Lionel 50 Gang car repair

One easy way is to use plastic track pins. As you were thinking just drill a hole to the pin diameter and stick it in from underneath so that the thickened part of the pin hits the gang car body, cut off the excess of the pin and epoxy or crazy glue in place. I believe I used 027 insulator pins but verify which fit the men best.

I do this repair quite frequently because I like to buy junk gang cars and fix them up.

I use short machine screws as replacement posts. I think 4-40 screws work the best, although I have used 3-48 screws too.

Trim the posts flush with the deck. I use an Xacto chisel blade for this, shaving a bit at a time so the blade doesn't mark the deck around the posts.

Drill the proper size hole right through the spot where the posts were. According to a chart I found online, 3-48 uses a 5/64 drill, 4-40 uses a #43.

(I use a drill press to get the hole nice and straight)

Then carefully tap the hole.

install the screw from the inside, until the head is flush with the casing.

There is plenty of clearance to leave the head in place.

I use trial and error to determine the length of the screw.

Nylon screws are easily trimmed with a pair of linesman pliers after being screwed in.

If I am using a metal screw, I determine the length, and remove it from the case before cutting.

Thread a nut on the screw.

It will act as a chaser to clean the threads after making the cut.

Given the small cross section of the screw, these are also easy to cut with a linesman pliers.

After cutting, I file the end of the screw smooth.

Removing the nut will chase the end of the thread.

Re-install the screw.

It took me longer to write this than it actually takes to do the work.

Thanks to you both!

I never thought of using track pins (neat idea!) and I do have some short brass 4-40 machine screws...the threads may even help hold the guys on but not sure how they will be "perceived"...  I'll try the screws first and let you know!

Thanks again, Mike

I've used the plastic/nylon track pins with great success.

How do the track pins hold the men? The diameter of a track pin seems like it would be a little too small

Thanks All!

Since I had a deck that already had other marks on it, thought I'd try both...

For the screw method I used a 4-40 x 3/8" brass machine screw into a 3/32 hole.  For the insulated track pin I used a 7/64 hole and inserted the pin from top.  The pin fit snug and does not require any glue but is a hair longer than needed.  Could go from the inside out, which would correct the length but lose the nice finish appearance.   Either way seems to work great!  The pin is a little thicker than needed but the guy can take it and holds him tight.  No cutting or glue needed for either option but the pin option does seem to blend nicely with the pivot guy's pin...

Thanks so much for the ideas!!  Mike

I have a gang car waiting for a rebuild.

I am going to try the track pin approach on this one.

Lenny suggested O-27 pins, which I didn't have, so I used O pins...O-27 may be the "perfect ones"...Mike