Trains.com

Subscriber & Member Login

Login, or register today to interact in our online community, comment on articles, receive our newsletter, manage your account online and more!

Total rebuild of an Athearn Hustler!

44146 views
53 replies
1 rating 2 rating 3 rating 4 rating 5 rating
  • Member since
    January 2010
  • 208 posts
Posted by WPAllen on Monday, June 28, 2010 8:37 PM

That did come out very nice. Excellent job.

  • Member since
    June 2005
  • 4,368 posts
Posted by Darth Santa Fe on Monday, June 28, 2010 8:28 PM

It's done!!Big SmileBig SmileBig Smile

Before:

After:




It's not one of my cleanest jobs, but I think it still turned out really well!Big Smile It's lettered for my fictional "Central Illinois Logging" railroad. If I ever have a larger layout, I'll have a section dedicated to the CIL. The Shays can do the main work, and this can maybe go back and forth between the logging and the main line? I don't know.

After the painting, I added "glass" to all the windows, put in a simple directional lighting circuit (two diodes and a 1K potentiometer), and filled all additional space in the hood with solid lead. Not only is it well detailed now, but it's also like a little brick that can pull just about anything I put behind it!Big Smile I'd call this big little project a success!Big SmileBig SmileBig Smile

_________________________________________________________________

  • Member since
    June 2005
  • 4,368 posts
Posted by Darth Santa Fe on Monday, June 28, 2010 8:14 PM

Forty Niner, my drive is pretty much like the old OMI "tank drive", except that the transfer gearbox I used has a 3.125:1 ratio, so the speed is much lower than the OMI diesels would have by about 1/3rd. This idea has been used countless times by many manufacturers in the past in one form or another, from the Rivarossi U25C to the standard Hobbytown drive, as well as many older brass diesels.

SteamFreak, I actually looked at regearing a Hobbytown with skewed, or helical, tower gears. The only problem is that it's hard to find appropriately sized gears for small projects like that. I've also found that the teeth would need a 45 degree angle to work really quietly (tested some Bachmann helical gears, and they still made the whining sound). It could make an interesting project though!

lbflattop, it sounds like you have quite a lot stuffed into that little engine! Who knows? If you can really do well with arranging it all, maybe you could still fit an interior in. Mine just barely fits the way I built mine, but the motor position isn't exactly low profile either.

_________________________________________________________________

  • Member since
    December 2003
  • From: Ft. Wayne Indiana Home of the Lake Division
  • 574 posts
Posted by Ibflattop on Sunday, June 27, 2010 9:16 AM

I also had the Ernst Gears on my Hustler also. Didnt like how sloppy it was. So we gutted it. Got a can motor from NWSL and had a old powered 4 wheel truck from Athearn. Found a worm gear that would mesh with the geared Athearn wheelset. Now in the process of putting it back together. So my Hustler will not have any gearbox to transfer the power to the drive axel. It will be a streight shot. Trying to find the New Digitrax N scale Decoder with sound to put it in also. I would like to detail it out with hand rails, I have got 3 mm LEDs for the headlights and also a Yellow 3 mm Led for the rotating becon for the roof. I dont think that I could cram an interior in to it thou.  :-(   Kevin

Home of the NS Lake Division.....(but NKP and Wabash rule!!!!!!!! ) :-) NMRA # 103172 Ham callsign KC9QZW
  • Member since
    July 2006
  • From: New Joizey
  • 1,983 posts
Posted by SteamFreak on Sunday, June 27, 2010 6:47 AM

Darth Santa Fe
Cannon only makes them in sets of two. Oh well, maybe I'll find a use for the other one.

Maybe another Hustler conversion? Whistling Ending up with spare project parts can be a bit like eating peanuts.

 Excellent work as always, Darth. The .015" wire handrails look great. Good move mounting the transfer box on foam, but they can be quiet if they're made well, especially if the gear teeth are skewed. Your project reminds me of a someone I know from another forum who retooled his own Hustler and made a slug for it. http://misterbobsmodelworksemporium.blogspot.com/2008/04/athearn-hustler.html

 I bought the Ernst kit for my newer generation Hustler, which turned out to be a mistake. The holes in the worms and flywheels were machined too small, and pressing them on actually warped them. I managed to true the flywheels, but the original Athearn armature is unbalanced enough that it vibrates badly, and the worms are on so tight that I can't get off to balance it without destroying them. I should have gone with the Accurate Lighting kit.

  • Member since
    June 2010
  • 1,012 posts
Posted by Forty Niner on Sunday, June 27, 2010 3:30 AM

It's very interesting what you have done there, do you realize that your entire driveline is an exact double of the old Overland Models "tank drive" assembly?

I'm not saying this to "rain on your parade" but as info for any future Hustlers you may wish to do and for all of the other fellows who would like to try this but are put off by the NWSL prices.

As most brass diesel modelers aren't to excited about the tank drives from Overland and converted them to tower drives some time ago I'm sure there are lots of "spare" tank drive parts to be had 2nd hand.

I converted several of my own and although I have no particular interest in the Hustler I have hung onto mine for the MDC shays and other future projects. (Rule #1 Never throw anythnig away that you "think" you might need someday!!)

I don't know if Overland still has any of these parts but I seriously doubt it, but as I said the 2nd hand market shoud be full of them.

As for the motor, one of the Kato switcher motors would seem to be an excellent choice or possibly one of the old GSB "Tan Can" motors. There are lots of can motors on the market now but of course the quality of some of them is always questionable.

Mark 

 

  • Member since
    June 2005
  • 4,368 posts
Posted by Darth Santa Fe on Saturday, June 26, 2010 10:51 PM

I've finally gotten to the painting!Big Smile It's hot here in central IL, so everything's sitting in a spare room at work where I did the actual painting. I'll be bringing it home tomorrow for lettering, so I'll post some pictures then. But, it's finally almost done!!Big Smile Colors are black with a silver frame, and the interior is light green.

_________________________________________________________________

  • Member since
    June 2005
  • 4,368 posts
Posted by Darth Santa Fe on Monday, June 7, 2010 6:26 PM

I'm back from vacation, and Hobbyland had the final detail in for me!Big Smile

The last thing I wanted to replace was the molded plastic radiator grill, which has gotten a Cannon dynamic brake fan in its place.Big Smile

Cannon only makes them in sets of two. Oh well, maybe I'll find a use for the other one.

The new fan next to the old one for comparison. What a difference!

To mount the new fan, I used a cone drill bit to make a 9/16" mounting hole. The old fan was slightly larger, so I had to trim the edges off and smooth out the area. The Hustler looks pretty good with that new Cannon fan!Big Smile I left the grill and fan unglued so I could paint it more easily.

All that's left now is painting and lettering!Big Smile

_________________________________________________________________

  • Member since
    June 2005
  • 4,368 posts
Posted by Darth Santa Fe on Tuesday, May 18, 2010 2:04 PM

0-6-0
Hello very nice Darth. I would like to know how you bent your hand rails? I use some kadee trip pliers for soft bends and a pair a flat nose pliers for sharp bends but they don't look as sharp as your. Have a nice day Frank

For the sharp bends, I hold the wire with serrated jaw pliers and bend it as sharp as I can with my thumb against the side of the pliers. If there isn't much wire to work with, I use the table instead of my thumb. For the larger bends, I bend the wire around a screwdriver or whatever round object I can find. The thin 0.015" wire I'm using also allows tighter and cleaner bends than my usual 0.02" wire.

_________________________________________________________________

  • Member since
    June 2006
  • From: northeast ohio
  • 966 posts
Posted by 0-6-0 on Tuesday, May 18, 2010 11:10 AM

Hello very nice Darth. I would like to know how you bent your hand rails? I use some kadee trip pliers for soft bends and a pair a flat nose pliers for sharp bends but they don't look as sharp as your. Have a nice day Frank

  • Member since
    June 2005
  • 4,368 posts
Posted by Darth Santa Fe on Tuesday, May 18, 2010 12:14 AM

I got most of my detail parts on Friday, and have been doing some work with them over the weekend.Big Smile


The handrails are made from Utah Pacific stanchions, 0.015" wire, and some A Line chain. The grab irons are also the 0.015" wire (scale 1 1/4"), and the lift bar is from Detail Associates.


Since the cab is fully open now, I thought I'd scratchbuild an interior.Big Smile It's mostly made from 0.02" styrene sheet, and I loosely based it off the EMD switcher interiors.


Another handrail constructed. It's really starting to look more complete now, especially with that interior in there!Big Smile


I used the old grab irons to more easily locate where to drill holes. Once the holes were done, I carefully cut them all off with a knife.


Many more parts assembled!Big Smile I mount the end railings by drilling a #55 hole for each stanchion, cutting the mounting pins off, and then gluing them in the holes. I'll fill the holes the rest of the way before painting. All those new details are making it look pretty good!


Last railing and horn!Big Smile The Hustler is looking pretty complete now! All that's left is the replacement radiator fan, which should be coming in soon.

That's all for tonight!Big Smile

_________________________________________________________________

  • Member since
    April 2003
  • 305,205 posts
Posted by Anonymous on Thursday, May 13, 2010 3:25 PM

That is what I was afraid of...I am also hoping to do some cab detailing and perhaps opening a hood door or two.

I have thought about using the PDT that I have and just build a new frame to fit both it and the shell.  What you have done might be easier though.

Either way, it's time to get busy!

  • Member since
    June 2005
  • 4,368 posts
Posted by Darth Santa Fe on Thursday, May 13, 2010 3:13 PM

centercab
Out of curiosity, did you try the 'Flea'?  I'm not sure if NWSL has any in stock or not...but that would eliminate the need to purchase one of the gear boxes and motor because it comes as one unit.

I did consider the FLEA, but there were a few problems I would've had to work around (as well as the higher total cost, since I already had a motor). The main unit probably would've had to have been mounted in the cab for the needed clearance, and it's only available with 33" wheels. All the necessary parts (main unit, two 42" wheelsets, additional gearbox, and universal) would've added up to $87.50 (unless you get the faster $50 unit) before shipping, which is $20 more than I spent. It may have been an easier installation, but then the cab wouldn't be open for something like an interior.Big Smile I may try a FLEA for some other project in the future though. It would work well for a tender powered steam switcher!Big Smile

_________________________________________________________________

  • Member since
    April 2003
  • 305,205 posts
Posted by Anonymous on Thursday, May 13, 2010 2:52 PM

Darth - Because of you, I've been looking at the NWSL site.  Out of curiosity, did you try the 'Flea'?  I'm not sure if NWSL has any in stock or not...but that would eliminate the need to purchase one of the gear boxes and motor because it comes as one unit.  The other gearbox would run of the output shaft of the flea.

I do have a PDT, but it is the wrong wheelbase!Sad

 

  • Member since
    July 2006
  • From: Chamberlain, ME
  • 5,084 posts
Posted by G Paine on Thursday, May 13, 2010 1:59 PM

Darth Santa Fe

Shown here is the diesel and all the main drive parts to be used. Hard to believe that that's about $70 worth of gearboxes and wheels!

$70 worth of parts to tame what was a $5.00 locomotive when the rubber band drive was the Athearn standard!! Cool DSF, you have done it again

George In Midcoast Maine, 'bout halfway up the Rockland branch 

  • Member since
    June 2005
  • 4,368 posts
Posted by Darth Santa Fe on Thursday, May 13, 2010 11:56 AM

oldline1, the rubber-band drive has always made the Hustler a fun engine. I did something like that little race you mentioned, only it was more of a stunt than anything. I have a length of track on my bedroom dresser, so I moved it to the edge and put a pillow underneath a couple feet forward. Then I cranked the Hustler up to full speed and watched as it flew off the "cliff" and landed safely on the pillow after a 2 foot long and 3 foot deep jump.

markpierce, I know we've got "Slugs", so how about a Snail? Or a sloth? Or "The Little Engine That Sort Of Could"? Or "The Little Engine That Only Moves As Fast As That Awful Movie Called "The Blood Waters Of Dr.Z""? Or maybe "Debbie"? Or maybe not.Big Smile

centercab, I've found that the transfer gearbox is much noisier when mounted directly to the frame. The same one is used in my Keystone Shay, and because it's screwed directly to the metal, it makes a lot more noise. That's why I mounted it to the noise and vibration dampening foam rubber. Either way, it's still quieter than MDC's gearbox!Big Smile

And like I said in the video, for anyone else who might do this conversion, I would recommend using a motor with a length of 25mm or less. It will allow a full universal to be used and make enough room for a flywheel. Since the torque of the gearing is so high, even a very small N-scale motor will work very well.Big Smile

_________________________________________________________________

  • Member since
    June 2005
  • 4,368 posts
Posted by Darth Santa Fe on Thursday, May 13, 2010 11:40 AM

modelmaker51, it sounds like that little Athearn has served you well.Big Smile It's kind of funny how we end up putting far more money into these little switchers than they were ever worth to begin with.

GainesvilleMidland209, these Hustler are very simple engines to work on, so repowering can be a fun project. The way I did it with the transfer gearbox does add a little complexity, but it sure slows it down!

 

_________________________________________________________________

  • Member since
    April 2003
  • 305,205 posts
Posted by Anonymous on Thursday, May 13, 2010 9:10 AM

Good job!  I also have one of these that I might do the same thing to.  In the past, I have used 2 of the transfer boxes in a couple MDC shays.  They work great for that, but they were still noisy!

Thanks for the tips on this; now I want to do mine!Smile

  • Member since
    March 2002
  • From: Milwaukee WI (Fox Point)
  • 11,439 posts
Posted by dknelson on Thursday, May 13, 2010 8:34 AM

markpierce

A Hustler without rubber-brand drive with a speed range between 50 to 200 mph is not a Hustler.   Would it be a Geezer?  No, but surely you can come up with a better name.

Mark

It's now so civilized and work-safe, it's not a Hustler it's a Maxim.

Dave Nelson

  • Member since
    April 2003
  • From: Martinez, CA
  • 5,440 posts
Posted by markpierce on Wednesday, May 12, 2010 11:14 PM

A Hustler without rubber-band drive with a speed range between 50 to 200 mph is not a Hustler.   Would it be a Geezer?  No, but surely you can come up with a better name.

Mark

  • Member since
    July 2006
  • From: Huntsville, AR
  • 1,251 posts
Posted by oldline1 on Wednesday, May 12, 2010 10:53 PM

 Darth,

What a great improvement for the Hustler! I look forward to seeing your detail changes also.

I've always loved the Hustlers since the first one I saw many, many years ago. I've done a couple with the Ernst regearing sets but what you've done makes them look lame.I have copied a model of a Hustler cow & calf I saw in MR a long time ago. It always fascinated me to see them run. Now with DCC and sound I plan on reworking them but I think I'll copy your mechanism & get rid of the Ernst stuff.

I remember as a kid growing up in Baltimore the YMCA used to sponser train shows and a highlight for me was the Hustler races. They had about 12 feet of parallel straight track wired to an MRC transformer set on max connected to both tracks. Two Hustlers were placed on the starting line and then the pack was turned ON and though and took off sideways. I think the prize was a Varney boxcar.

Anyway, please keep us up-to-date on your Hustler.

Roger Huber

  • Member since
    May 2010
  • From: Georgia
  • 28 posts
Posted by GainesvilleMidland209 on Wednesday, May 12, 2010 10:30 PM

I've heard about this and always meant to try it.  I think I'll step out on that limb and give it a go.  My Hustler is nearly useless with two speeds - parked and warp 6.

 

Loco_103
  • Member since
    August 2005
  • From: S.E. Adirondacks, NY
  • 3,246 posts
Posted by modelmaker51 on Wednesday, May 12, 2010 10:05 PM

Looks good. I regeared one with an Earnst regearing kit and some NWSL wheels. The kit also came with a flywheel for the Athearn motor. While mine didn't slow down to 25smph, it did bring it down to around 60smph with great slow speed control. I did add some Tomar rail wipers to improve electrical pickup and stuffed lead in every nook and cranny to improve traction. That was about 15 plus years ago and that sucker still runs like a charm, as a mater of fact I'm getting ready to install a decoder in it so it can continue life in the 21st century.

Jay 

C-415 Build: https://imageshack.com/a/tShC/1 

Other builds: https://imageshack.com/my/albums 

  • Member since
    June 2005
  • 4,368 posts
Total rebuild of an Athearn Hustler!
Posted by Darth Santa Fe on Wednesday, May 12, 2010 9:07 PM

I decided a couple weeks ago that my next project would be to repower and redetail an old Athearn Hustler diesel. A couple days ago, I got all the parts from NWSL to get it repowered.Big Smile So, let's get started!Big Smile


Shown here is the diesel and all the main drive parts to be used. Hard to believe that that's about $70 worth of gearboxes and wheels! The body has been stripped for the new details and paint which will come later.


The first thing I did was assemble the 3.125:1 transfer gearbox kit. On top is an 8-tooth brass gear, in the middle is a 25-tooth delrin gear, and last is a 25-tooth brass gear. The 25-tooth gears came nice and clean, but the 8-tooth gear needed a little cleaning before it was ready. I folded a piece of super fine grit sandpaper and ran it back and forth between all the teeth to get the gear perfect. The gearbox itself also needed a little cleaning, but it wasn't too bad. I assembled the gearbox with just a couple screws to test it out and make sure everything worked. Then I opened it, lubricated it, and then completely assembled it. The screws shouldn't be tightened all the way, or it will warp the gearbox and cause extreme tightness and binding. I let the motor run the gears in for a couple minutes in each direction.


Next was to build the FLEA gearboxes and axles. These use a 15-tooth brass gear on the axles with a tiny steel worm driving each one. The gears were perfect from the factory, but the gearboxes had a lot of flash in them that had to be cleaned out. After the gearboxes were clean, assembly was very simple. And after a little lubrication, they worked perfectly and absolutely freely.Big Smile I hooked each one up to the motor and transfer gears to test them out and run them in just a little.


The NWSL axles aren't pointed like the stock Athearn ones, so I had to change their mounting to the frame. I drilled each hole out with a 3/32" drill bit and put a short piece of 3/32" brass tube in each one to function as the bushing for the axles. Turns out the NWSL shouldered axles fit perfectly in K&S 3/32" brass tube, so that worked out very well.Big Smile


Since all the axles and gearboxes were now assembled, it was time to mount them in the chassis. The axles and their gearboxes are held in place by the brass bushings mounted in the frame, and the FLEA gearboxes are held in place by torque arms made from sheet mylar. The torque arms are screwed to the top of the coupler boxes, and I bent brass wire into a staple shape to hold the arms to the gearboxes. To mount the transfer gearbox, I glued som foam rubber to the floor and one side of the frame, and then I glued the gearbox to that. The foam rubber (or whatever it is) is surprisingly sturdy, but it also isolates most noise and vibration and holds to super glue very well. Before I finished all the mounting, I made and mounted the shafts for the universals.


Next, it was time to mount the motor. I started by gluing a block of lead to each side of the floor, and then I glued a piece of foam rubber on the top of those.  I also glued a small piece of the foam rubber to the top of the front gearbox to help support the motor. The motor was then glued to the foam rubber, and it had to be in exactly the right position because I could only fit a single ball and joint between the motor and gearbox.


Last for the mechanism was the electrical pickup. The entire frame is grounded to the right rail now, so I screwed one wire from the motor directly to the front coupler box. For the left wheels, I cut a Kadee centering spring in half, bent the arms out, and glued each one to the frame with a piece of plastic in between. Each arm touches a wheel. Wires are soldered to the new wipers, and those wires are soldered to the other motor wire. NWSL doesn't clean their wheels, so I had to clean the tread of each wheel before it could be run.

The new mechanism is now finished!Big Smile It now runs quietly and smoothly, has plenty of torque, and has a great speed range. The 12V speed is now 25 scale MPH instead of 400+, and the minimum speed at the moment is 1.5 scale MPH instead of 20.Big Smile WHAT AN IMPROVEMENT!!

I don't have the detail parts yet, so that part will come later. Until then, you can watch a before and after video of the Hustler running.Big Smile http://www.youtube.com/watch?v=D-svMRLSiEs

_________________________________________________________________

Subscriber & Member Login

Login, or register today to interact in our online community, comment on articles, receive our newsletter, manage your account online and more!

Users Online

There are no community member online

Search the Community

ADVERTISEMENT
ADVERTISEMENT
ADVERTISEMENT
Model Railroader Newsletter See all
Sign up for our FREE e-newsletter and get model railroad news in your inbox!