If you have a good piece you can cast with low temp metal. Any one can do it. It doesnt hurt anything. Get some clay and make a 2 or 3 piece mold and cast with low temp metal. It will be a lot cheaper and you can make plenty of parts with the mold until it wears out.
bob2 posted:Sorry - I missed the renewed activity here. I think we need the dimension from the articulating pin to the pilot beam. There were apparently two lengths.
Bob has had some work done on his shoulder, and may be a bit slow in the foundry - but if you can get some idea of that dimension, and an estimate of the quantity, maybe we can get this project rolling.
On the Meadville foundry - I think they were the ones who did my sand cast Erie-built sides, and all I can say is - best sand castings I have ever seen! I do not know if they do investment castings.
Bob has his own foundry. I guess if you know what you are doing it is easy.
Not sure this is allowed - apologies in advance:
Thanks for all the input Bob! Well folks, there we have it....let’s feed Bob2 the inputs he needs and kick this into gear.....I don’t own one of these models, so we’re relying on y’all to get these measurements and info needed.....thanks again Bob!.......Pat
Folks, lets have a roll call on how many brass sets we may need. I would take two sets. I would if I could measure the dimensions from the articulating pin to the pilot beam, but mine are crumbled.
I will buy at least one set.
I know where two sets would go, so I'll be in for two.
I'm surprised that the JLC models would have two different sideframes, that doesn't seem that likely.
Does anybody have a half descent enough set (or at least one) so we can get these measurements off to Bob2 ? ....and Bob, if you’re reading this, do you think the measurement between the bearing boxes would be another crucial measurement? Or are we splitting hairs at that point?......thanks again! ......Pat
I will take two sets, assuming that a set is two pieces. IOW, I'm in for four pieces. Depending on the price, maybe three sets = six pieces.
I would likely buy a 3rd set as well, it's only a matter of time in the future where someone will show up with the issue on one of these. Obviously, that is going to depend on how expensive they end up being.
I'm in for two sets as well providing the price point is reasonable. 
OEM Powered Truck Side Frame with Pilot were going for around $100.00 for each complete set (when they could still be found). 
Chief Bob (Retired) 
I would take a set also. Once people heard of these after market parts being made. I believe there be many more sold.
Sounds like there is more than enough demand for these, so now we just need someone to measure their's and provide that to Bob2....
One set for me also.
Two sets - one for me and one for my Train Time buddy.
I would be in for two sets, please!
I would buy a set.
I lost count. A "set" is enough to completely replace the main frames, right? A "shipset"?
Yes, measure the wheelbase. I will get the brass wheelbase in a minute - it is the exact 1/4" scale dimension from RR blueprints,so it should match Lionel.
These are big castings, and require assembly. Journal boxes and slack adjusters are separate. Not yet sure on the price, but it sounds like ten locomotives worth?
bob2 posted:I lost count. A "set" is enough to completely replace the main frames, right? A "shipset"?
Yes, measure the wheelbase. I will get the brass wheelbase in a minute - it is the exact 1/4" scale dimension from RR blueprints,so it should match Lionel.
These are big castings, and require assembly. Journal boxes and slack adjusters are separate. Not yet sure on the price, but it sounds like ten locomotives worth?
I’d say let’s keep it simple as far as the head count, .....if a “shipset” fixes one locomotive, then so be it...then let’s count them as shipsets....I count at least 15 shipsets as of right now....I’m sure there will be more.....we really need somebody to take the measurements to determine project feasibility......can some one bust out a ruler and maybe a caliper and post up some pics for Bob to see.....or if you email them to him, let us know....this could become reality.....still some unknowns....but it’s sure gaining traction!.....thanks again Bob!........Pat
When I said that I would buy a set, I meant that I would buy two of these (straight, of course; not bowed):
Or are we discussing more complete replacements being built, like these:
Tony D. posted:When I said that I would buy a set, I meant that I would buy two of these (straight, of course; not bowed):
Or are we discussing more complete replacements being built, like these:
The set that is pictured with the red circle around it Tony......that is one pair,..one pair = one shipset..........Pat
I am in for one shipset.
I truly can't imagine anyone buying a single frame. If your GG1 is affected, both sideframes are almost certainly defective. I'd be thinking in a pair as a shipping unit.
I agree, John. I would be in for replacements on both powered trucks, or both plus pilots.
I would take one set, maybe two, depending on how much they cost. Still think Lionel should get these made again due to all the problems.
Guys, lets not get too far ahead of ourselves here. I replaced all four affected frames on two of my six JLC GG1's. Not everything pictured as item #55 on GRJ's photo needs to be replaced/replicated. Granted, the Lionel supplied replacement part includes everything but the coupler, but not everything needs replacing in this instance. That would be a lot of unnecessary and expensive work.
The good parts, easily removable, are on the left side of the photo. They are screwed, tabbed, or slid on. They do not need to be replaced/replicated.
The main frame assembly, on the right, to the best of my knowledge, is the only part subject to 'zinc pest' crumbling. There are two per GG1, they are the same part. It is this part that needs to be replaced.
If this is not clear, or if you need more information, please contact me.
Side view.
Attachments
Correct, AFAIK, only the one piece is the problem piece. I haven't heard that the pilots are defective.
Great observation, and point well taken....problem being, getting somebody to tool up just for that one part of the problematic frame might be a whole new daunting task in itself......don’t get me wrong, I’d love to see just the affected frame section be produced.......but again could be a challenge to get all of this together for a batch....if the Wolfer/Duddy castings can be made in a somewhat reasonable realm, and the measurements work out, the tooling already exists according to Bob2 .....but certainly more avenues can be explored by all means.........Pat
I wonder if the factory in China still has the molds, or do they recycle the molds?
Been off thread for a while, just saw this about the G's.
I have all of the JLC GG1s and am planning on opening all of them to check the frames, my Weaver troop Sleepers were fine, Atlas Erie - Build knuckles rotted.
This all makes me want to go back to strictly postwar.
I'm sure we're not close to firm orders for new frames yet, but I'll have to get back to this after I get'm out and running (hopefully).
Sam
Well, there is going to be custom work involved in addition to simply soldering the Wolfer castings. Once you pass maybe 20 shipsets, it starts to look economical to do brass castings that exactly replace the Lionel part.
Surely someone can part with a bowed casting for me to take a look at? One that is crumbling won't help much.
Copying the Lionel casting involves shrinkage, unless special mold material is used. But that is a possibility.
It really is time for Lionel to step up - there has to be a lot more than 20 of these in trouble. If the holder of the dies is unwilling to shoot some replacements, Lionel should commission a good pattern maker here in the states. Obviously, the 2-rail community knows how to do this stuff. How else could Wolfer have been able to do such accurate pieces?
I have made patterns, but I am not good at it.
Should a parts supplier decide on a new venture, it looks like there may be a large market for aftermarket brass or aluminum GG1 side frames.
Update!
First, this thread was on page four this morning! I need a way to find it without looking through four pages - maybe we could move it to 3-rail scale?
I am expecting a part today. I am obligated not to alter it in any way, but both foundries are agreeing with me - a "no shrink" mold set will have to be in four pieces per truck. That means to go forward I will have to cut a good truck.
Next, I heard from Lionel!
I explained the problem, and Dean Brasseur got back to me. Somehow the mold for this casting was altered, and there will be no more castings. He pretty much gave me Lionel's blessing to proceed.
Finally, I am expecting a cost estimate soon. Bob Stevenson appears ready to do this. He has an excellent track record doing stuff for me. He returned from vacation this morning.
I want to re-assure you - I am doing this as part of my hobby. i have earmarked, in addition to my time, a hundred bucks or so for the "proof" set of castings. I am almost to the point where I ask you (as a group or as an individual) to provide a good casting to cut. If we are wildly successful, I might ask for my investment back. I am not interested in making $, but remember, the foundry is not an eleemosynary institution.
So - Regards - Bob
eleemosynary
[ el-uh-mos-uh-ner-ee, -moz-, el-ee-uh- ]
|
adjective
of or relating to alms, charity, or charitable donations; charitable.
derived from or provided by charity.
dependent on or supported by charity: an eleemosynary educational institution.
bob2 posted:Update!
First, this thread was on page four this morning! I need a way to find it without looking through four pages - maybe we could move it to 3-rail scale?
Here is a link to your comments within posts. If you scroll through your activity, you can find your most recent gg-1 post and go from there.
Here is a link to the actual post I quoted. Problem is , it will always be a link to that exact post, even after there are many more.
Hope this helps. Bookmark or Favorite (or whatever your chosen browser calls your favorite pages to go to) either one as a start point.
Oh, and regarding this topic, I still need to check, but I've got 2 of these GG-1's in my possession, but still need to see if they have the problem. If they do have the disease I would be interested in a set for them.
If they don't seem to have signs of the problem, I'm sorry to say I am not really willing to sacrifice a good one though.
-Dave
A lot of good info in this thread. Instead of getting all sophisticated about search functions, I am going to start a new thread in the 3-rail scale forum. You can help out by condensing the information about how many locomotive sets we need and re- posting it there.
See you on the 3-rail scale forum!
FYI, here's a link to Bob's new thread.
Lionel GG1 JLC (not "Legacy) truck restoration in brass.
Wow, So, Any updates on this?
Any updates on this?
Still in process, things got slowed down by current events. 
For those that have been following this topic. Mr. Henning has a fix on his website. Go to the following link page 4. Detailed info is located there. My GG-1 will run again.
I bought this engine new. It is unrun. Just checked it and the trucks/sideframes seem fine. Now a question/opinion(s), please. If there is no issues now, how likely do you think that there will be in the future (and therefore I should purchase a set to keep in reserve) -or do you think that I have one that will escape the problem. I know that one can never be 100% sure, but it seems for each engine/car with these same issues, some ( ? made at a different time, place, etc) seem not to develop the "rot" while others do. Thanks in advance, turtle7
