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How to Replace the Window Struts for Postwar Lionel Trains

Constructed of cast-metal, postwar Lionel trains are extremely durable model engines. Like many toys, however, use and abuse over the years often results in damage to the smaller components of the engine such as the grab rails, bells and the window struts. Because the engine's body is made with cast-metal, it is possible to solder these struts back into place after they have been broken as long as you have the original parts on which to solder. Once reattached, the struts can then be shaved into the correct shape and painted so that you would never know that there was previous damage to the train.

Things You'll Need

Soldering iron
Soldering flux
Solder
Fine metal file
Touch-up paintbrush
Model paint

Instructions

- 1
  Lay the Lionel train on its side so that you can easily access the broken window strut. Clean the break with the fine metal file to clean away excess paint.
- 2
  Fit the window strut back into position. Heat the first part of the break that you intend to repair, using the soldering iron. Heating the metal will make the solder flow more easily.
- 3
  Dip the soldering iron into the soldering flux. Hold the iron just above the repair area and touch the solder to the tip of the soldering iron.
- 4
  Hold the solder against the tip of the iron until it liquifies and flows down onto the broken portion of the engine's window strut. Keep the iron hot, touching the solder that drops onto the repair area to ensure that it runs into the crack where the window strut broke. Do the same with any other areas of the window strut that are broken. Allow the solder to cool.
- 5
  File down the excess solder material with the fine metal file. Solder is essentially tin and aluminum so it will file down quickly and will combine well with the die-cast metal. Shape the window strut to its original appearance.
- 6
  Apply a coat of paint that matches the Lionel engine's original paint color to the bare-metal repair areas. Allow the paint to dry completely before attempting to handle the engine.

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