CLOSE COUPLING AND END DETAIL UPGRADE KIT

For Hornby ‘K’ Type 8 Wheel and 12 wheel Pullmans.

The Close Coupling Draw Bar.

16.    Remove any flash with your finger nail and ensure the loop is smooth. Ensure the return spring hook is clear of  flash.

17.   Fit the the return spring, then loop the spring to the chassis and hook the draw bar into place.

18.    Screw the draw bar securing plate back into place.

Check the draw bar moves freely from side to side. If  the draw bar is tight  then check it again for smoothness and Refit.

The Bogie.

19.    Bare the wires and twist them together, be sure to insulate them.Tuck the wires back into the body of the carriage and push the bogies back into place.

The Pullman Body

1.     First remove the buffers with a straight pull.

2.     Remove the end plate.

3.     Remove the bellows by gripping the top and a straight pull.

4.     Separate the chassis from the body.

5.     Pull out the bogies.

6      Cut the wire at least 15mm above the joint in the wire.

7.     Unscrew the plate holding the draw bar in place.

8.     Remove the draw bars, then remove the centring spring from the draw bars and put them some where safe.

9.    Glue the T plate to the floor at the ends of the carriage. The T’ plate is to support the bottom of the carriage and keep the corridor connection perpendicular to the track.

10.   Refit the body to the chassis. Make sure there is a tail of  wire sticking out of the hole for the bogies.

PULLMAN

PULLMAN

PULLMAN

HORNBY

HORNBY

HORNBY

From this

To this

BEFORE

The Corridor Connection.

11.     Remove any flash and file away any imperfections from the top of the resin corridor connection.

12.     Colour the resin corridor connection with a black permanent marker. If paint is used DO NOT get any paint inside the aperture as this is a close fit for the Floating End Plate.

13.     Remove the lamp brackets from the floating end plates. Place the spring over the spigot at the back of the end plate and pass the spigot through the hole in the centre of the corridor connection. Push the fixing washer on to the spigot to hold the end plate in place. Allow about 0.6mm (20th) of float. Adjust the position of the fixing washer to set the end plate with an equal distance all round the corridor connection. Ensure the end plate moves smoothly in and out within the aperture of the corridor connection. Lock the fixing washer into place with a little super glue.

14.     Fix the corridor connection to the ends of the carriage.

The Buffers.

15.    Select the plastic buffers to be used, reduce the shank length to 4.25mm and push them fully home into the buffer stocks. Ensure all the buffer heads are an equal distance from the buffer stocks

The Couplings.

20.      If ROCO auto

couplings are to be

used they will fit

directly into the

coupling pocket and

he Floating End Plates

will touch and compress in

the corridor connection when the

carriages are coupled and on straight track.

21.      If the included Buck Eye couplers are to be

used then follow the instructions for them below.

The coupling pocket will need to be shortened by

1mm for the same operation of the Floating End Plate.

22.      With the couplings fitted by Hornby the ability to go round radius 1

curves is allowed by the sloppy tension lock couplings.

23.      With the replacement draw bar fitted the slop has been removed from the draw bars. A rigid draw bar between the carriages must be maintained to make the close coupling work correctly, but the carriages are restricted to radius 2 as the minimum curves.

24.      Only Kitchen cars had the large gas tanks under the chassis, so remove them from all other types of  Pullman carriage.

The Roco

auto coupler.

Use these

couplers

between

the carriages

and to couple to

the loco.

Bachmann

E-Z Mate

MkII

auto

coupler.

Do not used

between close

coupled carriages.

Good for coupling to loco.

Modified

Bachmann

auto coupler.

Do not

used between

close coupled

carriages.

Good for coupling to loco.

The Keen

Systems

Buckeye

coupler.

Used for

permanent

coupling

between close coupled carriages.

The finished job

The Buckeye Coupler

Using a small file or a scalpel carefully remove a tiny amount of plastic from this edge at the bottom of the coupling a little at a time until a pair of couplings will pass easily through each other with a minimum of side play.

Too much rotational side play will cause carriages to lock up and derail when pushed through reverse curves.