“Charles” Gets a Decoder

A project with a difference – PART 2.
A friend has a Fleischmann™ type 4028 0-6-0 Steam Locomotive which he would like to use as a “proving” loco for his under-construction Wolgan Valley layout. It’s a sort of a recycling exercise. This is the next exciting episode – Charles gets a decoder!

The decoder is a LokSound V4.0 running the ESU sound file: 54413-LSV4.0-Dampf-BR80-R5      It sounds like this:

Very Germanic!! But it will be OK for the purpose, assuming that the NSWGR may not have bothered changing the whistle.

This is where the LokSound decoder will reside. For a tank engine, the Fleischmann 0-6-0 has plenty of room. After a little testing, it was least obtrusive in the cab roof and is held in place with Blu Tack.

There are other things to do with DCC sound installs one of which is the Speaker and more details will follow. This is one is my favourite Sugar Cube speakers in my favourite mounting area – the smokebox. That way the sound comes from the right part of the loco! [post coming on fitting a sugar cube into the smokebox of a brass 30T class loco]

The motor, especially in this ringfield type requires special attention to make sure that it is isolated from the frame.
There is excellent technical advice on this in an article I obtained on the “All Aboard” Mittagong website – except it doesn’t seem to be there any more. The original PDF file I downloaded from “All Aboard” is however available HERE.

The replacement Isolated Motor Shield is shown below fitted to the mechanism. It is sold as Fleischmann replacement part # 50 4730 and is available from All Aboard as a spare part (not shown on the web site).

Here you can see the wiring from the decoder to the motor – Orange and Grey to the motor and Red and Black to the track pickups (loco frame and wheels). Some other wiring is visible and is described below.

The decoder has a number of unused function wires and they are held captive by the (yellow) kapton tape. Two extra simple PCBs are also visible. Simple PCBs are described in THIS POST.
The one on the LEFT has 4 strips – 2 carry the brown wires to the speaker (in the smokebox) and 2 carry the wires to the front headlight.  The bottom strip can be seen to have a connection via a resistor to the WHITE function wire (headlight).

The value of the resistor is 3k3 (3,300Ω) indicated more clearly on the board to the RIGHT where the colour code is ORANGE, ORANGE, BLACK, BROWN, BROWN which is 3 3 0 (1 nought) and (1 percent tolerance) ie 3300 Ohms ± 1%  This value is higher than most people use but it provides a more prototypical yellow glow in the Warm White LED.

Image© courtesy eBay

Incidentally the LED is a tiny pre-wired device where the LED size is 1mm x 0.5mm and is available in Warm White, Bright White, Red and Green & available on eBay for ridiculous prices.

Sold as: Pre-soldered micro Litz wired leads Warm White SMD LED 0402

They will fit into the smallest headlights on a loco but must be handled with care.

The pcb to the RIGHT is shown in detail below and feeds the rear headlight and the 3k3 resistor is on one strip which has been interrupted under the resistor making 2 isolated pads.

The common wire is BLUE and feeds to both small PCBs. The YELLOW wire is the function output to the rear headlight.

The speaker used is a Sugar Cube which measures 12mm x 14mm x 5.4mm thick (bare). This is one being prepared in an enclosure.The following speaker is ready to go in:More about speakers in a separate Post.
And to save you scrolling back up – the photo below is repeated and shows the sugar cube sitting in the Smokebox and under the chimney which has been drilled out so that the sound is coming from the front of the loco both top and bottom. I will go to any length to try to get the speaker OUT of the tender and into a more realistic place. You can detect the difference in a passing HO loco.

If the speaker enclosure is mounted on the chassis it is inconvenient to wire as a plug and socket arrangement would be needed. Instead, I have located the enclosure to the inside of the body shell by the simple of expedient of a blob of Blu Tack in the top of the body which “grabs” the speaker when you assemble the two parts.  [Yes, I know … there should be a plug connecting the decoder and the motor/pickups but I got lazy]

Here is another loco with homemade plugs and sockets so that the body mounted  speaker can be separated from the chassis:The 2 brown speaker wires from the decoder are connected to the speaker via a 2 pin plug. The body and chassis can then be separated. This loco is a 73 class shunter.

The next episode will cover painting into NSWGR “colours” but in the meantime, here is a preview of “Charles” making some noise! Deutschland Über alles!

“Charles” Gets a Makeover!

This is a project with a difference. A friend has a Fleischmann™ type 4028 0-6-0 Steam Locomotive which he would like to use as a “proving” loco for his under-construction layout. Sort of a recycling exercise.

He decided that a hypothetical, but possible scenario had occurred with his Wolgan Valley railway: “the NSWGR had decided to import a German 0-6-0 class loco for evaluation. Part of the process involved a repaint into NSWGR colours (or lack thereof) and a later sale to the Commonwealth Oil Corporation, Newnes for use on the Wolgan Valley line.”

Here is “Carl” pretty much as he arrived at Brolgan Road, with the exception of the Kadee couplers which have been fitted as described below.

My task was to implement that conversion on the model and convert it to DCC with sound. This is the story of that conversion of “Carl” (which name appeared on the side tanks) to “Charles” on its rebirth on the Wolgan valley line. I believe it will carry a NSW “X” number.

It is a little over the NSWR loading gauge but squeaks past my platforms. Wheel flanges are a bit gross but have been filed a little and now run through my code 75 points OK. As it is also to be a test bed for DCC it is an interesting exercise. The model itself is beautifully constructed.

Step 1 is the fitting of Kadees to match the rest of the rolling stock.
And in the process give it a good run on DC to make sure that the project is feasible. As you can see in the lead photo, it is running just fine on my layout under DC and it proved to be quite powerful and relatively smooth.

I am impressed by the engineering in this model but not surprised due to its West German origin. The chopper coupler keeper is easily removed by unscrewing the buffers.
That releases the keeper plate, chopper coupler and the centreing spring strip (latter 2 not used).
Tap the metal chassis with an 8BA thread (or to your choice) to suit a standard Kadee plastic machine screw.
As pointed out earlier, I found the existing hole in the front of the loco to be a little large and tapped the hole throught the plastic foot plate under the smokebox door. That means that the front coupler now needs to be unscrewed to remove the body.
The hole in the keeper plate needs to be enlarged to take the Kadee screw – I achieved that with a small file.
The screws are quite long and need to be cut to length (sprue cutter or similar) and the end filed smooth.
The chosen Kadee was a #149 Long Overset Whisker coupler to get the coupler jaws down to an acceptable height. The draft gear box fits within the existing housing and the mounting hole can be aligned with the original holes by trimming the back off the draft gear box.
The #149 coupler needs to be trimmed to length as shown below. You can see here why they are called “whisker” couplers.

The bottom plate is glued in place (I used Faller Expert Plastic Cement which has a nice fine delivery tube).
You can see here how the top lip has been cut and filed flush
The coupler height is still a fraction high – if it is a worry a small styrene shim could be added above the Kadee.
And here is “Carl Charles” happily coupled to a small freight consist. Still running DC.

The next post will cover conversion to DCC using a Loksound V4 decoder with sugar cube speaker in the firebox. Then the re-paint and a video of him chuffing happily away to his new home in the Blue Mountains.