Steve, Ive had afair bit of practise building US 4-4-0s and offer the following , [1] Frames .laser cut in 3/16 steel,, the main problem is the long thin front portion which carries the cylinders it will finish up about 1/4 inch deep if you keep scale proportion, but is ok once you bolt up the cylinder assembly to the boiler and frame.. [2] in 1:20 scale there is plenty of room for a 2 inch boiler inside a cosmetic shell/casing and because the firebox area is deep and long coal should be easy, its also ideal for alcohol firing. [3] Proper stephenson valve gear is fine because therse plenty of space in front of the main drivers. [4] Drive wheels are something of a problem now as Locosteam no,longer exist and we got our castings from them..you want 12 or 13 spoke and around 55 to 60 mm diameter, the segmental balance wieghts can be brass glued on and filled with epoxy .
[4] we can still cast ,Smokebox fronts, and pilots, and saddles for 1870s Baldwins in bronze[lost wax]. [5] axle pumps need to under the cab floor, therse no room on the drive axle.[ [6] Wieght distribution is a problem, the front end is heavy ni models , I find its best to have the front truck , unsprung on a bearing pad[but with side control] and just the drivers sprung, this way you can "set" the ride hieght with the truck and get the adhesion from sprung drivers also a good ride for youe engineer!. Maybe we could have a session at Diamonhead in January? over beer of course. Gordon Watson.