How to Attach Wheel Gear to Wheel?

Which wheel?

Some prewar styles actually had two different castings, one for the plain side and one for the gear side. The gear side would have a boss for the center of the gear, and sometimes a couple of lugs to engage holes placed partway out on the gear.

Other geared wheels were cast as one piece.

There may be other styles, it's early .

The old wheels may have expanded from zinc pest and gears will not set right. Here is a set of wheels I replaced on a Lionel 252.

The "O" gauge wheels w/ the steel gear: 

Remove the original steel gear, which is 'peened on' by either filing off the excess die cast or grinding off the excess die cast material down to the flat of the steel gear. Using a flat screw driver, you can now 'pry off' the steel gear from the original die cast hub. To mount the steel gear on the new gear wheel w/ hub, place the steel gear on the wheel and line up to the square hub as best you can. Now, I use a socket from a tool ratchet large enough to sit flat on the gear, but not touching the hub.  With a hammer and a  few light taps on the socket, you can now seat the gear flat on the wheel.  After making sure the gear is flat up against the wheel, you would use a flat end punch to 'tap' the cornors of the cast lug to drive the material out, securing the gear to the cast hub.  Secure all 4 cornors of the hub. 

On wheels w/ the gear cast on as part of the wheel, you would just use a press  to insert the axle to the wheel. I have axle tools to use in my Hobby Horse press to get the axle  inserted perfectly straight.  I know most of you guys do not have that luxury. Harbor Freight sells what I think is a 1/2 ton press for about $60.00.  If you are doing a lot of wheel replacements, This is an ideal tool. The axle tools are around $19.95 ea., and are available for Lionel "O" , "STD", etc. from "Just Trains", in NJ.   

The gear removal & mounting is the same procedure for Lionel, American Flyer, Ives etc. The important thing is to make sure the gear is mounted "FLAT".  Also should note that the 2 round holes in the Lionel standard gauge gears are ' NOT'  for peening over, but as an alignment  for the gear.   Harry

The axle centering on the HH press is a nice feature. Can be a chore to get axle on straight without but in the past have even tapped in with hammer.

The arbor presses are the BEST way to place wheels on their axles so they are TRUE. Other methods may work, but if wheels are not properly aligned, they will wobble!

I have used a vice with wood blocks with some degree of success, but you have to be very careful! Maybe better to send it off to Henning's?

I think what you all are basically saying is that yes, there are two different types of wheels used on prewar Lionels: a "drive gear" with a gear lug [? the square part around the axle hole?] and a plain, flat wheel. Right? Here is a photo.

CountOrlock posted:

I think what you all are basically saying is that yes, there are two different types of wheels used on prewar Lionels: a "drive gear" with a gear lug [? the square part around the axle hole?] and a plain, flat wheel. Right? Here is a photo.

Neither of the wheels you have pictured looks to have the square drive which is why you can't secure your gear. On a typical motor, 2 wheels would be flat (pictured) and 2 would be geared.

You are correct. Where the square lug is shown w/ gear, you now just 'peen over the 4 cornors.   2 wheels w gears installed on the square lugs, on one side of loco, and 2 plain wheels w/o the square lugs on the opposite side.  Harry 

CountOrlock posted:

I think what you all are basically saying is that yes, there are two different types of wheels used on prewar Lionels: a "drive gear" with a gear lug [? the square part around the axle hole?] and a plain, flat wheel. Right? Here is a photo.

Correct. If you removed that gear from that wheel, you most likely have had some of the casting come off with the gear. That is needed to mount the wheel. You should use an arbor press to cinch the gear onto the wheel then use the arbor press to press the wheels on.

Tin