Upgrade and repair of pocket couplers on the Bachmann EDM SD40-2
: 2 EACH. ACCURAIL #1017 STANDARD SIZE COUPLER BOXES.....................................P/N: 1017
: 2 EACH. BACHMANN E-Z MATE COUPLERS .......................................................................P/N:78025
: OR
: WALTHERS HORN-HOOK COUPLERS(X-2F) .....................................................P/N:933-995
: OR
: KADEE No.148 WHISKER COUPLERS ...................................................................P/N:148
: OR
: WALTHERS PROTO MAX COUPLERS ....................................................................P/N:920-6002
: 1 EACH. MICRO-MARK COUPLER GAUGE FOR HO STANDARD GAUGE ...................P/N:82824
: 1 EACH. X-ACTO No. PRECISION KNIFE .................................................................................P/N: EPIX3201
Remove the body shell and check the metal deck for straightness. (If dropped the back deck gets bent in the up direction). It is soft metal; you can straighten it by hand.
(https://images14.fotki.net/v1683/fileceXT/1569b/4/4125954/16532715/Picture1.gif) (https://images15.fotki.net/v1685/fileiG2E/1569b/4/4125954/16532715/Picture2.gif)
Damaged coupler box
The coupler mounting screw is striped out. Enlarge the hole to fit one evergreen polystyrene 1/8 tube 0.125 dia.
(https://images15.fotki.net/v1685/fileYuW2/b967b/4/4125954/16532715/Picture2A.gif)
Manufacture the replacement shaft using evergreen polystyrene 1/8 tube 0.125 dia. For pocket coupler insulation - Cut replacement shaft to fit flush with top of
coupler in place. Using a 2-56 tap, tap one end of the replacement shaft all the way to the shank of the tap.
(https://images15.fotki.net/v1685/fileHiut/b967b/4/4125954/16532715/Picture2B.gif)
Upgrading coupler box
Remove coupler cover and coupler.
(https://images49.fotki.net/v1680/fileK3bT/1569b/4/4125954/16532715/Picture3.gif)
With an ex-acto knife remove tabs and barrel as shown.
(https://images14.fotki.net/v1683/filekN8a/1569b/4/4125954/16532715/Picture4.gif)
Using the Kadee #246 tap and drill set tap the hole with the 2-56 tap.
(https://images12.fotki.net/v1686/fileexXs/1569b/4/4125954/16532715/Picture5.gif)
Using Accurail #1017 Standard Size Coupler Boxes.
(https://images49.fotki.net/v1679/fileI3JV/1569b/4/4125954/16532715/Picture6.gif)
Trim ends and install desired coupler with whiskers.
(https://images46.fotki.net/v1682/file4ayt/1569b/4/4125954/16532715/Picture7.gif)
Install Coupler Box to shell with a 2-56x3/16 blk zinc phil pan/thrd MS 485-532-82 screw.
(https://images34.fotki.net/v1681/fileqBWo/1569b/4/4125954/16532715/Picture8.gif)
(https://images20.fotki.net/v1638/fileSRCY/1569b/4/4125954/16532715/Picture9.gif)
Check coupler for proper height using a Coupler Gauge for HO Standard Gauge.
(https://images20.fotki.net/v1684/file165p/1569b/4/4125954/16532715/Picture10.gif)
(https://images14.fotki.net/v1683/filekCvm/1569b/4/4125954/16532715/Picture11.gif)