And the saga continues. After installing the electrics, I took Anita outside for a test run. "Lumpy" was the term which sprang to mind - though better in reverse than going forward - also sounded a bit like a bag of spanners, which was frustrating because on the bench it sounded quite sweet.
I dismantled everything and spent half a day trying to improve the mesh between the worm and worn-wheel. When it sounded as good as I was going to get it, I reassembled and took her outside for another test run. Much sweeter this time, but on the third run the loco stopped amid much whirring from the motor.
I dismantled again and discovered the worn had stripped the worm wheel of a goodly proportion of each tooth.

- DSCI0640.JPG (1.53 MiB) Viewed 186 times
Clearly, the worm I thought was a good match for the Bachmann worm wheel, wasn't!
I rooted through my bits-box of mechanisms and discovered a spur gear which seemed to mesh with the worm. I had to ream out the bore from 4mm to 6mm and gave it a go.....

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Almost the same result as previously - except the worm wheel de-toothed in about half the time!
So, a complete rethink!
Using what I'd learned from making my own mechanisms using GA25-370 gearmotors, I discovered I could fit one between the frames - but it would require a complete redesign of the chassis. Thanks to Tinkercad, this was achieved.

- New chassis - Tinkered.png (245.98 KiB) Viewed 186 times
TBC ........
Rik