Here are a list of the steps I used to create the Freight Train Instruction Book.

The very first step in creating an instruction book is to design the models. Some of the models are highly optimized to be mass produced as custom sets. For example, the Chessie System Engine was designed some time ago, but in preparation to convert this model into a set, it took Dwayne and I about 6 iterations over several weeks. Our goals were to optimize the choice of elements to those available in the loose element market, retain the integrity of the model, and keep the costs down. One comment we received was, "When I dumped out the bag of parts on my desk it didn't look like all the parts where there." This is a huge compliment based on our initial goals!

Once the models are designed the .dat files need to be created, MLCad was used for this project. Each one of the seven models were created in a separate .dat file and saved in their own sub-directory, the multipart feature in MLCad was not used. Each sub-assembly call-out in the instructions were created starting with the original .dat files. All unrelated elements were deleted and the remaining elements saved in a new file. Note, this was an iterative process. Although there were strategically placed steps in the original .dat files, it is only when the instructions are being laid out that it becomes apparent where exactly the sub-assembly will be needed.

This is a good time to state that a .dat file with steps is only the first step toward creating quality instructions.

Although there have been great strides in the CAD software for rendering .dat files to images they still do not have the quality needed for publishing, thus the decision to use POV RAY was made. Also, and perhaps more importantly, the work that Bram Lambrecht did in the POV rendering, discovering and pioneering the MEGA POV post processing for line drawing enhancements. In order to render using POV the .dat files needed to be converted into .POV files. To achieve this L3P was used via the L3PAO windows interface. The advantage to using this combination was in loading a preset camera angle for each model, which was auto calculated by L3PAO. The 'step' option was used in L3PAO, which creates a .POV file that can render each step from the original .dat file as a separate image. This saves a ton of time.

Unfortunately in order to apply Bram's 'secret sauce' in POV, each .POV file had to be hand modified to include a 'use MEGA POV' switch, special lighting settings, and post processing code to create the beautiful renderings that work so well for instructions. The nice thing is that POV has a file editor built in. Most of the images were rendered at 1600x1200, barely enough to meet the 300 dpi needed to obtain quality printed output. Based on scaling factors a lower resolution was used for the single element call-outs.

All 188 images needed to be laid out, which required scaling, transparency, numbering, arrows, call-out boxes, page separators and background images. I chose Microsoft Power Point for the following reasons: I know it well from my use at work and used it before to create the set instructions for BricWorx products. It handles all the requirements listed above and more over it is very good about maintaining image quality thru the print path. The only minor draw back is the lack of resolution control when outputting each page as a digital image. However, this can be over come by printing to a .pdf file, then using Acrobat to render the image.

After 15 revisions it was time to go to the presses. It was mandatory to get it printed professionally because it took one and a half hours to print one book at home, and the ink costs would have been outrageous. Full-color offset printing was very expensive unless you need thousands of copies. There is a huge setup cost involved, around $3000. So, I hit the pavement looking to get it color printed. I tried computer-based color laser printers but there was limited selection because not many handled legal paper size, and of the machines that did, the quality didn't meet my expectations. Then I tried copy shops like Office Depot and Kinko's. I had several samples printed and found that not all machines produce high quality prints. The best quality came from a Xerox Docu12 color copier/printer at Office Depot. However the cost was still very high ~$1.00 per page per side. Luckily I found a small privately-owned company that had the same Xerox Docu12 system and gave me a price that made this whole project possible.

It's just that easy! :)

Steve Barile