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 Posted - October 20 2012 : 8:20:20 PM
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OK guys,
How many of us threw away that original die cast part because it was bent so bad that we knew if we tried to straighten it cold, it would crack and break off! Well, here is my solution...
Using a pen torch and a smooth surface pair of pliers this repair is not only easy, but it is permanent, safe and fast!
See the series of photos below. The cab was so bent, I was not sure if I was going to be able to straighten it, but I thought it was worth a try. I have done this a dozen or so times already, but never took pictures as I did it. I figured this time I would. I have done this on engine and tender steps too. I cant tell you how many Pen Line Whitcomb mini locos I have received that had curled steps. After trying to straighten them cold and failing, only to break the step off and then be forced to CA the hell out of them, which was such an obvious F**k up that I just plain got disgusted with it. Since I have been doing this as a repair, I have yet to ever crack a single thin step!
The secret is to heat the metal with the torch, waving the flame back and forth at first. Actually, I use this torch that stands on it's own and I wave the piece back and forth. Cabs are easy because you can leave them attached to the boiler and use the boiler as a handle. The key is to get the metal soft, but not so soft that it starts warping and melting. (If it is RED, it is too hot and probably shot).
Apply steady but firm pressure with the pliers. Apply the pressure starting from the edges and gently work toward the deepest part of the dent, gently bringing it back into shape as you move along. If the dent is huge, do it in multiple passes with the pliers. Do not try to bring the dent completely out in one pass. Bring it out a little at a time.
See the below photos as done in series. As you can see, I took an intermediate picture showing most of the dent removed, but not completely. After a little filing with a jewelers file, it is done. The repair is as strong, if not stronger than anything else I have ever seen. To be honest, the impact dent, as long as the metal is not cracked, it can be repaired. It might even be the case that the heat actually relieves the internal stress that was applied to the metal from the impact and subsequent deformation. I have no way of testing this however.
Sean
"If everything seems under control, you're not going fast enough!" - Mario Andretti!
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Posted - October 20 2012 : 8:42:24 PM
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How cool is that!
" Heck with counting 'em rivets, TRAINS ARE FOR FUN! Not called the Mad Scientist for nothing either!"
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Posted - October 20 2012 : 8:56:09 PM
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Great idea, Sean. I'd never thought of heating it, frankly. I have en electric heat gun that should be sufficient for this. I've had luck cold bending very slight deformations in zamac, but beyond a certain point... *snap*. 
Nelson
The Tyco Depot
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Posted - October 20 2012 : 9:07:42 PM
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Sean, you maybe a Lionel collector's friend!
" Heck with counting 'em rivets, TRAINS ARE FOR FUN! Not called the Mad Scientist for nothing either!"
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Posted - October 20 2012 : 9:55:25 PM
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Sean,
Your taking lessons out of my old repairs manual!  I first done that about 10 years ago! (I haven't done it much but I done it on an old Lionel Pennsy S-2, 6-8-6 cab, on the same locomotive the cast pilot! Then with that as back then I was a certified Lionel repairs dept.....had to repaint the locomotive under specifications of the company......And then grant the item under the company, "reconditioned", and PASSED!
NICE work....I'll say tho, I have not done this often but at times, it does a world of miracles!
~John
Many have tried to, and failed, ya just can't repair stupid...
Do NOT try to Idiot-Proof anything!!!! God, will simply create a better......IDIOT!
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Posted - October 21 2012 : 09:55:01 AM
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Very impressive! I'll have to utilize this technique in the future. I very much appreciate the tutorial.
Maybe we should have a tutorials forum....
Starting my Tyco and other favorites collection over again after 37 years.
My still in progress list of inventory and wantlist: tyconut.com
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Posted - October 21 2012 : 10:18:05 AM
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good ole' fashioned blacksmithing...
caboose 1
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Posted - October 21 2012 : 12:24:36 PM
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quote:Sean,
"Your taking lessons out of my old repairs manual! "
"NICE work....I'll say tho, I have not done this often but at times, it does a world of miracles!"
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Thanks John!
Honestly though, I am completely self taught. I learn through experiment. I knew heating metal makes it softer so it can bend easier without weakening it, so I figured one day to give it a try with a repair. Not sure if it was a step or a cab that I first tried with, but I figured it was worth a shot. If I did it and failed, no loss since the piece was badly damaged anyway. Low and behold, it worked and that same day, I began digging through a huge pile of stuff fixing every bent piece I could get my hands on. I did not quit until I ran out of gas. Literally...
Since then, I can not count the number of times I have done it. I sell a pretty high volume on eBay, so it has been a lot, let me tell you. My Mantua parts bin consists of over 50 Pacific & Mikado chassis that are waiting to be repaired in some way or parted out and shoved out the door. I find myself repairing stuff all the time. Sometimes as many as 6-10 locomotives in one weekend. Lately an Athearn lil Monster with good gearing but weak motor has got me on the fritz.. After swapping the magnet with a rare earth magnet, I have not been able to get it to run yet. It has been quite frustrating, especially because the gearing is not split. I'll get it eventually though. This morning, I tore apart this engine, stripped the paint, cleaned it, replaced a drive rod rivet and re-assembled it. It will be this weeks locomotive of the week.
http://www.ebay.com/itm/320991466220?ssPageName=STRK:MESELX:IT&_trksid=p3984.m1558.l2649
I just ended it so I could relist it fixed.
This is the new listing:
http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=321007018842
Sean
"If everything seems under control, you're not going fast enough!" - Mario Andretti!
Edited by - Mustangs_n_Trains on October 21 2012 1:25:52 PM
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Posted - October 21 2012 : 1:34:48 PM
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Sean,
So, your a "tin knocker" then!
Thats old fashioned blacksmithing......
~John
Many have tried to, and failed, ya just can't repair stupid...
Do NOT try to Idiot-Proof anything!!!! God, will simply create a better......IDIOT!
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Posted - October 21 2012 : 4:13:30 PM
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Sean, I worked over a Li'l Monster earlier this year. It may be frame contact issues. Drove me nuts until I could find where the break in the electrical path was. I can give details if you like.
The Tyco Depot
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Posted - October 21 2012 : 7:30:45 PM
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quote:Sean, I worked over a Li'l Monster earlier this year. It may be frame contact issues. Drove me nuts until I could find where the break in the electrical path was. I can give details if you like.
Originally posted by NickelPlate759Â -Â October 21 2012Â :Â 4:13:30 PM
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Hi Nelson. It is not powering up with direct contact to the brushes!
After I accidentally broke off one rear step, I got disgusted and put it down. Too much going on to care right now..
Our girls are about to start ice hockey lessons. We have field soccer that I am head coach for and we have one game left on, indoor soccer starting next Saturday.... same day as our last game of field soccer, deck hockey in the early springs and street hockey in the early Summer that I assistant coach for both and Ty Kwan Do every Thursday. Tomorrow starts 8 weeks of bowling lessons!
Not to forget I just spent the day up in our addition sanding the drywall I put up (approx 65 of the 90 sheets I ordered) and I still list on eBay every two weeks! This week is listing week! I must be just plain stupid!
Sean
"If everything seems under control, you're not going fast enough!" - Mario Andretti!
Edited by - Mustangs_n_Trains on October 21 2012 7:32:54 PM
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Posted - October 22 2012 : 12:26:03 AM
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One other thought, Sean: if you used two stacks of magnets, make sure they are oriented with their poles facing the same direction. If they attract each other, they will cancel each other out.
The Tyco Depot
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Posted - October 22 2012 : 11:53:08 AM
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quote:One other thought, Sean: if you used two stacks of magnets, make sure they are oriented with their poles facing the same direction. If they attract each other, they will cancel each other out.
Originally posted by NickelPlate759Â -Â October 22 2012Â :Â 12:26:03 AM
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Nelson,
I used one stack of magnets. I was thinking it might have something to do with it though. Not sure. I'll have to go back at some point and check. Not sure when.
Sean
"If everything seems under control, you're not going fast enough!" - Mario Andretti!
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Posted - December 13 2012 : 1:31:38 PM
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I tried this technique on the valve gear mounting pins on a Bachmann I10 Consolidation, which are very thin and impossible to straighten otherwise. Just heating them with a Bernz-O-Matic grill lighter allowed me to bend them back into shape. Thanks!
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