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I hope this is the correct forum but I don't see an alternative.  I have a Lionel ACL GP-7 6-28503 which has had a rough life from the US postal service over the last few days.  It has had the two front screw posts (which attach the cab to the frame) broken.  If you look in the picture, you can see where they used to be (the two circles).  Does anyone have any ideas on how to replace these posts or install some sort of alternative block of material to attach the hold down screws to the cab?  I hope some ideas are out there and thanks to all. 

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If you look where the circles are on the picture you will see the missing screw post locations.
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If you still have the broken posts, you might be able to glue them back into place using an epoxy adhesive to provide a good bond and additional support.

If not, then you might be able to mould replacement posts out of epoxy or a similar material, and then drill holes to accept the screws.

I'm sure that others who are more knowledgeable in this area can probably provide some alternatives. 

Good luck.

Great suggestions and thanks- Unfortunately I have no idea what happened to the broken posts- almost like someone in the postal system opened the box and shook out the broken parts- it is also missing the little strobe light cover- another mystery.

 I looked at the J-B site and they say the epoxy can be tapped etc.  I worry about it formed as a tube in a one inch long shape- seems epoxy may be brittle?  Would the group agree that it may be better to get a piece of the evergreen or plastruct and then epoxy that to the shell to replace the screw posts?

If this seems to be feasible and make sense, does anyone have a recommendation on what plastic rod material might be best for holding the screws?  

The Plastruct website has detailed information on plastic properties.

Tube material attached with a fillet of J-B Weld Quick should suffice.

Read and follow the directions on the J-B packaging.

A practice piece of tubing cemented to a piece of scrap material will give you an idea of the holding properties before working on the loco shell.

Your description sounds like you might have gotten a bad engine from a seller who knew what he/she was selling you.  I bought one like that from a guy, and he feigned that his son listed it incorrectly.  It was an original MTH PS engine with bad board(s) that he said MTH told him could have upgraded boards installed for $90 - NOT.  The cost of the engine plus actual board cost (replacement or upgrade) was considerably more than a new one.  His ad on ebay said the boards were only $90 and that I could easily install the upgraded boards myself.  I cancelled the order.

I would use a stub of a wooden dowel glued with Loctitee Super Glue Ultra Gel Control.

Drill the hole in it first, deep enough for several screws. Then cut it to length. Next, run a small screw in it to create threads. Then, glue it to the old location.

 

You can also get a new shell from North Lima Trainworks for $70.

Here's the Lionel Parts reference for the part #6208503007.

 

Well, you have enough ideas. Time to fix 'er and run it. The ACL colors are nice.

 

I was referring to the piece in the long end, I believe the short post is in the front and is part of the shell.  You could create new post or drill out the circular hole in the lower nose of the shell...When you look at the end you can see where Lionel put a plug in the die and closed the original mounting hole.  Then you could make a small L shaped mounting point on the frame to secure the end of the shell.  I also have the yellow strobe lite cover for the roof.  The ACL shell is really a nice looking engine.

 

Marty

These are not too difficult to repair. I've done a fair amount of messing with these traditional Geeps, swapping shells, etc. (being relatively interchangeable, they're really a lot of fun to mess with, putting MPC era shells on TMCC chassis, using the strobe light to make a MARS light in front, and other kinds of stuff).

 

The absolute simplest way is to do what Chuck Sartor suggested above, using a screw though the front. Although when this ACL Geep was made Lionel had begun using these plastic posts, as Chuck noted the older design just had a single screw through the front and into the hole in that upright metal tab in front that the shell fits over. Lionel probably did the change to hide the screw end, and also because occasionally the shell plastic around the screw hole would develop a crack.

 

At the time this ACL Geep was made, Lionel hadn't changed the metal frame at all, so the metal tab with the screw hole in it was still present. So simply put the shell down in place on the frame, and drill a hole through the plastic, lining up with the hole in the metal tab. You'll have to measure and judge this just a little, because the tab hole is inside the shell and not visible when the shell is in place. You have some leeway, though, because the head of the screw will cover the hole if you have to make it a little bigger to hit the metal tab hole. After you've drilled the hole, insert a screw, and you're done. Don't over-tighten the screw, by the way. The small screw head will be visible on the outside of the shell, but it's no big deal, and you can paint it if you want to blend it in more, although it's not very visible.

 

Another option is to grind the broken posts down flush, and then glue small blocks of wood to the shell over the spots where the posts were. Then, holding the shell in place, turn the engine over and drill small pilot holes through the frame holes and into the wood (don't drive it too deep). Then insert screws, and you're done.

 

Other methods discussed by posters above will work also.

 

Another modification you might consider is one I always do with these engines, and that is to move the front light bulb forward until it's just behind the lens. Lionel placed these bulbs back so they would also illuminate the cab, but the result is that the front headlight is rather dull. When you reverse, you'll note how much brighter the rear light is than the front, because it's mounted next to the rear lens.

 

So move the foil (keeps the bulb from melting the plastic shell) and bulb holder forward until they're right behind (not touching) the front lens, and secure them there. If the wires aren't long enough to move the bulb forward, slice in a little more wire. The light in the cab won't be as bright (you'll get just a little glow), but prototypically there's little if any light glowing out of cabs at night anyway, just like your car.

 

Last edited by breezinup

Thanks to all for the great suggestions- I read through them all and summarized what seemed to be the sweet spot of the recommendations: 1) I took the remainder of the posts down flat; 2) I super glued the crack at the front- still a visible hair line but the fact it had a crack there was why I did not want to put a screw into the "old style" metal cleat at the front; 3) I used  Loctite "stick and seal" (not an epoxy- I was worried about heat- could epoxy get hot enough as it hardens to warp the plastic???) to anchor two wooden blocks at the exact height as the hips on the cab - and fit them into the corners so they would not spin when the screws went in; 4) drilled pilot holes for the screws; 5) Inserted the screws and gently the cab settled into position.

 

I did relocate the light and it makes a big difference. 

Originally Posted by breezinup:
Originally Posted by hokie71:

3) I used  Loctite "stick and seal" (not an epoxy- I was worried about heat- could epoxy get hot enough as it hardens to warp the plastic???) . 

For future reference, the answer is No. Nothing of the kind.

 

Incidently, I haven't seen anything stronger than JB Weld, as pointed out by Old Goat above. The KwikSet version he shows is good, but the strongest is the regular JB Weld epoxy. Your Loctite will probably be strong enough for your application, though, provided it can be used with wood.

 

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