelevision]

Been looking at those online. I think I’m going to buy one just to try it out. It’s sort of looks like the core additions are too large but it’s really hard to see from the pictures. But it’s not expensive so I’m gonna give it a shot! Thanks for the information

[@GrumpSkull]

@@ToyManTelevision The alloy rollers have their corrugations 3.5mm apart. My real world corrugated iron is 72mm apart so it is very close for 1:20.3 scale.

[@GrumpSkull]

@@ToyManTelevision I've had one for this purpose for quite a while but only briefly tried it once. I just gave it another go and the technique is to roll it back and forth with the wrist several times before advancing and it works perfectly that way giving deep corrugations! It doesn't stress the plastic tool either. Running it through only once barely makes the impression and you could easily not line things up the same for subsequent rolls. As the say. It's all in the wrist action!

[@williamdegnan4718]

You can store your corrugated panels, for future use, on the layout as disorganized scrap piles and random blown-off sheets.

[@bernardc2553]

Pur..T..darn..kwel..OBTW Hope ya had a great happy Heartburn day :-)

[@ToyManTelevision]

Yup. Grand day in. Home just us.

[@kenshores9900]

Fantastic outcome producing realistic results. Never boring, unique, interesting, and informative.

[@ToyManTelevision]

Thanks!!!!!

[@1800clyde]

That looks so nasty . . . love it!!!

[@roseking2175]

im doing an On30 layout and i think that this would be fine as it is with the tube roller. There is an old barn near my house and using a tape measure on its corrugated siding it was about 3 inches between 2 crests or 2 troughs and i feel like the foil through the tube roller in o scale could come out to 3-4 inches.

[@ToyManTelevision]

Yup. Steve made a jig. Simple. Get a small sheet of evergreen plastic. Like 4 x 4 inches. Glue evergreen plastic rounds or half rounds (better) like .030 Mostly edge to edge. But shoot for your 3 inches in O scale. (1/48”) or .06. Now lay your foil on it and press in place. Try kitchen foil. Fragile but will work better if you can use such fragile material

[@OutdoorsWithShawn]

I've used toilet bowl cleaner to rustify aluminum flashing for scale buildings. The hydrochloric acid in it works well, but not as fast as the acid you used. The cleaner is inexpensive and found just about everywhere.

[@ToyManTelevision]

Probably a lot safer than what I’m using to!

[@stefanella2]

Hey, coukd you tell me which one you are using and how long to you hold your metal in it? Thank you!

[@robertweldon7909]

If you don't want to fool around with acid, there are acrylic paints that resemble rust. Even though it becomes water resistant, when dry, You would use some sort of clear sealer for outdoor use. I've seen Jason Jensen use the stuff with super results. Jason is a master "structure" modeler in HO scale. Visit his you Tube site Janson Jenson Trains. I've been amazed with his skill. I can't wait to see the coaling tower videos and finished product. ;-)

[@ToyManTelevision]

In this case the acid actually has iron in it, so the rust you see is actual iron! Really comes out nice and I really love the way that each one looks very unique and individual without really putting in any work at all

[@SaintCoemgen]

I remember an article in Model Railroader (or maybe it was Railroad Model Craftsman) how to make corrugated panels back in the 1990's or earlier using a bit different method for HO scale. All my copies of MR are no longer accessible to me, else I could quote the issue. Sad. Reasons are complicated. Moving on.

[@ToyManTelevision]

You can get mr on dvd!

[@SaintCoemgen]

@@ToyManTelevision I do indeed read a lot of material digitally, I guess I was more regretting I lost access to my original copies as "collectables" from my childhood. And I collect old books as well, some going back to the 19th century.

[@daviemaclean61]

Great technique for producing corrugated iron. For HO/OO scale I have found foil takeaway containers are a bit more robust than kitchen foil, ie you can't accidentally knock the corrugations back out when handling them - guess how I found that out! ;-)

[@ToyManTelevision]

I have also used that celebratory plastic version of crêpe paper streamers. Can look really good except it it’s that mylar plastic and Hass to be painted

[@RailyardProductions]

I see a "Bear" in the panel lower left hand corner at 13:27

[@tccarr7162]

As for mr crusty short how bout a side wall with the 'eaten' end in the dirt, debris, etc.

[@ToyManTelevision]

Fence…!! kzbin.info/www/bejne/iXS8eHyvrtFskLc

[@Tiedye6336]

Does anyone have a good recommendation for a easy model truck for some who has never build one before I don’t want to to be very hard?

[@ToyManTelevision]

What kind of truck? Simi? Pickup? Old new?

[@Tiedye6336]

@@ToyManTelevision what I meant is if anyone had any ideas for some that is just starting out with building models cars, or trucks what would be the easiest to start with I end up ordering model Ford pick up truck

[@Tablelegs123]

How much baking soda did you add that silverware tray? Also Did you heat the water to dissolve it? Thanks

[@ToyManTelevision]

A lot! Yes hot water. Tap hot. But it really gets icky fast. But works better when it’s really thick and black. Water works. But soda adds a black tarnish.

[@PracheeKorday]

Can we cut and use tin can that we get for drinks?

[@ToyManTelevision]

Probably too thick. But perhaps.

[@southernrailwayfan1338]

I always wonder how did they get coal into the coaling tower

[@royreynolds108]

Go to 0:42; that is the side of the real Chama coaling tower. There are 4 sets of vertical posts and three spaces. The 2 outside spaces have rectangular buckets hanging from cables over pulleys in the covered overhead. These buckets are lowered into depressions in the ground below the level of the near track which is the coaling track and have openings to dump the coal through the track and the coal slides down a chute to be dumped into the buckets. The full buckets are raised to the top by the cables and dump the coal into the framed structure to store the coal until a locomotive is spotted under the gate on the other side of the structure to let the coal pour into the tender.

[@southernrailwayfan1338]

@@royreynolds108 cool

[@isaiasoliveira9489]

Como fazer esse modelador de telhinha?

[@ToyManTelevision]

Hello! It’s a “tube squeezer”. A tool artists use to squeeze paint out of the paint tube. I bought it on Amazon. Toothpaste Squeezer, Metal Toothpaste Tube Squeezer Paint Tube Wringer for Artist, Hair Salon, Painter… a.co/d/h0vYifi

[@giancarloferucciorusalen4756]

Plase Brother . A water container. a ferric container Correct ?

[@ToyManTelevision]

Three. Water. Soda. Ferric. Start in the ferric. Then you can go straight to water. Slowly stops the reaction. Rich brown color. Or from the ferric into the soda water. Just baking soda. Fizzes and stops the reaction. Slowly turns black. Then over the next hour the rust comes out. All the ones seen here are done that way.

[@Leatherfacemcbowson]

Or since indoors you cold use corrugated cardboard

[@NYCJDClark]

The look is great but that acid is nasty stuff to use. I really like your finished product. Very nice and realistic looking.

[@Omar-td2gl]

I went the cheap way i use cardboard and I peeled the cardboard and I got my panels out of there and then I painted it Looks like peeled cardboard for older hobbies it is too much work I have to go to easy cheap way

[@ToyManTelevision]

That works. Know a guy who puts latex house paint on wax paper and peels it away and glues it to walls. Uses it for peeling paint but most often failed wallpaper that was peeling