Lionel Aluminum ACF Hopper Deformities

that I have never seen

Yes i have a lionel chessie hopper did the samething on both ends. Lionel replaced the hopper once and it did it again.

Is that a K-line mold that Lionel took over? Thinking this is the start of Zinc rot.

It’s zinc pest. I’ve had to toss a few of those aluminum hoppers because the ends did that. The ladders swell and have no where to go, so they bow like that. I have a few K line ones that are fine. It’s the Lionel ones that do this.

Thanks for explanation.   I knew the zinc pest caused crumbling but I didn’t know it caused expansion.  

What a shame - these are hands down the best O gauge ACF hoppers out there, and I wish Lionel would bring them back (albeit they would probably be $199.99 a piece these days).

I've got a few at home and now I'm anxious as to what I will find when I get home from work and inspect...anyone know if this issue plagues the earlier 2003-2005ish runs or just the later 2010-2013ish runs?

Oh boy. Maybe I better dig out the extra ones, stashed under the layout, and have a look.

@Catonsville Central Railway posted:

What a shame - these are hands down the best O gauge ACF hoppers out there, and I wish Lionel would bring them back (albeit they would probably be $199.99 a piece these days).

I've got a few at home and now I'm anxious as to what I will find when I get home from work and inspect...anyone know if this issue plagues the earlier 2003-2005ish runs or just the later 2010-2013ish runs?

Based on all the looking I have done to try and build a small collection of them, the issue seems mostly with the later run.  Particularly, models:

6-27461 Union Pacific 4-Bay

6-27462 Chessie 4-Bay

6-27463 PRR 3-Bay

6-27464 BN 3-Bay

@Steims posted:

I have several of these Lionel aluminum ACF 3 & 4-bay hoppers but I don't want them to end up with warped and broken ladders like shown below.  This problem seems to plague this model freight car.  I think the pot-aluminum ladder rails might be sagging under their own weight when stored horizontally.  I am keeping my cars vertical (in their boxes) to prevent warping until I can unleash them some day on a nice layout.   Any thoughts on what is causing and fool-proof method to prevent?

Since you love these cars try this, get out a Dremel or any cutter. Cut near the body and carefully bend back into position . The piece cut out should be more than enough for the expansion. Then leave it alone, to see if it continues to grow. Once you get the first one correct. A small bit of hot glue will hold it in place and allow some movement. Match paint and go, if the space does not close up to your liking, there are plenty of companies that make scale steel/ladders and alike.