Kato HO Early DD51 DCC install

[Kiha66]

Hello, today I will be doing a wired DCC install of an early (no nmra 8 pin socket) Kato dd51.  I will be using a Digitrax DZ126 and attempting to make the install as painless and modification free as possible.  I will also be upgrading to LED headlights.  

Edited November 10, 2018 by Kiha66

[Kiha66]

To start once the shell has been removed, unclip the motor contacts and the original headlights.  To remove the headlights you must unwrap the wires from the plastic tabs.  One is on top of the board and the other is under the board.  

Edited November 10, 2018 by Kiha66

[Kiha66]

To access the other tab unscrew the board from the top of the motor.  You can also slide off the truck power wires as you'll need to remove the board completely later to make a hole for the decoder wires.

 

Edited November 10, 2018 by Kiha66

[Kiha66]

My intention for this install is to put the decoder under the existing board on the side without the flywheel.  To route the wires to the upper side of the board we will need to make a hole just after the screw hole on the side opposite the flywheel.

Edited November 10, 2018 by Kiha66

[Kiha66]

To cut the hole I used a pin vise with 1.5 mm drill bits too make a outline of the opening, then used an xacto the break the remaining connecting tabs.  I then cleaned up the remains of the cuts with the xacto blade.  The size of the hole is not to critical, so I erred on the larger side.  

Edited November 10, 2018 by Kiha66

[Kiha66]

Not the most professional finish, but it will work just fine.

[Kiha66]

Laying out all the parts.  I'm using Leds salvaged from other digitrax decoders that were in my parts bin, but any 3mm led will work well.

[Kiha66]

A quick test fit to ensure it all goes together.  The motor leads will go around the sides while the headlight and track power wires will go on top of the board.

[Kiha66]

I used tacky glue to secure the decoder to the underside of the light board.  However the stuff I used has a unmentioned long drying time and honestly is horrible at securing, next time I would have used low temp hot glue or something similarly quick and effective.

[Kiha66]

While waiting for the glue to dry I bent the Led wires to match the angle of the bulb holder, then soldered a 1k ohm resistor to one of the legs.  I chose the positive leg just so I would later know what the polarity of the led was once it was installed.

 

[serotta1972]

4 hours ago, Kiha66 said:

Hello, today I will be doing a wired DCC install of an early (no nmra 8 pin socket) Kato dd51.  I will be using a Digitrax DZ126 and attempting to make the install as painless and modification free as possible.  I will also be upgrading to LED headlights.  

Nice Radio Shack nipper you have there, those come highly recommended.  Thanks for documenting the decoder installation.

[Kiha66]

1 minute ago, serotta1972 said:

Nice Radio Shack nipper you have there, those come highly recommended.  Thanks for documenting the decoder installation.

 

If I recall, It came from you actually!  They are so great, I honestly use it for striping wires way more than my actual wire strippers.  I'm waiting the tacky glue to dry overnight and will try to get the installation finished up tomorrow.

[Kiha66]

Decoder attached to the board, now the two track pickup wires are stripped and soldered to the bus bars.  

Edited November 11, 2018 by Kiha66

[Kiha66]

Next I attached the wires to the LEDs, then soldered the tuck pickup to the ends of the bus bars.  I used a popsicle stick to space the wires and to keep any of the hot metal from touching the plastic frame.

Edited November 11, 2018 by Kiha66

[Kiha66]

Finally I secured the headlight LEDs in place with a small dab of hot glue over the wires.  Now just put the shell back on and test it out!

Edited November 11, 2018 by Kiha66

[Kiha66]

In the future I may revisit this installation to add sound, but for now that's all folks!

 

[Kiha66]

[serotta1972]

Wow, nice pictures. Is this a private layout or a club? Nice rock formations and I even see a rock climber.

 

[Kiha66]

1 minute ago, serotta1972 said:

Wow, nice pictures. Is this a private layout or a club? Nice rock formations and I even see a rock climber.

 

Its actually the private layout of the President of the Los Angeles Model Railroad Society.  They are loosing their building and in talks with our club use part of our club building (depending on if the older less charitable members can be persuaded to give up the couches).  A few of us were invited to join in on an operations session of his personal layout and I snuck in a quick lap with the DD51 afterwards.  Hes a great guy and all of the models on the wall are brass with sound that he lets people run when visiting, I had a great time.