03/18/05  

Stage 2: (the full .20" lower *approx*)

I decided to finish lowering it the rest of the way, approximately another 1/8" for an approx total of .20".  Everything has been completed except raising the fuel tank.  I will raise it but only slightly as I like the look of it hung lower.

Here is the final method I used to drill the plates and the slots.  Using the original surface's holes and slots, I centered the pattern on the plate and drilled three small holes for each slot and one larger one in the center.   I then used the same large bit to drill a hole in the center of each of the glide slots with the already small hole as a guide to keep the bit from wandering and to get perfect placement of the hole.  I then used a proper sized round file to file out each side slot in the same shape and size as the original.  This was done by constantly comparing the template to the plate and test fitting and pivoting on the trucks.  After the holes were of proper size, I lightly sanded the surface with 1500 grit sand paper to polish and smooth the surface.  Next, the edges of the holes were dulled by lightly sanding with my thumb pressed in the hole.  Next, a strip of 1500 grit sand paper was wrapped around the file and the inside of the holes was sanded smooth to reduce wear on the truck pegs. 

Note:   The center hole in this case was drilled to a perfect fit with enough rounding of the edges to allow the plate to rock in all directions.  No lateral movement front to back or side to side was allowed for.  This should limit the contact of the truck frames against the tank and front and rear frames when the trucks twist around corners.  Also note that the slots were not filed out as long as the original, this again was to limit the distance the trucks could twist.  I intend to run 10ft curves at a minimum and since the engine was designed for 8ft, I figured it could be limited and still run the 10ft corners I had.  Tests proved my thoughts correct.

Below are picture of how the plates look installed.  These pics are with the first set of plates I made. 

To secure the plates to the frame I mounted the plates in place and drilled four holes through the plate and frame.  #2 Stainless Steel bolts and nuts (from Lowes) were used.  To get the plates properly centered, I put the plate in place, installed the truck in the slots then from the top of the frame twisted the plate clockwise or counter clockwise and slid it around to get the proper orientation.  Next I then screwed the big washer in place that holds the truck to the plate and further centered it so it was perfectly centered.  Next, I then applied hot glue in the exposed 'swing' areas where the plate was now exposed and let dry.  This freezes the plate in place so you can drill the four holes for the permanent screws without the plate sliding around or getting out of position. 

Here are the pictures of it reassembled with the new 787 Kadee coupler (a combination of the 836 knuckle and 789 box) that compensates for the new lowered stance.  The front plow and front and rear pilots were sanded down a bit with a block sander to allow more space between them and the rail. 

To install the 787 coupler, I installed the coupler upside down in the Kadee coupler box, drilled out the main Kadee coupler hole and installed it over the existing Aristocraft coupler post.  I then used a slightly larger washer with the original screw to secure the coupler in place.  Kadee coupler install info is below.

 

And here it is....

Overall lowering the engine has made this great looking engine even better. 

 

01/03/08  

*Completed* Dash-9 with tank raised

 

Below are a series of photos showing two different engines. (both lowered .20")  One has the tank raised  ~.16" and the other is in it's original position. 

For reference, here are examples of the real thing:

 

Here are photos that show the steps I took to raise the tank.  I cut out the raised portion of the frame, then cut the tabs off the tank with a modelers cutter.  The tabs were moved to the outside of the tank and were bolted in place with 2-56 size screws and nuts.  I then ground the excess of the 2-56 screw on the inside of the tank which and the added benefit of heating them which allowed them to melt and recess into the inside of the tank.  The recessing was necessary in order for it to clear the weights inside.  All cut areas were painted with Tamiya Acrylic flat black paint (XF-1).  If you mount the cut tabs at the right height, you won't need to shim or add spacers to get the tank to the proper position. (the tank may be too high depending on where you've mounted them.)  If you need to adjust the height lower, you can use something simple like electrical tape to space it back down to the desired height.  Also note the air tank pipes must be clipped in order to allow the tank to be raised.  Also, because the tank tabs were moved to the outside of the tank, new holes have to be drilled in order to screw the tank to the frame.  You may need to use a longer screw to retain the tank to the frame if you've added enough spacer to lower the tank.  Because the tank isn't raised all the way to the bottom of the frame, there will be a space between the top of the tank and the frame.  You really can't see it unless you look hard and at ground level.  To hide the weights you can either paint the weights black where they are exposed or wrap with electrical tape. 

 

Kadee Coupler install

If you lower your engine, you will need to use an offset Kadee coupler in order to achieve proper coupling.  In the photos below you will see the original screw + #8 washer and two unmodified 787 Kadee couplers and one on the right that has had the mounting hole enlarged with a 15/64 drill bit.  Simply install and use a #8 washer to secure.

 

 

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07/31/05  

Gary To's Dash 9

Gary To (from Hong Kong) posted a link to these pictures of his outstanding work on his Dash-9.  Discussion about can be found on www.aristocraft.com under the Kitbashers' forum under the thread name "My Dash9".  Great work and thanks for letting me share your pictures here.  :)

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