Set 21344: Upgrading the Sapphire Star

[L-Gauger]

It appears that previous discussions on improving the Orient Express train set have focused on motorization like in this thread: 

However, it appears there isn't yet a thread specifically for upgrading the locomotive. I know there's been discussion on the deficiencies of the Sapphire Star in the thread for general discussion of the Orient Express, this thread isn't for re-visiting that discussion. Instead, this thread is for showing off what you've done to remedy the deficiencies in the Orient Express locomotive as you perceive them. 

In my case, I desired to correct the following matters: 

- Add Power Functions equipment to the locomotive. 

- Increase the width of the pilot/footplate. 

- Improve the running qualities of the locomotive. 

- Equip the locomotive with magnet couplings. 

I considered re-working some of the details on the locomotive to better match a Swiss Federal Railways class A 3/5, but realized that doing so would involve more effort and parts than the result would be worth, especially given the fact that I'd need to build a new tender from scratch to be truly accurate. 

The result: 

Expanding the width of the pilot to 8-wide from 6 was the easiest change, involving only a few part substitutions and replacements. The running gear took a bit more time to figure out, but eventually I realized that replacing the technic cross-axle piston rod from the original set with a 6-stud long antenna would completely eliminate the problem of the "piston" binding on its shaft. 

The coupler was a bit more intensive, but in the end I discovered a means of attaching the magnet coupling to the pilot truck, similar to the coupler on the Emerald Night. Though it's a pity that the red bufferbeam is gone, the presence of a functional coupler on the front of this engine makes up for it. 

As for the motorization: 

The tender only needed slight modification. The coal load was raised by 2 plates to clear the PF cable on top of the battery box. 

The engine was another story altogether. I had to completely re-design the inside of the boiler to accommodate the PF L motor and IR receiver. 

The IR receiver is mounted sideways, with the actual receiver "eye" peeking out of the firebox. The arrangement works reasonably well, and completely hides the IR receiver from external view. Building the firebox around the IR receiver was a major challenge though, and I did have to settle for some minor changes to the outside appearance. Let me know if you can spot them!

The motor is geared very simply at a 1:1 ratio to the middle pair of drivers, using two pairs of bevel gears. However, I had to get creative when bracing the top pair of gears, making use of this element: 

So far, since adopting this method of bracing I have encountered no issues with gear slippage, no matter how heavy the train's load is. 

I have yet to properly test this series of modifications with rubber bands applied to the Sapphire Star's drive wheels. However, I suspect it will be able to manage an un-modified pair of Orient Express coaches over R56 and greater curves. If the coaches are equipped with the old PF or 9V-era wheels, maybe this locomotive could even pull the train over R40 curves. 

Is there anything I could be doing better? What have you done to improve the Sapphire Star? 

 

[Feuer Zug]

Looks good so far. If it's not slipping, you might have a solid solution.

[L-Gauger]

@Feuer Zug I can say for sure this gear setup will not slip. In my testing, I think the gear teeth would break before slippage could occur. I say that because I've actually held the drive wheels still with my hand while the motor was running (obviously not for long, I was just trying to force the gears to slip for testing purposes... and the motor just came to a stall. No gears slipped) 

Now I just need to get in some rubber bands and test how this locomotive can handle two un-modified Orient Express coaches over R40 curves and switches. The engine might not be heavy enough to successfully manage the train of that radius, but we shall see! 

[zephyr1934]

23 hours ago, L-Gauger said:

Now I just need to get in some rubber bands and test how this locomotive can handle two un-modified Orient Express coaches over R40 curves and switches. The engine might not be heavy enough to successfully manage the train of that radius, but we shall see! 

That's probably what @Feuer Zug was talking about. The OE cars are heavy and the engine is light. Worse yet, the wheels on the car are high friction.

 

If it slips too much you might be able to replace what look like stacked of two red and blue 2x4's in the following picture with one or more weight bricks. If you don't have any weight bricks I suggest testing with something else weighty (roll of coins?) before making the investment.

 

On 6/27/2025 at 5:33 PM, L-Gauger said:

 

[L-Gauger]

@zephyr1934That's a good idea regarding the weight brick. If I were using Powered UP, I probably would have found a way to put the PUP hub inside the boiler, again to increase weight. 

That said, the only real troubles I've encountered during testing are with the increased friction of R40 curves. R56 and broader don't appear to be much of an issue for a traction-tire equipped Sapphire Star despite its relatively light weight. But, time and more testing will tell.