What's the best way to file a wheel flange to a lower profile?

Not being a Machinist, my concern would first be, what kind of metal the wheels are made of. If they are some sort of sintered (sp) metal, they might disintegrate.   

The trouble with the grinder is repeatability on all four wheels.

A lathe would be the most accurate. With the proper set-up it could be done without disassembling the truck. And the resulting wide tread on the flange could be dealt with.

Out of curiosity, what are the diameters of the different sized flanges?

Dave

Send them to Al Z.  He did the infamous Lionel flanges for folks. 

You can file most wheel flanges, but you need a way to spin the wheel.  It can be done with a rubber sanding drum without the sandpaper, but you need three hands.

the few I have done with a file were removed from the truck, held by the axle in an electric drill, and planed with a single cut file.  For sintered iron, you might need a new file, and you will use it up pretty quick.

Here is what I would do: Get some ancient steel Walthers scale wheels, drill the truck out to accept the larger axle (easy) and install them.  File the pointed axle ends off, and dab with black paint.

The new style wheels have a 2.2 cm flange while the 90s wheels have a 2.1 cm flange. No joke folks, that's actually how tight clearance was on the 90s flanges to begin with.

Thanks for the input so far guys. Marty, I actually did just find Al's webpage for the turning service. I love his results, so I think I will contact him and ask if he can perform the same procedure on these wheels. If he's attending this coming York again I can even drop them off in person. How about it Al?

http://www.studiozphoto.com/Wheel_turning.html

PC9850-

This might be a silly question, but is it possible to swap the wheels from the 90s era Hudson pilot truck with the wider flanged wheels from your Vision line truck? It might be easier than grinding down wheels.

-John

Get a hold of CSX Al, Millhouse Products, maker of Turntables...He can give you advice.

He use to advertise this service. Leapin Larry

I considered that, but I would prefer to make the Vision Hudson wheels work. The actual design of the face of the wheel is more accurate than the older 90s wheels.

Nick,

Frank Timko does beautiful machine work. You can Google, Timko Repair Depot. Since he's not a sponsor, it's better that I not post his contact information.