Friday, 31 May 2019

Update 31.05.19

Since the last update most of our work has concentrated on mark 1 TSO 5057.  The coach was fitted with aluminium doors a few years ago.  Whilst the doors themselves are in good condition the interior door furniture was poor.  Therefore it was decided to completely strip them down.

The window runners and interior panels were fixed to the aluminium frame using self tapping screws.   Many of these were broken with the remains of the screws still in the door and impossible to get out.  This picture shows the door frame being fitted with timber inserts to which the runners and panels will now be fixed.

The next picture shows a window refitted into the door.  The operating mechanism at the bottom, which is called the "lazy tongues" have been cleaned and lightly oiled.  The two window runners on either side have been screwed into the wooden blocks and have had new felt fitted to the slides.

One of the bogies also had a problem.  One of the track control tubes (not the correct name but its what I call them) had become loose and could be rotated by hand.  This picture shows the tube, bolt and rubber bushes removed as well as the horn clips in preparation for lifting the coach.

After lifting the coach to check the centre casting which was all ok, it was decided to change the bolster springs, fitting new spacers whilst doing so.  The track control rod was refitted also using new bushes.

A view of the bogie showing the position of the springs and rod.

Inside the coach the steam heat pipe covers have been repaired, painted and re-fitted using new hinges.

The next picture shows the first stage in replacing the seat frames.  The new lino floor covering, a very light grey can be seen under the seats.  The centre aisle is protected with hardboard.

The next stage in replacing the seat frames.  The back frame and centre aisle end panels are fitted.

A close up of the seat ends, repainted in a grey finish.  The edges will be varnished later, they are currently covered up using masking tape.

Another view of the seat frames, all of which have had extensive repairs followed by a coat of paint.

Transformation! the new upholstery now in place.

The next stage, the tables going back.  They have all had the fixings repaired, the legs have been cleaned, painted and fitted with new rubber blocks which go in the base of the leg where it fits to the floor.

Another general view.

One of the doors with some of its interior panels fitted.  These will be stained and finished with multiple coats of varnish.

During this time there has been a small amount of work taking place on RU 1936.  Murray is pictured below preparing the exterior for paint.

This door hinge pillar has had a new wooden insert fitted.  the door itself has been cleaned up, especially the very corroded bottom step.

The saloon roof panels needed edging with a moulding.  This had a very tight curve at the sides and was proving very difficult to bend.  This is our attempt at steam bending timber, the idea for which I got from a LMSCA video.  So if you read this guys, thank you.

The saloon end panels and sliding door have been put into place.

This is the sliding door.  It has had the Formica covering removed which left a glue residue covering it.  This has been sanded down and then varnished.

More pictures of the exterior work.

The coach had to have a trip outside whilst the lifting jacks were moved.  This profile view shows where the two windows and kitchen door have been panelled over.  These are to the left, whilst the doors to the centre and right are the new emergency doors.  At this stage some areas are in red oxide primer.

two more views.

The next stage.  The roof has been painted in steel grey whilst the sides have received a coat of light grey undercoat.

The other side view.

The saloon roof showing the new mouldings which were mentioned earlier.

Another roof view.

During the last week the window surround panelling and mouldings have started to be re-fitted.

One slight distraction is that the pressure switch and gauge in the dining car pantry vehicle had to be replaced.  Pictured here before the covering panels went back on.

Thursday, 21 February 2019

Update 21.02.2019

Work has continued on mark 1 TSO 5057.  The floor was lined with 4mm ply and the Marmoleum (lino) has been laid.

A new set of mouldings have been prepared for the window surrounds.

A few of the windows have had the moulding fitted, this will have wood dye and varnish applied.  The seats which have returned from the upholsterer and can be seen through the window awaiting their turn at being fitted.

One of the skirt panel joints was cracking badly owing to rust underneath.  The filler has been cut back and rust preventative applied.

On RU 1936 a few jobs have been completed.  This is the curved vestibule door from the saloon end.  The exterior side has been rubbed down, painted with primer, undercoat and is seen here in top coat.

The battery boxes have had new doors made.

Friday, 1 February 2019

Progress report 01.02.2019

RU 1936 work progress.
The high capacity batteries have now been fitted.  This is one of two boxes showing the shelf built into the box to allow two levels.

A wider view to show the two battery boxes.

One of the problems to over come was the balance pipe between the two water tanks.  previously made of plastic, a more robust arrangement was needed.  The solution was this stainless steel flexible pipe arrangement.

The interior panelling of the saloon has progressed along both sides.

The bar has now had the flap and access door fitted.

A close up of the flap and door.

The bar back unit close up.

A close up of the fitting arrangement of the bar flap and door to the emergency door.  The flap sits on a batten fixed to the emergency door and simply lifts away from it.  The bar door fits up against a vertical batten fitted to the emergency door and is secured by a brass bolt.  The action of opening the emergency door, which swings outwards, releases the bolt allowing the bar door to swing out of the way.

The interior panelling has got as far as the end of the coach and is proving to be a big jigsaw puzzle, mainly because of the length of time since we took it apart.  The rear panels have been covered with oak faced ply and varnished, they are laid out to dry inside the saloon.

There are two wings at the entrance to the vestibule, these are pictured leaning against the side windows.

The frame at the vestibule end has been repaired and fitted.

The sliding door gear has also been cleaned and re-fitted.

A major project that we have taken on during the winter break is the re-upholster of mark 1 TSO 5057.  For some time now the seat cushions were becoming more and more thread bare and were in need of attention.  The coach is pictured here outside the carriage shed attached to mark 1 TSO 5060 which has the same seat material.  Any seat cushions in 5057 that had been recovered and were still in reasonable condition were exchanged with worn ones from 5060 to improve the interior of that vehicle.

The seat backs and cushions having been removed await the attention of the upholsterer.

The wooden trims from the top of the seats have been sanded and have received a coat of varnish.

The interior of the coach after the seats had been removed.  The frames are being removed for repairs as they are in poor condition.

Removal of the seats revealed an earlier seat material, possibly the original fitted when it was built.  This red and black striped material was known as red candy stripe.

A small area of four tables being separated from the rest of the coach by a bulkhead had green and black candy stripe material.  The seat sides were fitted with green Formica, whereas the rest of the coach had grey Formica and the bulkhead showed signs of where hinges for a swing door had been fitted.  Research into this suggests that this area was the smoking compartment.

The interior after the seat frames had been removed.  We have run into further problems, the lino was lifting under the tables, dirt had got underneath which when cleaned out, in trying to re-fix the lino it broke owing to being brittle.  The whole coach will have to have the lino renewed.  The next problem is that two of the steam heat pipes had cracked and have to be removed for repairs.  Finally the window rubber is perished and will need replacing.

This end of the coach has had the old lino lifted, after cleaning it will be covered with a sheet of 4mm plywood to provide a good base for the new lino.

Not a brilliant picture but this is a steam heating on / off valve which controls the pipe on the left.  The bend on the pipe on the right is the end of the next steam heat pipe arrangement, its valve will be at the end which is out of sight away to the right.  Steam enters via the valve along the small pipe, flows around the pipe and exits via the pipe which goes through the floor.  The casting into which the entry and exit pipes attach is where the cracking has occurred.

The seat frames set out in order along the floor awaiting their turn for repair.

A small diversion, commonwealth bogie spring packers made from marine ply awaiting painting.

A square version which is used as a packer for the equalisation beam on a commonwealth bogie.