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Page One - Articulated Loco Project by Fred Rawling (lbdrummer3 at yahoo.com)   next page
Picture 1-1
Here are some of the tools and materials you will need
to build your own American Flyer 4-6-6-4 Challenger: 
Materials- 2 junker America Flyer Hudsons.
Sheet metal, metal impregnated epoxy (JB weld), epoxy
clay, lead, nylon skateboard rail, and satin black
spray paint.

Tools- Safety glasses, bench grinder, fine wire brush,
drill press, assorted SHARP files, hacksaw, welding
set for brazing, Dremal tool (nice to have but not
necessary), screw drivers and pliers.

During construction, I didn't use exact measurements. 
Everything was assembled by trial and error and very
little actual measuring was done.  If you find an
easier or better way of making one of the parts or
completing one of the steps feel free to do what you
like.  I offer this only as a guide.
Also, I recommend building the chassis first before
the boiler shell so the builder can adjust its length
to fit the chassis.

Picture 2-1
(Picture 1-1) 
These are the victims, 2 American Flyer 322 Hudsons
that were junked out.  One is striped and the other is
painted so one could tell them apart during
construction.  Disassemble all of the parts from the
boiler shells and strip all of the handrails, cotter
pins and piping.

(Picture 2-1)
This is the steam cylinder for the rear chassis.  File
down the exhaust pipes flush with the outside edges of
the cradle.  Then file flat the small nubs on the left
and right side right above the two holes.

Picture 3-1
(Pictures 3-1 and 4-1)
These show the sheet metal brackets that need to be
made to support the steam cylinders.
Picture 4-1 (Picture 4-1)
Note the extra modifications made to the front of the
steam cylinder for the rear chassis (left). It needs
to be rounded and then angled slightly downward. 
The only modification that needs to be made to the
steam cylinder for the front chassis (right) is to
grid the exhaust pipes smooth with the tops of the
cylinders.  Then grind the outside edges of the cradle
down so they are even with the center/lowest point of
the piece.  This is so the bottom of the boiler shell
will clear it when the engine goes around curves.
Extra note: In (picture  4-1) the steam cylinder isn't ground
down enough.
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