Chocolate Train

by Peter on Oct.15, 2009, under Stuff, Uni

To become a Design & Technology teacher, I need to have some skills in woodwork/metalwork. I’m doing an introductory to workshop course and our first project it to create chocolate moulds. I’ve decided to create a mould that resembles a model train.

The Chocolate Train Portfolio – 2mb PDF

The basic assembly of pieces to identify possible problems that may arise.

The basic assembly of pieces to identify possible problems that may arise.

Showing the detail of the spoked wheels that were obtained by cutting 3mm MDF with the laser cutter.

Showing the detail of the spoked wheels that were obtained by cutting 3mm MDF with the laser cutter.

Now onto the photos of the build…

Train CAD template
Train CAD template
The tunnel needed a base for the train tracks to be fixed to. I originally cut some sheet metal from a computer case but it was too thin to weld. Also note that the rust has been sanded off in preparation for paint.
The tunnel needed a base for the train tracks to be fixed to. I originally cut some sheet metal from a computer case but it was too thin to weld. Also note that the rust has been sanded off in preparation for paint.
A light coat of primer was used to stop further rusting.
A light coat of primer was used to stop further rusting.
The base piece welded to the tunnel. I sanded back the primer in spots I was going to weld. I used a gasless MIG welder at home.
The base piece welded to the tunnel. I sanded back the primer in spots I was going to weld. I used a gasless MIG welder at home.

The heat of the welding caused some of the sheet metal to warp a little. I contemplated using filler to smooth the join but had success getting it level using a file.
The heat of the welding caused some of the sheet metal to warp a little. I contemplated using filler to smooth the join but had success getting it level using a file.
A thin coat of stop putty was used and later sanded to create a seamless join.
A thin coat of stop putty was used and later sanded to create a seamless join.
Calculating how many paddle pop sticks would be needed to obtain the desired look of railway sleepers. A test sample of stain was also used to check for colour.
Calculating how many paddle pop sticks would be needed to obtain the desired look of railway sleepers. A test sample of stain was also used to check for colour.
Cutting all the paddle pop sticks (railway sleepers) at the same time to achieve a consistent length.
Cutting all the paddle pop sticks (railway sleepers) at the same time to achieve a consistent length.

The railway sleepers drying after they had been dipped into the stain. They were then cut again to the finished size of 75mm
The railway sleepers drying after they had been dipped into the stain. They were then cut again to the finished size of 75mm
The entire tunnel was sprayed with white primer to achieve a good bond onto bare metal and assist in a consistent depth of colour in top coats. Preparing the tunnel for paint. The top of the tunnel was masked off.
The entire tunnel was sprayed with white primer to achieve a good bond onto bare metal and assist in a consistent depth of colour in top coats. Preparing the tunnel for paint. The top of the tunnel was masked off.
The inside of the tunnel is painted with a black primer/surfacer. This will be its finished coat. Testing the colour scheme of the stained paddle pop sticks.
The inside of the tunnel is painted with a black primer/surfacer. This will be its finished coat. Testing the colour scheme of the stained paddle pop sticks.
A grey primer/surfacer was applied to the outside of the tunnel. This was wet sanded using 1200 grit sandpaper to achieve a flat base for the colour coat.
A grey primer/surfacer was applied to the outside of the tunnel. This was wet sanded using 1200 grit sandpaper to achieve a flat base for the colour coat.

I used the colour Blue Mica, it is a metallic automotive touch up paint.
I used the colour Blue Mica, it is a metallic automotive touch up paint.
The train template cut out on 3mm MDF using the laser cutter.
The train template cut out on 3mm MDF using the laser cutter.
Showing the detail of the spoked wheels that were obtained by cutting 3mm MDF with the laser cutter.
Showing the detail of the spoked wheels that were obtained by cutting 3mm MDF with the laser cutter.
Planing the edges in preparation for using the lathe.
Planing the edges in preparation for using the lathe.

Pete turning wood...
Pete turning wood...
Can see the woodchips flying
Can see the woodchips flying
Assembly showing the chimney fitting into the 20mm hole that was cut using the milling machine.
Assembly showing the chimney fitting into the 20mm hole that was cut using the milling machine.
The basic assembly of pieces to identify possible problems that may arise.
The basic assembly of pieces to identify possible problems that may arise.

Slight problem with my measurement, or lack of! The train is longer than the tunnel. Bring on the saw.
Slight problem with my measurement, or lack of! The train is longer than the tunnel. Bring on the saw.
This is my left side template glued into place. I need to add some filler between the barrel and base.
This is my left side template glued into place. I need to add some filler between the barrel and base.
Applying filler to smooth the gap between barrel & base
Applying filler to smooth the gap between barrel & base
Sanding the filler.
Sanding the filler.

Mounted, ready for plastic vacuum moulding.
Mounted, ready for plastic vacuum moulding.
Inside of the plastic mould, the wheels are stuck in there.
Inside of the plastic mould, the wheels are stuck in there.
Outside of the mould showing the detail of the train!
Outside of the mould showing the detail of the train!
Attemped a process called "colour sanding" or "wet sanding" and buffed the tunnel to get a glass finish.
Attemped a process called "colour sanding" or "wet sanding" and buffed the tunnel to get a glass finish.

The chocolate once removed from the mould.
The chocolate once removed from the mould.
Railway sleepers and tracks glued into place.
Railway sleepers and tracks glued into place.
The complete chocolate train and tunnel. Had to patch it up a bit as it cracked when removing from the mould.
The complete chocolate train and tunnel. Had to patch it up a bit as it cracked when removing from the mould.
The final product with a solid mould.
The final product with a solid mould.


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