Starting point: Beat up Life-Like 40 foot boxcar from the bargain bin at the LHS. Missing both doors, broken stirrups, missing wheels, horn-hook truck-mounted couplers, and sanp-in trucks.

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Goal: Create a servicable boxcar similar to the prototype photo. The photo is from 1979. Note the ACI label and the wheel dot. Also, the roofwalk has been removed and the ladders have been shortened. (Image linked from <!-- m --><a class="postlink" href="http://www.rrpicturearchives.net">http://www.rrpicturearchives.net</a><!-- m -->)

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First, the model is not quite exactly like the prototype. It has different ends, and has riveted sides instead of welded. That's okay by me, I won't bother with reconstructing those items. After all, I'm really just after a useable car, not an exact match.

Mechanically, I will bodymount Kadee couplers, replace the trucks with screw-attached trucks/metal wheels, and replace the steel weight with lead.

Aesthetically, I will replace the broken stirrups, replace the door slider rails with smaller ones, replace the molded on grab irons,and install doors (perhaps in the open position as shown, which will require some detailing of the floor). I'll also either trim the ladders down to half height, or perhaps shave them completely off and go with new ladders (can't see the brake wheel end, so not sure if they lowered the brake wheel or not... will make that decision later). I may add brake hardware under the chassis a la DocWayne if I get up the gumption. The factory lettering and blue plastic is satisfactory, but the data on the right side of the car will be replaced to match the photo. I'll add the ACI label, lube plate, and wheel dot. Now, the hard part... the roofwalk is molded on, and will have to be removed. I'll carve it off and rebuild the roof under the roofwalk. Add a bit of weathering, and we are there.

I probably have the exact same car lying around... can't wait to see how this one comes out.

Kevin, this will take awhile. My number one goal for the next month is to get my layout building finished, so this will definitely be a spare time project.

Since I was sitting around at the workbench anyway, I decided to make a start on this tonight. I took the car apart, and removed the weight from the floor. Cut of the melted plastic nubs holding it down, but it was also glued. Took some cutting with a hobby knife between the floor and the weight to get it off.

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Then I sanded the floor a bit to remove the high spots left from the glue, then filled in the center depression and glue spots with green putty. Shaved of the grabs, stirrups, and door rails, and removed the data from the right side of the car. Also dug through my stock of doors, found these 7 footers which will serve, even though the proto photo has 6 foot doors.

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I also noticed that the rivet line at the top of the car by the roof is completely wrong. I'm debating whether to shave it off or not. If I was completely repainting the car, I would shave it off, but since I will be using the blue color of the plastic, it would be tough to hide the modification.

Just noticed that the bottom sill is different too. A little bit of cutting should fix that.

I have one of those cars Gary and am impressed by your plans! For a guy who might be too busy to get started on this project you're well underway! The proto photo is a great guide. Looking forward to updates!
Ralph

Ralph, thanks. I wish that the model didn't have that rivet line which is way too far down from the roof. Still, I think we can make this thing servicable, although certainly not rivet-counter quality. Ha! Not even close to RCQ! But my moto is "The three foot rule is in effect at all times."

Found a little more time to work. First, filled in the grooves above the truck mounting holes, not so much to make a flat floor, but to reinforce the area where I will drill and tap for the truck mounting screws.

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Then found some sprue that was a tight fit into the old holes that the trucks snapped into. I'll cut the sprues off with a razor knife and sand them to a flat surface for the trucks.

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While the glue is drying, started on removing the molded on running board. This looks to be the most tedious part of the mod. Because of the molding of the car body under the roof, I sliced along the grooves and removed the center part of the roof from end to end. Then I started carving off the remainder of the roofwalk. Once that is completed, I will fill the groove in with plastic strip and then file and sand it back to match the roof. And... some green putty and paint and heavy weathering should hide the modification, at least enough for the three foot rule.

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I managed to catch a bug, sore throat and sniffles and all that. Stayed at home today, layed in bedfor awhile, then decided I might as well do a little on the project.

First, I drilled pilot holes for the Kadee coupler boxes

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Then, because the floor is so thin, and won't tap very well for the coupler screw, I added a thick plastic piece on top of the floor. The lead weights will also be glued on top of the plastic piece. I'll cut some smaller pieces of lead from the big piece in the photo. Since I plan to model the car with the door partially opened on one side, I'll have to keep the lead at the ends of the cars.

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And while I was working, I was feeling rather cramped for space, and took a look at my workbench. Well, I can give ol' Ralph a run for his money as far as cluttered workbenches go! I'm stopping right now and am going to clean this mess up.

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Hey, sitting around the house being sick isn't all that bad.

Cleaned up the workbench:

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Then scribed some lines on the floor to represent the boards:

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Tapped the screw holes for the trucks and coupler boxes:

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Painted the floor and am gluing the weights on. There will be another piece of lead on top of the lead in the photo.

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More progress:

All of the roofwalk carved off:

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Put in some thin plastic underneath the roof as a backer for the plastic strip I'll use to fill in the hole in the roof:

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Added in the plastic strip to build the roof back up. I'll use some green putty to fill in the cracks, but I can't find my small files that I need to file the plastic strip down to match the existing roof. Might have to buy new ones.

I also painted some of the floor boards different shades of gray and tan. I'll put a black wash over that later.

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That's some sweet progress!

Gary you got a lot done on your sick day! Looking good!!!! As far as the cluttered work bench is concerned...at least you had some semblance of organization with your boxes on shelves so things could be put away! Nice work on the boxcar! Feel better, by the way.

Ralph

Thanks Kevin.

I decided to do the brake rigging. First, had to dig through the scrap parts box to find the cylinder and air tank and valve.

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Then I added them to the chassis, added brass wire for the pipes and brake rods. I didn't do the airlines which run from one end to the other, or the rod which goes to the brake wheel.

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Ralph Wrote:Gary you got a lot done on your sick day! Looking good!!!! As far as the cluttered work bench is concerned...at least you had some semblance of organization with your boxes on shelves so things could be put away! Nice work on the boxcar! Feel better, by the way.

Thanks Ralph, and thanks for the get well wishes. I'm feeling better, not totally over it... but I have no choice but to go into work tomorrow, due to some things that I have to get done.

About the workbench: Yes, I do have lots of drawers and containers, and a system of where things go. So, it is pretty easy to clean up when I wreck the place. Just put the stuff back where it is supposed to be.

One last thing and then done for the night. Got the chassis painted.

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Things left to do: Finish filing and sanding the roof and paint it, a little detail and paint on the inside of the car, put on the doors, trucks and couplers, grab irons, ladders, and stirrups, decals, and mild weathering.

Great progress! I like your idea of throwing all the old pieces into a bin. I think I'll work on that one as all of my old pieces are scattered throughout all the old model boxes. Might free up some space to boot!