ESU LokSound Select Micro Install in Kato N-Scale SD45

[RBrodzinsky]

Back in December, I started a project to install a LokSound Select Micro into a Kato SD45, with adding front ditch lights. The details on the ditch lights can be found in this thread https://www.therailwire.net/forum/index.php?topic=43416.15. As a quick reference, here is the prototype

http://s3.amazonaws.com/rrpa_photos/7907/DSCN4710.JPG

and here is my ditch light installation on the shell



To jump right to the chase, here is a video of the finished install (detailed installation posts follow)

[RBrodzinsky]

First up was milling the frame to make room for the decoder and speaker.  I made a decision to put the keep alive capacitors in the fuel tank, as there just wasn't a lot of room with this frame and shell

In this photo, you can see that I took down the read portion of the frame, down to the top of the part numbers, and made another large pad area in front, near the cab. Since the capacitors are in the fuel tank, I also milled a channel, to the rear, for the wires from them.   I also touched down a couple of high spots, which resulted in an oops, right above the motor tab, due to complete stupidity on my part while moving the X-Y table, and forgetting to adjust Z. 

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View of milling, from above

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Here is the fuel tank (which also demonstrates the importance of double checking your dimensions - all I needed was the smaller opening, but when marking... oh well)  You can see the start of the wire channel

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Close up of wire channel
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[RBrodzinsky]

Here are the capacitors (3x 20V 150uF Tantalum) in their cubby

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This shows the wires coming up from below

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And the full view of the decoder install, speaker, light board, etc. I tapped 00-90 holes for power pick up screws, with brass scrap as contacts. 8mm x 12mm Soberton speaker with Keystone Designs enclosure in rear. Ditchlights are tethered to shell, and front light is attached to white styrene piece on left, rear light is on speaker enclosure (not seen), with wires to far side of board. 1K ohm resistors for each LED.

An alternative to putting the caps in the fuel tank would have been to ditch the cab shield (black plastic clip), and put them there.

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[RBrodzinsky]

Here is a track side photo of the unit with front lights on

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And with ditch lights on

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[jdcolombo]

Very nice work, Rick.

I see you are enjoying your milling machine!   

John C.

[Jbub]

Very nice work, Rick.

I see you are enjoying your milling machine!   

John C.

Both of you are making me want to get one.

[RBrodzinsky]

My next four installs won't require any milling.   Have 4 Kato Mikados ready for decoders (and installing their detail kits)

[Nick Lorusso]

Have you noticed a difference in performance with all the milling???

[woodone]

Rick, when you have to machine frame halves bolt the two halves together. Makes for a mirror machine job on the frame. I use some 4-40 bolts and nuts. You will have to file or grind the nuts to fit into the hex holes and reduce the diameter of the screw heads.

[carlso]

Very professional job on that SD45 Rick. I like the .0090 screws for decoder power pickup. That should be about the most positive contact you can have. I have done that once or twice. The caps in the fuel tank are neat, if one blows your shell would most likely be OK ? ? ?

Appreciate your posts,

Carl

[RBrodzinsky]

Carl,

Yeah, at worst one would damage the fuel tank cover if a Ta Cap blows, but with the Kapton tape wrapped around them, I doubt much if any damage would occur.

[peteski]

Nice install Rick.  Milling machine really makes things easier to do., I like the channel you milled for the wires.
If this was my model I would try my hardest to prevent the headlight's light from leaking into the cab.  I just don't care for glowing cabs.

[ednadolski]

Both of you are making me want to get one.

Ditto!  I could certainly use one for the GEs that I want to modify.

at worst one would damage the fuel tank cover if a Ta Cap blows, but with the Kapton tape wrapped around them, I doubt much if any damage would occur.

Just don't let them short against the metal frame.

Ed

[Steveruger45]

Nice install Rick.  It just so happens I am working on a kato sd45 right now.  No ditch lights for me though and I am going to put the decoder in the tank. After some great inspiration from AKNscale and the fact that the frame I have is an Aztec dcc frame with the fuel tank milled out albeit for a smaller decoder which I have just enlarged.
  Now just need usps to deliver the decoder. [ Guests cannot view attachments ] [ Guests cannot view attachments ]

[MK]

What kind of milling machine did you use?  Cost?  Link?