Upgrade and repair of pocket couplers on the Bachmann EDM SD40-2

[Desert Rose]

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.



Damaged coupler box

The coupler mounting screw is striped out. Enlarge the hole to fit one evergreen polystyrene 1/8 tube 0.125 dia.

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.


Upgrading coupler box

Remove coupler cover and coupler.



With an ex-acto knife remove tabs and barrel as shown.


 
Using the Kadee #246 tap and drill set tap the hole with the 2-56 tap.



Using Accurail #1017 Standard Size Coupler Boxes.



Trim ends and install desired coupler with whiskers.



Install Coupler Box to shell with a 2-56x3/16  blk zinc phil pan/thrd MS 485-532-82 screw.




Check coupler for proper height using a Coupler Gauge for HO Standard Gauge.