Downsizing a Big Hauler

[PJM20]

Nice bash/scratchbuild! - Peter

[Mik]

They're fairly cheap.  They're plentiful. And they're simply a bit too big to look good on R-1 and R-2 curves.

The Bachmann "Big Hauler" 4-6-0 is probably the most common US outline locomotive in the LS hobby. The later drives are fairly sturdy. But the size simply overwhelms many smaller layouts. However, with some work, combining it with readily available NoS (new old stock) Delton c-16 parts off 'the Bay', it can be remade into a rather good looking Mogul for much less than the cost of a ratty used LGB one!

I had a 5th generation one from a set. It had nearly no run time, but it got dropped... twice. The second time was a tumble from a high shelf - destroying the cab and breaking off many detail parts. Thus it became a perfect candidate for a bash... too good to junk, but too messed up to repair.

The first step was to take off the superstructure... lots of screws, some not in very obvious places. This is also a good time to remove any details that you may wish to re-use (like the gauge cluster, sand dome, bell and headlight). Snack size baggies are great for keeping track of the tiny fiddly bits, while pill bottles work great for screws. Removing the rods, monkey motion (Walshaerts gear) and crosshead guides at this time is a good idea as well - to help prevent damage to them.

The next step makes a big mess, so don't try it in the livingroom!  A reinforced cutoff disc in a dremel is probably about the best way to cut away the lower boiler parts cast into the chassis. You need to shorten it quite a bit to look right with the smaller boiler and cab. I took an inch off the rear overhang. It's just plastic, air and the sound switch board there. I then relocated the cylinders rearward and shortened the pilot a bunch. I used Marine (UV resistant) Goop and a several of the salvaged screws to reassemble everything at the length I wanted.  I also used some plastic pipe (3/4") to make the cylinders appear larger.

A quick mock-up with the Delton boiler and cab shows that this WILL work.

The siderods were spliced about 3/8" longer. I chose not to make new ones because I don't have a mill. Moving the long crank pin was the worst part of this job. I think they're supposed to press out, but I ended up cutting part of the long one off and splicing it onto the pin on the 3rd axle. A bit of all-thread and Loc-Tite was used to strengthen the joint. The Delton pony truck frame needed drilled for the Bachmann wheelset, then shortened to fit the chassis. Some sheet plastic was needed to block off the gaping holes in the chassis to keep dirt and water out. I also removed the sound trigger since I don't like the factory sound and am too poor (or is it cheap?) to buy aftermarket.    Note: While you've got it apart it's a great time to check the back to back spacing on the wheels and relube everything. The chassis is where a little extra careful work can make a BIG difference in the end result.

The boiler shell got shortened to match the length of the chassis. I probably could have left the rear overhang on the frame instead, but I wanted it as short as possible. I had to cut away all the Delton running board cross bracing and part of the bottom of the boiler shell to clear the stock Big hauler weight. I also added 6 oz over the front drivers to help center the balance a bit better . The Bachmann sand dome was re-used. But the steam dome was much too large. An Annie airpump and piping was used because I had it here.

Handmade prototypical cab piping was salvaged from the Big Hauler and modified to fit the smaller firebox and cab. It's just tubing, wire and snaps, but it still looks pretty good. I didn't have a Delton firebox section on hand so I had to make one from scratch.

The steam dome is a pvc pipe cap with a hand bent .060 brass band at the top. The 'jewelry' is a mixture of Ozark Miniatures,  Trackside Details, and handmade. I spent the extra money on the TD chime whistle because this engine will be used in passenger service. Freight hogs on the Allegheny Valley only get a plain single.

Since the Bachmann builder's plates say 1918, the Delton 1870s smokebox door was replaced with the Big Hauler one - after a bit of trimming. The opening door also allowed me access to solder stuff AFTER assembly! It has an LGB smoke unit in the stack because the element in the Big Hauler one didn't survive the fall. There's probably room for a nicer one, but I rarely run smoke anyway. The spark arrestor is just screen from a dollar store splatter shield, and flat washers.

A Delton tender base,  HLW shorty tank car body, acrylic sheet and wood would become a short Vanderbilt tender. I started building this for another project, then discarded the idea...but decided to resurrect it for this one.

A 2c water hatch... literally.  It's made from 2 pennies, wire and plastic

I think it looks plausible, even nice..... for a mongrel Mogul

Not quite done, but out for her maiden run. with 10 pickup points it ran smoothly even though I hadn't cleaned the track in over a month

If it works, a short vid clip of it running on the AV

It's still not quite finished, but it will be before long. This project certainly wasn't what I'd call a "beginner's" bash, but it wasn't impossibly difficult either. Simply buying an LGB Mogul would have been much easier, but I had fun, saved a lot of money,  and now I have a unique high stepping little Mogul.