Project "Blue Box" GP40-2 - Printable Version

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Project "Blue Box" GP40-2 - pacbelt - 05-20-2013

GP40M??? GP40-2M???

Anyway, this will take you through my Athearn GP40-2, that is getting some superdetailing(in some of the most unorthodox ways you've ever seen)!!
She'll also be getting extensive mechanical and electrical mods as well...

Then, she'll get a coat of the Pacific Belt's newest scheme!! Wink

Here's what I'm starting with..... [Image: Ath_GP40-2_original.jpg]
:hey:

Re: Project "Blue Box" GP40-2 - pacbelt - 05-20-2013

STEP ONE:
Something no DCC/Sound equipped Athearn should be without!!
[Image: Ath_repower1.jpg]
Lower amp draw, MUCH quieter (yes! The driveline and trucks will be addressed too!) :p

Got it on EvilBay for $21.00!!!! Thumbsup

Re: Project "Blue Box" GP40-2 - pacbelt - 05-20-2013

THE UNORTHODOX BITS BEGIN!! 35 Icon_lol

I had to do a "make it fit"......
Some of you already know, that Athearn GP38/40/50/60's take a different, shorter, squatter motor. WHY?? Only so it can clear the inside posts for those dumb body clips!!!
SO.... I ground them off with my Dremel, and coarse sanding drum.
[Image: IMG_20130417_152258_656-1.jpg] BE CAREFUL grinding - you could easily blow a hole in the body (DON'T ask me how I know!!) Shoot

Fits Perfectly now!!! train

Re: Project "Blue Box" GP40-2 - pacbelt - 05-20-2013

THE UNORTHODOX BITS BEGIN 2!! 35
I also had to do EXTENSIVE grinding to the frame! [Image: IMG_20130418_020535.jpg] Did it for fit, and also to lower the motor, for room for DCC and sound components!! Thumbsup

Re: Project "Blue Box" GP40-2 - pacbelt - 05-20-2013

Now that ALL the grinding is done, after 5 test fits, and more grinding.....
I got to nestle the motor in - now a bit lower! Wink
The driveline is more level too!! Thumbsup
[Image: IMG_20130419_164012_827-1.jpg]
I set the Mashima motor in a gooey bed of Ultra Black RTV automotive silicone.....
Oh, the thick paper was my method of flywheel clearance!!!

Now - its just got to sit around, until the silicone sets - about 24 hours.
(REGARDLESS of what the directions say!!! You will be applying the RTV much thicker than any typical automotive use!!)

Re: Project "Blue Box" GP40-2 - pacbelt - 05-20-2013

Side note - those silly body clips are gonna be GONE!
I'm planning on using the coupler pockets, to mount the frame with the body! Wink

Can't squeeze the body with a speaker, decoder, and Keep-Alive stuffed in the body! :p

Re: Project "Blue Box" GP40-2 - pacbelt - 05-20-2013

Motor clearance was so tight, I even had to superglue the negative wire to the front of the motor... [Image: IMG_20130419_155934_239-1.jpg]
(Well, it does help keep the wire away from the flywheel!)

Re: Project "Blue Box" GP40-2 - pacbelt - 05-21-2013

The Best way I was shown, to wire a Blue Box loco!!!
[Image: IMG_20130419_112018_300-1.jpg] Direct and secure power to the decoder! Wink

Re: Project "Blue Box" GP40-2 - Southern Tuxedo - 05-21-2013

I love these mechanical how-to posts as I always learn something new.

Carmine, thanks for taking the time to photograph, document and post your progress. Thumbsup Worship

I'm eagerly awaiting more. Popcornbeer

Mark

Re: Project "Blue Box" GP40-2 - pacbelt - 05-21-2013

Thanks for the kind words, Mark!!!
You're welcome. THAT'S why I do it!! Wink

Re: Project "Blue Box" GP40-2 - Sumpter250 - 05-21-2013

pacbelt Wrote:Oh, the thick paper was my method of flywheel clearance!!!
Cheers That should do the trick ! Thumbsup

Looks like you are off to a really good start on this project! Thumbsup
Another great "learning Curve" Thumbsup

I'm going to enjoy following this thread. Cheers Cheers

Re: Project "Blue Box" GP40-2 - faraway - 05-21-2013

That is a very nice step by step report. Thanks for posting.
How did you glue the flywheels on the axis? I had problems because the result was in my case a not balanced motor-flywheel assembly.

ps. The Athearn RTR GP38 - GP60(M) shells fit with some easy milling on the Atlas Trainman GP38 drives.

Re: Project "Blue Box" GP40-2 - pacbelt - 05-21-2013

faraway Wrote:That is a very nice step by step report. Thanks for posting.
How did you glue the flywheels on the axis? I had problems because the result was in my case a not balanced motor-flywheel assembly.

ps. The Athearn RTR GP38 - GP60(M) shells fit with some easy milling on the Atlas Trainman GP38 drives.

I APPRECIATE the Comments, Gentlemen!! Cheers
I will be proud to continue this project - HERE!!

Faraway, I used medium thick, slow cure CA. It's much better at filling gaps, so the flywheels center better! Wink
I then put the motor Assembly in a soft vise, ran it at 13 volts, and held a file lightly against the flywheels while spinning.
Its a poor man's method of truing! :p

Brings me to the last point....
Yes, I could easily put an Atlas frame under it. Unfortunately, life events have left me quite poor. Sad
I have a few Blue Boxes laying around from many years. My object: to turn these into highly detailed models, with DCC and Sound, for less than $100 each!! Thumbsup

Re: Project "Blue Box" GP40-2 - pacbelt - 05-21-2013

Here's some of the "Toys" I had/picked up for this:
[Image: IMG_20130422_164312_428-1.jpg]
This will be FUN!!!! Smile

Re: Project "Blue Box" GP40-2 - pacbelt - 05-21-2013

ON TO THE BODYWORK!!!
[Image: IMG_20130422_185555_605-1.jpg]
My "low tech" method of aligning the fan grab iron!! :p