Since MTH doesn't seem to make the non-powered units any longer, I pick up any of the Santa Fe units when I can find them. I like to run multiple units, but don't always need the extra power, or want the hassle of MU "issues". I've picked up the Dash 8, Dash 9, and even an older Dash 9 tooled non-powered diesels. That gives me four Dash 8's and five Dash 9's now, but all my powered units are the -2 type with fixed pilots and Kadee couplers. Time to convert some dummies.
The "GAP", the "CLAW" and scrawny hoses.
Both ends of the frame have to be cut. It's a different frame from the -2 fixed pilot models, but once it's cut, I used the same pilot mounting holes to attach the pilot with #4 x 1/2" screws. Once the pilots are removed, you can remove the claw without taking the trucks off the frame. The pilots also have to be cut or ground down in order to clear the frame. Since the pilots get screwed to the shell, they must clear the frame if you ever wish to remove the shell, not to mention mounting the pilots flat.
This is the rear of the engine and you can see where the frame was cut (Dremel w/ fiberglass cutoff wheel) along with the pilot being ground down with the bench grinder to allow the clearance between the frame and the shell/pilot. A ton of back and forth between the grinder and the frame, taking off a little at a time. If you take off too too much material, you'll lose the mounting holes in the diecast pilot.
Much time was spent fabricating these two spacers. .125" styrene was used to fill the "gap" between the shell and the pilot. A combination of the band saw, bench grinder, bench sander, Dremel tool, files, and emery boards were used to cut, sand, or remove material to the right shape and size.
The spacer sits in place with "through" holes drilled for coupler and shell mount screws. A lot more time was spent figuring out the correct thickness for the coupler mounting pad in order for the Kadee to sit at the proper height. Turned out I used .100" and .080" styrene glued together to get the proper mounting height. The pilot has the screw holes for Kadee couplers already, so I just had to line them up, drill them out, and I also re-tapped the screw holes in the pilot for 2-56 1/2" screws.
The front pilot was completely rebuilt with improved hoses, re-located grab iron on the plow, and of course filling in that huge hole in its face.
This is a good time to drill new holes in the pilot for the full length handrails. Be patient as it's not easy drilling a #68 hole in this hard material.
Pilot is in place, coupler is at the right height, but the handrails are still an eye sore.
A couple of the handrails broke when I tried to straighten them out (I think it's piano wire) so I had to make 4 new handrails total, the 2 on the nose, one of the long rear and one of the front front rails. All the others were straightened and re-bent without breakage. Paint touched up and it's ready for the weathering station to match its three sisters.
