This week’s shop time is silver soldering for sure!
Here’s the pocket assembled, fluxed and with bits of silver solder by each joint, just waiting for heat to be applied. This will solder the upright pieces to the base.
After a pickle and cleanup, I set up to solder the edges of the box together.
And finally, I soldered the back flange onto the unit. This is AFTER soldering this time. Turned out pretty well.
Another pickle and clean up, and we’re ready to take the coupler pocket down to size. I have to mill off the excess pieces that were there just to hold things together during soldering. I started by evening off the bottom. It’s just flat, so quite straight forward.
Next, I did the sides. Here I had to be a little more careful because the back needs to remain wider than the pocket. But I milled off the parts that were just there to hold the pocket sides in place. (And the head of the screw).
After completing both sides, I did the top. Then I put the part in at an angle (adjusted by eye) and took off the corners at an angle. The rest will be cleaned up with files.
After filing everything flush, I needed to round off the front of the pocket. The drawing showed a 3/4" radius. However, the center of the arc was about 3/16” out in mid-air. Rather than free-handing the arc, I double-sticky-taped a little piece of wood to the rear flange and use that to support the dividers while I drew the arc.
Then I filed the arc following the line.
Next, I drilled four mounting holes; two in the backplate (as shown below) and two in the back flange (not shown).
And finally, I drilled and reamed a 1/8” hole for the coupler pin. I drilled this from the bottom since I could get a better hold on the part that way. I would have been good to do this step BEFORE I rounded the front of the pocket, but I didn’t think about it. I almost forgot the coupler pin hole completely!
You may also note the two little dimples in my vice jaws in the above picture
. I had a piece of packing in place when I drilled the mounting holes, but apparently, it wasn’t enough – or I was too exuberant in drilling my holes because I clearly drilled into my vice jaws on both sides. How sad is that?
Ah well, it's bound to happen sooner or later. And my vice is now 1.5 years old. Guess its time for some battle scars.
And here’s the completed coupler pocket!
The only thing remaining is to mount it to the frame.
Back when I was doing the rear end sill, I marked these holes, but I did not drill them. I wanted to wait to make the holes till I had the part in hand so I could make sure they matched up. Turns out, they matched up perfectly!
So, I drilled and tapped the holes (3-48).
Then, I mounted the coupler pocket. Here it is, in its final resting place on the rear of the tender frame.
And another shot, just because it's fun.
Now, the Rear Coupler Pocket is officially complete.
Only a few more pieces of the frame (Footboard, and Coupler Pins) then we’ll be on to tank itself!
Thanks for looking in,
Kim