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Reply to "Rebuilt Lionel 2020 questions."

@radar493 posted:

Couldn't someone reuse the metal cap with the conversion?

Yes.  The difference is in the elements ability to tolerate the heat it produces without evaporation helping to cool it. 

If needed, automotive red high heat silicone for a sealer or homemade gasket (form a bead and let skin well then add the shell. Some plastic wrap masking might be a good idea for messy folk. A piece over top beween the cover & shell too.  (sometimes squeezing/popping some ooze happens. Controlling it with a pin-pop weep hole or two makes for a nicer molding, but you've got to catch it in the masking.)

Good silicone can take the direct heat of an element. You could mold a custom well from it.   I put a PW Element in a little round silcone pill/quarter holder; no problems. No discoloration let alone char.

With some careful taping or shrink tube protection, it could likely hang free under the cab/over in front of the firebox, etc. 

Attaching it out of the way with JB Weld or epoxy is another choice. (you just might have to destroy the sw to replace it. Not so bad).

JBW grinds and sands away better on metal than "rubbery" epoxys imo.  (It could even hold some springs in place 😎)

Because switch wire terminals are usually opposed the switch handle; gluing the side of the switch to the frame or shell, is likely easier. This makes a slide sw. hard to use; I'd lean at a micro-toggle mounted for a side to side throw vs up or down. (sand some scratches into smooth frame for JBW to grab)

Keep in mind mounting on the shell, you'll want to be able to disconnect the wires at one end or the other for servicing easier.

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