Continuing the series on rebuilding two vintage Super-Scale OO Diesel switchers, we turn to the cabs and hoods. With the goal of smoothing out the really big differences between the bodies of their SW-1 and NW-2 models, so that they can ultimately be run together and generally match. (To totally match being impossible).

Before reading on, you may want to review the previous installment, which was the starting point of dealing with the many issues. In short though, the two cabs didn’t match very well and the hoods were different heights.

Breaking them down

To begin, step one was flattening out the two cabs. I had to reuse the ends of the cabs, but really could not use the sides, they were either not wide enough or not tall enough.

My tool of choice is the jeweler’s saw. Not everyone will be comfortable with it, but I felt much more in control than I would with a razor saw.

I had to not only cut apart the cab to save the ends but also make new sides. Those I made to match the dimensions/style of the James Trout NW-2 model (and the scale drawing). Trout opted to make them with the windows open.

Below is the start of my process of cutting the sides. It took a LONG time, crazy person work really. Had to drill holes for the saw in the openings (you thread the saw through the holes to cut the opening), and spent lots of time with small files and measuring tools. Bench vise very helpful as well.

Worth mentioning, as a tip, I often mark my cut lines with blue painter’s tape. It’s very straight and easy to see.

After all the filing and mods (including modifying almost all the window openings in the ends — adding two windows to the SW-1 end) it all had to come back together. To do so, I needed to make a jig to hold the parts. I added a 1/16″ square rod for reinforcement in each corner and did the joints using my resistance soldering setup.

Interlude: hood modifications

Working on the cab ends, it was clear I had to modify the hoods to see how it all fit together. They needed modification as the SW-1 hood was about 1/16 inch too tall and the NW-2 hood about 1/16 inch too short. By themselves they looked OK, but together not so good.

The SW-1 hood, that was simply a lot of filing with a big file. It just had to be shorter.

The NW-2 hood, after pondering options, I added a 1/16 brass square rod on the bottom of each side. Big challenge being getting the parts lined up perfectly to solder them using clamps and annealed steel wire. The setup for the second of the two pieces is below, before soldering.

Oh and look, they are the same height now. The SW-1 hood is still wider and lacks roof details, I’m just going to have to live with some of the differences.

Back to the cabs

Finally, we have cabs to look at.

First we have this side view. The new sides are very plain but the proportions are correct, so a big visual improvement over the originals.

Looking at them from the front, the SW-1 cab (left) is slightly wider than the NW-2 cab, but it matches the hood in the same way, so it’s not at all obvious.

Finally the rear end. The SW-1 cab (right), this end was kind of a disaster as the original didn’t lay out the door correctly and also there were no lower windows. Now, they are both visually close and, for both, I followed the general look of the James Trout NW-2 ends, as I think he was correct to only push them this far towards accuracy in relation to the original setup. You “buy it” as being correct, even if the window openings should be even wider. Mostly, again, I just need the models to match as close as I can reasonably make them.

Sharp eyed readers will see there is a gap at the bottom of the SW-1 cab end. I don’t know why exactly my model was as it was, but the ends/sides were too short and mounted on a block of brass that made them too tall! I’ll work out filling that gap later in the build. I might actually solder the blocks needed on the frame.

No photo, but I modified (shortened, in length) the SW-1 cab roof to match the new cab, cutting one end down with the jeweler’s saw and using the big file to finish the job. The original NW-2 cab roof, surprisingly, will work without modification.

I’ve got the next steps in mind, they involve attaching the cabs to the hoods. But first I have to puzzle about those oddball handrails on the SW-1 and have some other decisions to make (plus a couple things to track down for them), so I’ll likely turn to other projects for now as I get things set for another run of activity on this one.

More likely, my next steps are on the SW-8 body, improving the radiator end especially, which is also part of this overall project. Hopefully on to that soon.