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Under The Hood: Lionel 2457 Caboose Conversion (Budget Boxcab)

A recent discussion on 2457 cabeeses prompted me to see what was available on the Bay.  This rather distressed shell spoke to me as a possible boxcab candidate...

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A mockup with one of two MPC era switcher chasses I had knocking about and a large Lionel pan showed that this was going to work out dandily...

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I briefly considered, then discarded, the idea of a jackshaft boxcab.  Perhaps another time... 

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Since the motor would be up against the wall of the shell, a small bushing made of Plastruct tube was cemented in place to keep the shaft from rubbing.

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The bashed up corner was straightened out somewhat. 

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A plastic patch panel to keep the rain out.  I briefly considered balsa, but decided it was a bit too bulky.

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Plastruct bosses JB Welded in place...

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...and clamped to set overnight.

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I JB Welded the roof patch in place...

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...and put the balsa to work holding it in place overnight while the JB Weld cured.

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ProTip:  A piece of masking tape makes a good disposable mixing surface for epoxies et cetera. 

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Since Norma Bates Kitteh was napping, Assistant Shop Supervisor Sylvia S. Siamese approved the work in progress.

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Since the chassis is an MPC era DC chassis, a vintage bridge rectifier salvaged from another project was put into play.   I also replaced a mangled ground pickup. 

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The first test run was a smashing success! 

To be continued... 

Mitch

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