DK Pilot 04: Coupler boxes, cross brace, and muffler

Prepare and install the coupler boxes:

• Remove coupler boxes from the sprue. Note that there is an internal support inside the coupler box print that is easily removed.  After minor prep, the boxes will snap together similar to a Kadee draft gearbox.  The model will accept many Kadee or similar couplers. File the sides, top, and bottom of the box so that it slides in and out of the holes in the end beam and cab easily.  

Assembled box shown adjacent to boxes on the sprue.

As with other parts, separate the raft first, then cut the attachments to the angle iron portions.  Note the internal support in the left side of the coupler box as viewed from this angle.

The box will be a tight fit as supplied (there is a small tolerance built in).  File so the box slides in and out easily but does not wobble.

• Install the draft gear boxes in the narrow end and the cab using the supplied screws.  Do not over-tighten the screw as it can distort the box and push it out of level.  The outer face of the coupler box is symmetrical top to bottom, and may be installed with either side up.
• The coupler boxes remain removable for painting and coupler installation.  WDLR style couplers are supplied.

Prepare and install the muffler and cross piece:

• Remove the muffler from the sprue.  Note there is a "lip" on the edge of the muffler to be careful of.  Test fit, but do not glue, the exhaust pipe (1/16" brass tube.  Thin the section of the tube ends using a round tile to make the section appear thinner.

Muffler and brace on the sprue.

• Temporarily remove coupler box.  Apply epoxy to the mounting spaces on the inside of the sides, and slide the brace and muffler into place, aligning the hole with the exhaust ports on the sides.

Apply epoxy to the sides.

Slide brace and muffler in from below.

• Apply a small amount of CA to the brass exhaust pipe and slide it through the muffler from the outside.  Adjust the position of the exhaust pipe so that it is centered in the model, and make minor adjustments to the position of the muffler assembly to center the exhaust pipe on the ports.

Align hole in muffler with port.

Align entire assembly after sliding exhaust pipe into place.