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First, a little bit of history. .....

I've always liked building things and got into trains back in the early 70's when AHM came out with an O-scale plastic model of a Indiana Harbor Belt 0-8-0 switch engine, a model of the 4-6-0 "Casey Jones" engine and two early 4-4-0 western engines.
They made motorizing kits so you could run the engines on two rail track.

I bought one of the 0-8-0 model kits and built it up with the motorizing kit.
It was fun to build and run it around a section of track and I found that I wanted to build some more.
So I bought some more model kits and started putting them together to make other types of locomotives out of the kits.

This is the first one that I built into a 2-6-6-4 articulated locomotive.
The oil tender was built from the front of the 0-8-0 tender and a piece of PVC plastic drain pipe.
The little 0-4-0 switcher ( on the lower right ) was built with the parts that were left over.

Both of these engines are motorized and still run well.
My daughter ( who is 46 now ) was 4 then so I put a number-4 on the little switch engine and let her run it around the track.




This became a "winter hobby" and over the years, I built other locomotives out of those AHM kits and also got into building rail cars and other train equipment.
The blue engine on the top shelf and the black engine on the seconded shelf are built from the AHM model kits.




In the 80's and 90's I started experimenting with building models out of brass.
Starting with the frames and running gears and eventually to building the whole brass engines.

Here is a photo that was taken back in the late 90's of some of my builds.
These models are all freelance builds and none of these locomotives are modeled exactly like an existing locomotive.  
The ( unfinished ) articulated engine on the lower left, has a boiler made out of a piece of tube from an old brass bed.




Eventually, I accumulated the necessary tools for working with brass like a resistance solderer, drills and taps and small drill press, mill and lathe.
We are in the process of selling our house so we can move out of state and all those fancy tools are packed away in storage in southern Indiana.  

So that brings me to my current problem.
I picked up this brass engine shell off ebay awhile back and didn't intend to do anything with it until after we got moved.
In the mean time, to have something to work on, I have been making houses and other buildings for my future O-scale layout

This brass engine shell is a nicely built model but it does have one problem.
The sand dome is placed so far forward that there isn't any room for a smoke stack.




This fall I got this 0-4-4-0 chassis for a small logging engine and it has been sitting on a shelf with the engine shell.




The chassis came with a bag of linkage and a bag with some end caps for the steam cylinders and some spoke wheels.






I've gotten a little tired of making buildings all the time and started thinking about that engine shell and the articulated chassis.
If I added a smoke box to the front of that engine shell it would be the right length to fit on that chassis.

Luckily, I kept the small lathe here when I packed up the rest of the tools.
Besides a few hand tools, the only other tools for working with metal are a 325 watt soldering gun and a hand drill.
I already know from experience long ago that the soldering gun isn't going to be very effective for soldering on a brass engine shell.  


What the heck, I decided to go ahead and see how far I can get on putting these two parts together.

The wheels on the chassis would not rotate a full revaluation because the shaft that goes into the steam cylinders have rust on them.
I took the chassis's apart and cleaned them up.
The rust was removed from the shafts and I rubbed them down with a piece of canning wax.
The bearing blocks got a little light lubricating grease put on them before I re-assembled the axles.




I've ordered a smoke box from PSC and that should be here next week.
In the mean time I'm going to see about getting the chassis mounted to the engine shell.

Normally, the steam cylinders of the a steam chassis would be mounted to the underside of the boiler with a screw going up thru the center of the saddle for the steam cylinders.
However this articulated chassis has a pivot pin on the back of the front unit that fits into a hole in the center of the steam cylinder on the rear unit.
There is also a flexible drive shaft that goes right thru the center so I can't put a mounting screw up from the bottom.






There is a threaded hole in the center of the steam cylinders on the rear chassis so I could mount it with a screw coming down from the top.




The problem with that is the mounting screw would have to go all the way thru the boiler and the head of the screw would be on top of the boiler right behind the bell.




As luck would have it, there is a small lip sticking out the front of the saddle on the rear steam cylinders.




Using a piece of .020 thick brass, I made up a little piece that fits onto the underside of the boiler.
This is mounted with machine screws.   After we get moved, I can solder this piece on so it will look smoother.




The lip on the front of the rear steam cylinder fits into this piece and the area that is bent up on each side keeps the steam cylinder from moving sideways.




The tail end of the rear unit is fastened to the underside of the cab with a single machine screw.
This is how the engine looks so far with the complete chassis installed under it.




I'm thinking of using those spoke wheels that came with this chassis and making a leading and trailing truck for this engine.
That would make it a 2-4-4-2 locomotive.

Last edited by jdcrawler
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Originally Posted by Yves:

Ray,

 

I wish you could post closer and bigger pictures of the early models you built from the AHM kits. They deserve better representation.

 

Yves

 

Those shots were scanned from old photos and the engines have been packed away for some time now.

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Today I used some Brasso and an old toothbrush and spent a couple of hours scrubbing.
It still needs some more work in some places but my hands are tired.
There has to be a better way to clean something like this !



Originally Posted by Jay C:

Looks fine to me but upon further review I now say the mechanism is from a 2-4-4-2 but the superstructure looks like a UP consolidation that's missing it's smokebox.

 

Jay

I did some searching on the internet and see that you are right on both the chassis and the engine shell

Both of the real engines were nice looking locomotives.

 

I realize that putting odd parts together like this is unorthodox and probably frond on by most people that build locomotives.

However, I've also found out from experience that trying to find the rest of the parts to restore either of these units will most likely end up costing more than you ever thought it would.

 

Some time ago, I got excited about putting together a Challenger and ended up paying a lot more than I should have for the correct parts.

Both of these units were really cheep off ebay and I figure the cost of finding the rest of the parts was why nobody bid very high.

 

Over the years I've built a few "freelance" locomotives from odd parts that I've picked up.

I'm retired so cost is a big factor and I enjoy being able to gather parts together and build something that still looks realistic and I can run it down the track.

 

Last edited by jdcrawler

Thanks guys.   It's encouraging to know that there other modelers that enjoy doing freelance engine building.

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I've been working on mounting the pilot and making up the deck plate on the front.




The framework for the deck is soldered to the underside of the deck plate.




Drilling a .040 diameter into the end of a .062 diameter brass rod.




The air pipe fits into the hole in the brass rod and is soldered in place.
Then the brass rod is bent to shape.




The air line is then mounted to the top of the deck plate with two "U-bolts".



 

 

 

 

Last edited by jdcrawler

Turning a piece of plastic down to make the insulating hub for the leading and trailing truck wheels.




The wheel is pressed onto the plastic hub.




With the wheel then clamped in the chuck, the back of the plastic hub is faced off and the hole is drilled for the axle.




Two of the wheels have the axle shaft pressed in place now.




Here are the finished wheels.




The frame for the trucks is cut from a piece of sheet brass.
The axle shaft for the wheels fits nicely in the piece of small brass tube.




The sides are bent over to make the truck frame ridged and give it some thickness when viewed from the side.
The front lip on the truck frame is also bent over and the small brass tube is soldered in place.
There is a small hole drilled in the top of the small brass tube to oil the axle shaft.




Here is the finished leading truck mounted on the chassis.




This is how the chassis looks so far with both trucks installed.

I thought that I was going to be able to purchase a smoke box from PSC but they didn't have any with a large enough outside diameter.
So it looks like I'm just going to have to build one.

Starting by turning down a brass bushing so it fits snugly into the front of the boiler.




The bushing was then cut in half so I have two support rings for the smoke box.




Then I cut a strip from a sheet of .020 thick brass and bent it around a piece of pipe to start forming the shape for the smoke box.




The brass strip is wrapped around one of the support rings.
This ring sticks out a little and will be the part that fits into the front of the boiler.




Both support rings are soldered inside the brass strip to form the smoke box.




The smoke stack and the boiler front are soldered in place and the finished smoke box is soldered onto the front of the boiler.
The hinges, hand rail and engine number were missing from the boiler front so those parts were also soldered on.







Sorting thru the bag of side rods and valve gear, I find that most of the parts that I need are there.
I got out the expansion links and radius rods for one of the chassis assemblies.




The mounting brackets for these two parts are about .070 wider than the expansion link and radius rod together.
I made up a small spacer and soldered it to the inside of the radius rod to take up the space.




Here is a look at how the two parts now fit into the mounting bracket.
You can see the spacer to the inside of the rod with a straight pin holding both parts in place.




There wasn't any rivets or pins for joining the linkage arms together so I'm using small nails that are .040 diameter.
The parts are joined together with the nail going thru both parts and then the nail is soldered on back side.
Then the excess length of the nail is cut off and the end is filed down a little to smooth it off.  

Here are the return crank, eccentric rod and expansion link assemblies.




And the radius rods and reverse lift link assemblies.




There aren't any union link arms so I'm going to have to make them.
I have end pieces that were cut off of some valve linkage arms that I shortened for another project.
These are trimmed to the correct length and the cut end is rounded off.
Then a .045 diameter hole is drilled thru all four pieces.




Here are the finished union links.




There is no provision for mounting the union links to the crosshead assembly.
Looking at photos of the 2-4-4-2 type locomotives, I see that the bottom flange on the crosshead extends down below the lower crosshead guide and the union link attaches to it.

Similar to this drawing.




I can't solder an extension to the lower part of the crosshead because the design of the guide assembly would then not allow the crosshead to be removed from the guide bars.
So I need to make a bracket that will bolt onto the face of the crosshead that the union link can attach to.
This bracket also needs to set out about .100 from the face of the crosshead in order to line up with the valve linkage.

I drew out the design for this bracket on a sheet of .012 thick brass.
A hole is drilled thru the end of the bracket.
This will be trimmed out to form a notch in the end of the bracket.




The bracket is cut out and the notch is cut into the end.




The bracket is bent to shape and the mounting holes are drilled in place.
The end with the notch is bent so that it fits over the steam cylinder shaft on the front of the crosshead.
This will keep the bracket from rocking back and forth when it is screwed to the center of the crosshead.
The union link and combination lever are attached to the bracket.



Here is the bracket attached to the crosshead.
This whole assembly can be removed so the crosshead can be slid out of the guide bars.

Made up the two steam supply pipes that run from the side of the steam dome down to the steam cylinders on the rear chassis.
These are formed from 3/16 diameter brass tube.
It was an interesting job to bend these so they wrap down around the boiler and curve forward to end up along side the casting for the steam cylinders.
Here is a view of the two tubes on the underside of the boiler.




The straight brass tube was bent to shape using this tool for bending brake lines and the ends were cut off at and angle.




The end with the angle cut on each tube fits snugly to the side of the steam cylinder casting.






Holes were drilled thru the foot boards and in the sides of the steam dome.
The steam supply pipes were put up thru the holes in the foot boards and fit into the sides of the steam dome and then soldered in place.
Here is the left side with the chassis mounted on.




And the right side.




Here is how they look from the top.

Unfortunately, my tools for building brass locomotives have been packed away for several years.

I bought the resistance solder unit about 20 years ago but I don't remember what the brand name of my unit is or what the wattage is.

I'm sure there are other forum members that can recommend soldering makes for you.

 

Besides the small drill press, mill and lathe, I found that a rivet press with a calibrated table is a handy thing to have for building in brass.

There is about a 3/8 high open space between the rear chassis frame and the underside of the cab.




I'm going to make op a pan to fill this space.
The pattern is first made up out of a piece of cardboard and then transferred to a piece of brass.




The finished pan is bent to shape and the brake cylinders and levers are soldered to it.




Here is how it looks mounted under the cab.




I also got the foot boards made for each side of the smoke box and the headlight is mounted.

Putting a motor in this may not be as easy as I thought it would be.
I mounted a universal joint to the shaft on the back of the drive transmission today.
This only leaves a little under two inches to fit an electric motor in and still be able to fit the chassis to it's front and rear mounting points.

In order to be able to have a big enough motor to power both drive transmissions ( and all the moving parts ) and still pull some box cars,  I may have to put the electric motor in the tender and extend a driveshaft up to the transmission.
All my electric motors are packed away right now so I'll have to wait until after we move to finish that part of this project.
For now, there is a wood dowel attached to the U-joint so I can turn the wheels over by hand.

I have this tender that fits with the style of the locomotive and it looks as bad as what the engine shell looked when I got it.
The tender has cast pot metal sides on the top for the coal box and I would like to replace them with sides made out of brass.




Now I have a nice rivet press but it is packed away with the rest of my train stuff.
So I decided to make up a temporary rivet press using my drill press.
First I turned a piece of steel rod so it has a small bump on the end.




Then I drilled three small holes in the table on the drill press.
The one on the left is for brass and the other two are two deeper holes for working with a plastic sheet.




The small steel rod is held in the drill chuck and a back stop is mounted on the table top for an edge gauge.




Here are the test pieces in brass and plastic.



Last edited by jdcrawler

I've ordered some parts for the locomotive so while I'm waiting on those, I'm starting on the tender.

As a reminder, this is how it looked.




The potmetal coal bunker sides and the water hatch have been removed.
Then I removed as much of the excess solder from the outside of the tender as I could.
Here is the main body of the tender after it is cleaned up.






I cut a strip of brass for the coal bunker sides and started putting the rivets on it.




Here is the finished brass strip.




The bottom edge is bent over to form and area to solder to and then the strip is bent to form the shape for the coal bunker.




This is soldered to the top of the tender body.






The door for the coal bunker is made out of potmetal and I'm going to leave that on the tender.


I changed the looks of the coal load a little.

This coal load was off a larger tender from the AHM plastic 0-8-0 locomotive model kit.
It had a flat piece that angled up from the back of the coal bunker on the larger tender but this smaller tender didn't have that extra piece of metal sticking up at the back.

So I cut that part off the coal load and rounded the back of it so it fits below the back side of the coal bunker.

Doing this left a smooth rounded area at the back of the coal load so I took my soldering gun and kept poking the hot tip into the plastic to rough it up so it looks like coal.





The problem of mounting the motor has been resolved.

Originally there was an "L" shaped bracket that was fastened to the back of the cab.
This bracket set down on top of the tail end of the rear chassis frame and a screw went up thru the frame and threaded into this bracket to hold the rear chassis in place.

I took this "L" bracket off the back of the cab and mounted it to the rear chassis frame.
This now gives me about 3/4 inch more clearance under the cab for sliding a motor in place.

The motor is mounted to the back of the rear chassis frame and connects to the transmission thru a U-joint.






A nut is soldered to each side on the the inside of the motor mounting bracket and this bracket is then  attached to the rear frame with a screw on each side.




Here is how it looks with the boiler shell fastened in place.




The back of the rear chassis frame is now attached to the back of the cab with the two screws located under the tender deck plate.

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