4-4-0 Conversion Redux

 It has been a while since I have visited this topic. In my last post on the subject the body and tender had been completed and sent out for paint. To make a long story short, they never got painted and returned, so as a result I have had the conversion hardware in a box for the past 7 years or so.

 Recently I got another chance to perform this conversion, on a completely different locomotive. Since the last time I have learned some new tricks as far as the tender wheels are concerned, which was actually going to be the next topic on this subject.

I will be restarting the entire series as I am performing the conversion from the start, so unlike my last post on the subject there will be pictures this time. This post will not be a part of that series insofar as doing the actual conversion, it is more of a "more to come" sort of post for those who were interested in converting a locomotive of their very own. 

The normal method of completing the Nn3 conversion on a Bachmann 4-4-0 tender is to file and carve the constituent pieces of the existing tender trucks to narrow them to 6.5 mm gauge. However, anyone familiar with the Bachmann 4-4-0 knows that the weak point in the entire mechanism is, in fact, the tender trucks, and narrowing them doesn't improve them a single bit.

To put it bluntly, the tender trucks are mechanisms of pain and sorrow, created by evil hell-spawn out of suck and fail for the sole purpose of causing tears and sadness. To say they suck is to bring grave insult to vacuum itself. I am certain that some engineer who worked for Bachmann long long ago secretly hated N scale and wanted to see it fail, and this was his contribution.

The problem is they are not free rolling in any sense of the word. Sure, you can get the wheels to move on their poop-metal stub axles, but they don't free wheel, even after liberal applications of Conduct-A-Lube oil, and they cause so much drag that the locomotive can't usually even pull the cars in the train sets they came in. They sit on the tracks with their drivers spinning helplessly as the train sits like a stone or moves so slowly that it is barely moving at all. In spite of their traction tires, the drivers flail about, causing only violent vibrations to the locomotive body until it finally flings itself off the tracks in disgust. 2 to 3 cars is about all you can expect if you are lucky, and all of this misery is due to the horrid tender trucks.

Fortunately for us Nn3'ers, in the past seven years there is a newcomer to the Z scale scene, and their name is Rokuhan. What has that got to do with this? Simply put, they have created all-wheel pickup bogies (trucks to those of us in the US) that have the same sort of needle-point side frames as used on the Kato Mikado as well as the newer Bachmann steam locomotives. (See Bachmann? We know you can do better!)

These trucks are readily available by buying their SA003-1 non-powered type A trailer. This link goes to Z Track Center, which is where I found them for $15.75 plus shipping, and I have found that to be about the cheapest place to get them.

Note that there is also a powered chassis, which may be useful for other things. There are also knuckle couplers if you prefer to use them rather than installing body mounted Micro Trains couplers, which may be a bit easier for the 4-4-0 conversion. I already had the Micro Trains coupler installed, but the installation of the Rokuhan bogies raised the tender body up enough that I had to shim the coupler to put it at the right height. More on that in a bit.

These bogies can easily be modified to put pickups on Republic Locomotive Works Nn3 kit locos (if you can find them; an appeal to Monroe Models is in order here), and better yet, they will work on the Bachmann conversion. The side frames have to be sanded off so that side frames from the original Bachmann or Micro Trains arch bar trucks can be glued on, or you may be able to find 3D files that uses the contact plates and wheel sets; I know they exist. 

I have been working on a proof of concept on my sole remaining Nn3 4-4-0 and I have to say the results are promising. I just had it orbiting a 195mm radius circle of track with 7 EBT freight cars made from RLW kits (which are quite heavy for their size) and a narrowed Bachmann old-time combine, a task which usually left the poor loco spinning it's wheels.

As I mentioned, the truck replacement causes the tender body to sit up a bit more than the stock trucks, which means the locomotive chassis has to be filed a bit to keep the rear drivers seated securely on the rails. This also means the driveshaft is angled downwards from the tender to the locomotive, but this hasn't so far caused a problem even with the thick clunky driveshaft on my present model. If you are using the new and improves mechanism with the narrow driveshafts, this should be even less of the non-problem that I am having with mine (by the way, this new series will be based on the newer chassis, so there will be pictures of that).

All in all I'm excited to get started. Stay tuned! 

Progress Report 7/14/26

 A mixed bag for this report.

 Last time I mentioned how the Bachmann 4-8-4 has a magical ability to detect trackwork flaws. It still does.

I did change up the narrow gauge, installing a turntable in place of the Y. This did indeed give me the opportunity to broaden the curve going into the hill, which helped considerably. I didn't single-track the line on the hill though, instead I combined the sidings and built a 2 track main because that's a long stretch, and if I want to run trains in both directions I am going to need a way for them to pass each other.

I was a little concerned about the curve at the top of the hill, I didn't know if there would be enough separation for long cars to pass each other. I tested it with a couple of strings of autoracks, and they did not hit each other. I also tested with passenger cars, and they were fine as well.

However, I have run into another problem, one that won't be so easily solved. My benchwork structure is not working out. I have the basic frame built out of 1x2's in an L arrangement which works well. I then topped it with 1/8" masonite and topped that with 1/2" foam.

This was a bad idea. The masonite isn't dense enough to support itself, let alone the foam, between the frame crossmembers, and it is sagging badly. I have as much as 1/4" between stringers 2 feet apart, which of course means the track has the same undulations, and the aforementioned Northerns have struggles making it through the turnouts in that area. The biggest problem is the main from where the loop return ties in to where the curve is starting the grade, a total distance of about 5 feet, which is where this whole thing started to begin with.

My options are to take up the track (ugh) and fill/sand those areas, tear off the foam/masonite and replace the masonite with true 1/8 or 1/4 plywood, brace the area with 1x2 framework, or cut the affected mainline out completely and replace it with a piece of 1x4 hardwood. 

I'm not fond of the first option because there is nothing to prevent future sagging. I don't like the second option (although realistically it is probably the best one) because it would mean pretty much starting over. The third option would probably be the easiest because it wouldn't involve removing the trackwork, and is probably the route I will take. The fourth option is something I will explore if the third option doesn't work out like I want it to. 

And then maybe those darn Northerns will run on the layout.

As a side note, I have a picture of my track plan below. Maybe it will help to envision what I am doing. I should stress that it is definitely not to scale, the yellow loop is smaller than in the picture and the tunnel portals on the yellow loop will be side by side. You will also note that 1) the yard to the left is completely un-designed at this point and 2) the narrow gauge is not shown. You may also note the layout is broken into blocks to facilitate the DC operation option, although at present all the blocks are wired together for DCC operations.

 

A Few Simple Repairs

 Yesterday, for a brief shining instant, trains were running on the Nodaway Valley Railroad.

Yes, I finally got the final track wiring accomplished and then I ran some trains. I found a dead piece of track that needed feeders and a few turnouts that needed to be tuned up, but I was able to run a cleaning train around a few times.

I then broke out the Bachmann 4-8-4 locos. These are almost magical in their ability to find flaws in trackwork, and boy did they find them. A few of the issues were due to wheel guage, which was quickly fixed, but two (three) major issues were soon found to be a problem.

Due to my desire to have a turning Y for the narrow gauge, I created a stretch of dual gauge trackage approximately 5 feet long. This dual gauge trackage led eventually to the coal processing plant where it turned back into a standard gauge yard. Due to the placement, the main line was forced into a tighter curve, 12" where originally 15" was planned.

On the beginning of a hill.

So two model railroad no-no's in one short stretch of track.

I made the decision this morning to tear out the dual gauge and replace the Y with a narrow gauge turntable, which means I will have to purchase and modify another Peco N scale turntable for that end of the narrow gauge. This will allow me to broaden the standard gauge curve going into the coal plant (thus eliminating another future headache), which allows me to install the 15" curve on the main that I wanted in the first place.

Still on a hill, but at least the broader curve will be less of an issue.

In the process I will be eliminating a siding that I had installed for a joint train station for the standard and narrow gauge railroads, but I won't miss it. This gives me an additional opportunity to smooth the vertical transition more than it is, which eliminates another issue since the vertical transition was co-located with the beginning of the curve.

You can see why I had issues there.

While I'm at it, I am going to eliminate the two passing sidings on the hill. I had added them in as an afterthought, one on each incline, and the turnouts are problematic because of the vertical distance the throwbar actuator had to travel. 

The Northerns had problems with derailing their pony trucks on these turnouts, and since I don't really need them they can go away. This will also give me some room to put scenery on the wall next to the incline since there will only be one track instead of two.

I will re-test the mainline when these repairs are complete, and I'm expecting better results.

Starts and Stops

Thursday I was supposed to get a visit from the plumbers to do some major work. They had to beg off, so instead I tackled the wiring on the layout (which I was going to do regardless, since I wasn't going to irritate the professionals).

After eight hours of continuous labor, I was able to get blocks 1 through 4 and 6 through 11 wired from the track to what will become the control panel connector. In a real sense that means the main part of the standard gauge is done; all that is left is the mountain loop (block 12), the dual gauge section (blocks 5 and 14), and the coal washing plant yard (block 15).

The mountain loop is one continuous run with one siding (block 13). I will have to wire about three drops for the continuous section, but the drop for the siding is done. Two dual gauge turnouts have to be built and installed along with the rest of the dual gauge track before the coal plant standard gauge yard can be laid and wired. 

The common rail has continuity all the way around the standard gauge section, and the common rail for the coal plant yard will be wired into this continuous section. The common rail for the dual gauge section, however, will be wired through a switch so that it, along with the dual gauge approach block can be switched between standard and narrow gauge.

I haven't even begun to attempt the yard design. It occupies a blank section on my layout map labeled "Here Be Dragons" beyond the two turnouts that will lead to it. Whatever it ends up being, it will occupy a 28 inch by 8 foot section of bench work that has already been built. The narrow gauge portion at least has a solid plan, but it will have to wait until I complete the rest of the standard gauge section. Time will tell which of these sections (yard or narrow gauge) will be built first. 

One day I will take a picture of my doodles so that you can see what blocks are where and how they connect, but today is not that day.

Layout Build Progress Report 5/14/26

Work continues on the railroad today.

I was on vacation the first half of the month, but before I left I managed to get the last piece of track down on the Nodaway Valley (standard gauge portion) Railroad. All of the track work, turnouts and Tortoise switch machines are installed and tested. All that is left before scenery can be applied is wiring.

My goal today is to get all the common rail wiring complete, then get the block rails wired to terminal blocks. After that I'll have to build control panels so that the block rails can be wired to block switches and the Tortoise switch machines can be connected to their control switches. My plan is to be able to switch control systems from DC to DCC, the same as I could do on the last layout.

I am using Digitrax DCC on this layout because I have it, and if I program my locos on the Digitrax they will run the same at home as they do on the club layouts. I have a Cooler Crawler kit to put together that I will use for DC power. Along with the kit are throttles, and if I am seeing things correctly at least one of them is a radio throttle. I guess I will see when I build the circuit.

Once I can get the wiring complete I will run some trains for a while to verify everything is working the way I want it to, and then I will start on the narrow gauge Path Valley Railroad. I have turnouts to build and control systems to figure out. I want to use servos for the turnouts, controlled by Arduinos, so that I can set up an automatic continuous operations loop for when I want to run locomotives for break-in or just to run them around like fish in a bowl. 

That will take some figuring out because what I will have is a loop-to-loop on the Scenic Ridge layout with a branch line to the coal processing plant and dual gauge interchange. I want to be able to control them all individually for normal operations or switch to the automatic operation on the loop-to-loop and lock the branch line out for continuous operation.

And now the plans have been made, I need to get started. 

New Acquisitions

 I have upped my NS Heritage Unit count by two. 

 Sort of. 

Let me explain.

The first is a Monongahela ES44AC. I wanted this one because the Monongahela ran through Waynesburg PA where it had a connection to the narrow gauge Washington and Waynesburg. All of the narrow gauge is gone now, with no sign of remains, but the Monongahela main is still used by the Norfolk Southern (and occasionally CSX) to access coal mines in the area.

The second is a fantasy paint PRR ES44AC in Brunswick Green. The actual PRR Heritage unit, number 8102, is Tuscan Red. This foobie unit carries the number 1846, which is actually carried by an SD70ACC on the Norfolk Southern. The number 1846 on this unit is likely - almost certainly - due to the establishment of the Pennsylvania Rail Road on April 13 of that year. As such, it really isn't an NS heritage unit at all.

At any rate, the first thing I did when I unboxed them was drop the Monongahela unit on the floor and bend a wheel. Unfortunately, since they are Fox Valley Models locomotives, there is no manufacturer support. Fortunately (but not really surprisingly) the Kato 6 axle diesel wheel sets are a drop-in replacement. In fact, the entire truck is a drop-in replacement, but I only have gray ones on hand and the ones on the locomotive are black.

At any rate the damage was quickly repaired using my stash of Kato spare parts and both locomotives were put through their paces. The PRR unit programmed with no issues, but the Monongahela unit is slow at the top speed, only able to achieve 118 SMPH. It is still faster than the Southern unit, which tops out at 105. I have programmed CV5 on both locomotives to achieve the same speeds at 5% increments up to their top speeds, so they will run with the other locomotives on my roster. If it bothered me overly much I would replace the motors with Kato units and make rocket ships out of them all. 

This brings my total number of NS Heritage units up to four (six if you count the Kato Erie and the foobie PRR): Erie, PRR, Monongahela and Southern. I want to find a Norfolk Southern (the original NS, not the current one) and a Norfolk and Western and then I think I may be done.

Progress

 We have had  winter storms for the past two consecutive weekends. The weekend of January 23rd we had an ice storm that dumped freezing rain and sleet on us, followed by a week of sub-freezing temperatures overnights that kept the ice around for a while.

All told it wasn't as bad as it could have been. We got about a quarter inch or less of ice, we never lost power, and I was able to clear the driveway and sidewalks during the daytime before it could re-freeze, so all the ice that was left was on the grass.

This past weekend we got powder snow. We were forecast to get between 5 and 7 inches, but all through the day we were in a snow-free corridor that stretched from South Hill VA south to the coast between Wilmington NC and Myrtle Beach SC. When the corridor finally closed, like a zipper from north to south, we ended up getting about 3 inches or so. Since it was powdery snow I was able to clear it from the driveway and sidewalks very easily.

What that means is I had a lot of time to spend on the railroad. The benchwork has been completed for a while now, but it was covered with construction materials and tools. Last weekend I got it cleaned off, so this past weekend I was able to get some track planning done and put some cork down.

My new layout is going to have four distinct sections. The yard will be along the north wall to the left as you walk in the door. The Nodaway Valley section is along the east wall and the track plan is basically what I have on my 2x8 layout right now. The coal washing plant will be on the south wall and will have standard, narrow, and dual gauge. Finally, the narrow gauge Path Valley section will be on a peninsula jutting out from the west wall. In its entirety the layout will be in a reversed G shape. 

I have almost all the track planning done.. The only thing left on the standard gauge is the yard which I still haven't decided what to do with. I got the cork entirely laid down on the Nodaway Valley section this weekend, including the turnouts to the yard at the north end and the coal washing plant on the south end. 

The lead to the coal washing plant will be dual gauged so that it can be used as one of the legs of the narrow gauge turning wye. This will require the building of five dual gauge turnouts, including a curved one that will have to be built on site. I'm thinking of building them all on-site so they can be code 55 rail instead of the code 40 that is used in the Fast Tracks dual gauge jig. I also have a handful of narrow gauge turnouts to build, but I can use the Fast Tracks jig for those since it is for code 55 rail. The rest of the track work will be Peco Code 55 for both standard and narrow gauge sections.

I have the narrow gauge Path Valley track plan almost all figured out as well. It is being built as a heavily modified Woodland Scenics Scenic Ridge layout. I have single-tracked the hill section between the loops and as such I have created two turnaround loops, which will require some special wiring. The only question left is where I am going to put the turntable and round house.

I have a Peco 6" turntable that I am going to modify to narrow gauge, and I have an old wooden kit for the Nevada Northern roundhouse. I have the kit for the two added on stalls as well, but I don't think I will have the room for them. I have just about decided that it will go in the lower right corner as you look at the plan on paper. There should be just enough room for the turntable and the four stall roundhouse.

I am going to automate some of it using an Arduino to control the loop turnouts. To further complicate things, I am also going to automate the turnout leading into the turning Y at the coal washing plant. There will be a sensor on each loop and one on the wye that will cause all three turnouts to change as the polarity on the main is switched. I will be able to run it as a point-to-point from the coal mine on the upper loop to the coal washing station wye and back, or as a continuous run around the upper and lower loops.

I am waiting on insulated rail joiners for the Electrofrog turnouts, and then I will be able to lay some track. That might be a while though because I have the show in New Bern coming up this month on the 21st and I have a couple of modules that need attention before then.

I don't know how much I will be able to get done during the month of February, but my workplace will have a shut-down in March, so (depending on whatever plans The Management has) I should be able to get some more done then. I would like to get some track laid this month, and maybe build some turnouts as well.

If it all works the way I have imagined it, it should be awesome.