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I bought an articulated heavy Lionel steam from the early 2000's.  It arrived with the front pilot pieces bent.  USPS must have thrown this as it was packed really well.  Anyhow, I was able to bend back the thinner more decorated pieces.  The cowcatcher can be glued to reattach where it broke.  I then realized the thicker cast part is bent as well.  You can tell the way the front coupler is pointing downwards.  It looks ok, but it is too low hitting the middle rail when it goes across a switch with anything but perfect flatness.  The slotted cow catcher is the part that is actually touching the rail.  It seem like that couldn't be bent anymore due to hitting the coupler now.  The parts are not available from Lionel, so if it breaks that's it!  The only other option would be to remove the slotted cowcatcher part.

Is this something you think could be bent back without breaking?  I could heat it somewhat with our wood stove, holding it over the top.  It seems pretty thick though so I would think it would need to be heated pretty good.  I also don't want to ruin the paint.  Any advice?



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If the part is brass (a "golden" color under the paint),  then straightening it by hand or with minimal tools is eminently possible. Saving the paint and repairing it may not be entirely possible. It's just paint, and if it is black, well, you know what to do. Even if it is not black, really.

If it is a zinc (a "silver" color under the paint) casting, you can still fix it, probably, but be patient. Heating it can help. Again, don't let paint stop you. I've never heated any part to straighten it, but not a bad idea.

Parts can be found on eBay. "If it breaks...." it probably can be acceptably repaired. That's model railroading.

Patience.

I've straightened a few of those, I use heat and also time.  I create a wooden block or two of the right shape so I can use a vise to put some pressure on it.  Then I heat it with a heat gun and apply tension with the vise.  I give it 24 hours and then heat it again and take another turn on the vise.

When they arrive broken, I usually try to reassemble them with JB-Weld.

I have also straightened a few. Following the same protocol as John stated.  What you would be doing is "cold flow" or "cold forming".  As John stated, take your time (can take days).

Also, as a fall back, search the Lionel parts website for other pilots that may work for your engine.  Some of these are the same except for the hand railing height (which you might be able to change with using epoxy to hold the railing).  I think they reissued this same engine and listed the pilot without a hand railing. But I am only guessing on your specific engine given the pilot P/N you have listed.

Good luck! and again, take your time.

STEAM -

I found two that are listed as available that might work.  One has the horizontal slat design and the other matches what is currently on the engine (minus the railing).  Take a look and maybe others can comment on these as well. Looks like you would have to move the headlight bracket and maybe the cut bar and the hand rails.  I could not see the mounting holes for the headlight bracket.  Might need some hole drilling, etc.  Take a look at the one you have to see if the headlight bracket is easily removed for a transplant.  Again, these are just options.

I have had a couple of these engines where the front pilot was broken and could not be repaired.  I would purchase something very close and modify as needed.  While not 100% pure as Lionel sold/prototype, at least it would look good when done.

Like others have said, try to carefully bend the bent parts back to position.  If that does not work, you have options.



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