Modify a Sergent EN87 to fit in a RailFlyer chassis
What I did to mate the Sergent coupler with the RailFlyer chassis
Fairly simple modification to fit in the coupler pocket.
This seemed like it was going to be a tall order. The Sergent EN87 is designed to fit in an Accurail
P:HO narrow coupler box. The RailFlyer chassis is deigned to prototype specs.
The first thing you'll notice is the Sergent EN87's coupler pivot hole is too far forward to fit in the
RailFlyer pocket. I figured I could just file the rear of the coupler, or the rear of the box to make due.
However this turned out to be an impractical idea, as the coupler would nearly brush the coupler plate
when done! Here's my solution.
- Begin by removing the Sergent EN87 from the Accurail coupler box (if you're using the preassembled
EC87A). Save the box & spring in case you need them in the future.
- To fill the slot on the coupler shank, cut a .070" chunk from a strip of .060" x .188" styrene strip. It
should end up being a tad thicker, and longer then the slot. The .060" thickness fits snugly in the slot.
- Notch on end to fit the small spring notch on the slot. Trim off little at a time until the styrene part
almost fits, then round off the non-notched end to match the curve of the hole. Don't worry if it ends
up being a tad too short.
- Insert the styrene part. Fill the openings with gap filling CA, and allow to dry (CA accelerator works
well here).
- Mark off the location of the new hole. I moved it back about 1/3 of the distance to the rear of the
coupler shank. The hole center should be at 9/32" from the rear of the coupler lever dimple on the
bottom of the coupler.
- Drill out the hole for the pin. I started with a #62, then a #56, then #50. I then filed it with a round file
to fit. The pin is around the size of a #48. Use a pin vise and drill slowly by hand, so you do not
damage the shank, as it'll get fairly thin.
- File down the sides of the coupler shank at its widest location, so that you can press it through the
RailFlyer coupler pocket. Go slow, as you do not want to break through the sides.
Warning/Notes:
I have not yet determined if this will be a viable solution, do so at your own risk! The coupler will rest
at a prototypical (or close to) distance from the pocket, and have very little side to side play.
[Ed. Sergent eventually made a drop in solution for these chassis kits, which are no longer available.]
© 2008, 2019 Josh Baakko, http://www.modelrailroadtips.com
