Installing the new ESU XL 5.0 sound decoder

                       

Live From The Workshop - Part 1

Reporting live from   "Famous Klaus Workshop" : preparing and installing the XL 5.0 ESU sound decoder into ( today) the LGB# 4067 cleaning loco.

Installing a digital ESU sound decoder into an LGB loco in 5 steps steps:

• check and prepare for loudspeaker mounting and installation
• check and prepare for decoder board mounting and installation
• programming and editing of ESU XL 5.0 sound decoder
• installation of decoder, hall sensor set (when needed), and connecting loudspeakers
• re-assembly of loco parts and test driving the new decoder w/fine tuning

Please note that these steps are in Klaus' procedure no matter what type of digital decoder he installs. Can you do it any other way? YES -- which in Klaus' view  means mangling an otherwise very fine engine of  very fine provenance... Therefore:

ventilation grille painted on loco housing

Check and prepare for loudspeaker mounting:
It's hard to say what takes the longest in prepping an LGB engine for sound decoder installation. Klaus being Klaus he stands for Old Original LGB standards where a loco is the better the more she looks like her Original.
Installing sound therefore means to provide space for the loudspeakers and create openings for the sound not by merely drilling holes somewhere ( urrrghh--- you can hear Klaus say, even from your spot!) But to provide meaningful openings where the sound would come from in reality. In the case of the 2067 Cleaning engine this is clearly the front side of the engine where the

ventilation grille cut out

grills are painted with black lines to visualize the ventilation grille for the diesel engine(s). On the pics to the right: the upper engine shows the painted ventilation grilles where the lower pic shows cutouts have been made. Note: the LGB 2060 and 2067 share these same housing parts.

Klaus starts by dismantling the 2067 engine housing to extract the housing part. Klaus uses his 3-D milling machine - programmed accordingly- to cut out the "ventilation grille" part of the housing.

3-D milling in action

Detail cleaning the new opening by hand  is the next step.






Klaus will need mounting support for the loudspeakers so he cuts supporting blocks from hard-PVC plate (1/2 " thick). They guarantee non-deforming support in hot and cold environments. The loudspeaker mounting gets glued into place  in the respective housing part.
Klaus uses a specialty glue that slightly 'melts' the surface of the engine housing so the hard PVC piece will 'combine' with the housing plastic. Then the loudspeaker is wired and mounted. In the photo left notice the little piece of rectangular plastic below Klaus' wrist; that is the first mounting piece. He will need two in this case.






 Trying to mount the loudspeaker Klaus notices a need for space currently held by the lead weight. Each LGB engine sports a lead weight to ensure optimum driving characteristics. In the case of the LGB 2067 the lead weight is elongated and needs to be adjusted to give Klaus enough room to install the loudspeaker. Klaus utilizes his 3-D mill again, programmed, to refit the lead weight.

Now the loudspeaker is connected to the deoder board and mounted into the engine housing.

And the cutouts made previously are getting a mesh for looks

Follow Klaus in his workshop with the next steps, programming, editing and installing the sound decoder.++++ to be continued