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DUMMY COUPLERS MADE OF WOOD October 23-24, 2010

I have a number of engines that have empty coupler pockets in front.  So I thought why not make some dummy couplers out of plywood scraps.  These couplers will never pull anything, we just need something that will look like a coupler.  So here goes.

After I cut a second piece I filed off the rough edges and then glued them together with Titebond glue.  The holes are from finishing nails I used instead of clamps.

I made a pattern out of .040 styrene, traced it onto a piece of 3/4 plywood, and cut it on the bandsaw.  I used a lot of cuts to get the inside profile right.

Next I used the bandsaw and a file to trim the shank and shape the coupler.

Overhead view, showing the outline of a generic knuckle coupler.

I added a small square to the top and gave it a coat of flat black spray paint.

Here is the finished product on the pilot of Engine No. 4.  Looks like a real coupler!