Sergent Engineering Coupler Videos

[Fluesheet]

I have a couple of questions.

First, how difficult is the Sergent coupler to assemble without using the jig, or do I need to buy the jig to assemble them reliably.

Hello Russ. Assembly isn't too bad without a jig - I've assembled eight pairs with few problems. I haven't timed it, but I'd guess it takes less than 10 minutes to assemble the coupler (not including mounting it to a car or coupler box). However, if I was planning on assembling another 10 or 20, I'd pick up the jig.

The trickiest part of assembly, for me, is one the jig won't help with - setting the damping spring in place. I think the jig would help with the second trickiest part - putting the bottom cover on. This part forms the bottom half of the coupler shank / locking mechanism, and includes the lower pivot pin for the knuckle. I've spent 10 minutes putting one on, and I've put one on in 30 seconds. I suspect (this is speculation since I haven't used one) that the stability that the jig would add would make assembly time more consistent. A key for either approach is to use tweezers that are not magnetized so the locking ball drops into the coupler assembly with a minimum of fuss.

I have another video that shows assembly (without a jig): <!-- m --><a class="postlink" href="http://www.youtube.com/watch?v=GXCf0iKvgr0">http://www.youtube.com/watch?v=GXCf0iKvgr0</a><!-- m -->
I found this one which shows assembly with a jig, for comparison: <!-- m --><a class="postlink" href="http://www.youtube.com/watch?v=lwt057ZbC3E">http://www.youtube.com/watch?v=lwt057ZbC3E</a><!-- m -->
Parts overview detail here: <!-- m --><a class="postlink" href="http://www.youtube.com/watch?v=52E4W9FGf70">http://www.youtube.com/watch?v=52E4W9FGf70</a><!-- m -->

The second question is since Sergent has discontinued manufacture of the "rusted" color couplers, will the available chemicals like "Rust all" work to give the couplers a rusted appearance or do I need to paint them rust color?

I don't know the answer to the first question. Frank Sergent most likely does - shoot him an email, he's very helpful. My thought is that "rusting" the coupler at home may change the surface enough to impact performance - but this is pure speculation. If you get an answer one way or the other, let me know - I like the rust look quite a bit, and it's a shame to see it go.

Frank is recommending paint going forward (the pre-assembled ones will be painted). As a side note, there are some couplers left in rust - from an email from Sergent Engineering:
"All of the EC87 style kit couplers are now black (kind of gray actually). I still have quite a few of the narrow shank (EN87) style available in rusty brown. Those will switch to black as well as stock is depleted. The assembled couplers are still rusty brown - but its done with paint now."