Mikado,
Thanks for your reply. The blue comet tender shell has two long plastic prongs in the back and the middle of the tender has a divider. The RailSounds tender shell is totally open it's 16665 from 1993. The same style tender shell as the Blue Comet.
Hmm,
Well, that would explain a lot. I've never actually opened up the Blue Comet tender, but I did something similar to the Wabash 4-6-2 and it seemed to go fine for me, but I guess since it's a later engine...
Anyways, since you don't want to cut the inside out, maybe you should follow Ed Boyle's technique and use a postwar 2046W chassis and run it with the classic air whistle. The only other thing I can think of is try to rearrange the baords, but that is very risky and not recommended.