The last 6 months have seen the base frame for the body assembled on the underframe and this included glueing together the two side bottom rails and completing the sub-floor structure (as seen in the photos above, taken in July 2009). The individual sections are glued together and then bolts added, countersunk into the top surface with nuts and washers underneath.The next task (later in July, seen in the first photo below) was to loose-fit the floor boards to give a platform to work on to assemble the body frame.
In addition, the "greenhouse" up to this point only had doors on the end large enough to enable the underframe to be shunted in and out. With the impending erection of the body, the end had to be modified to create a larger pair of doors, as seen below.
There was some delay after this as the body framework needed some more attention and several trail assemblies before it could finally be fitted to the base. Once all the pieces of the jigsaw fitted, as seen in the photo on the right mastic was applied to joints (in place of the white lead paste that would originally have been used) and the assembly finally put together for one last time.Next the roof hoops were fitted, each having to be adjusted individually to give a straight roof line. The four knee brackets which hold the sides to the base were fitted and adjusted to make the sides vertical. Brackets were then fitted between the door and corner posts and the bottom rails.
The photos below, taken on 10th December show most of the hoops aligned. Some however cannot be fixed until after the internal timber cladding has been fitted.
Finally, as seen on the left and below, on Christmas Eve the first of the outer panels were fitted. These are cut from ply, and painted before fitting. We're pleased to find that the 8x4 sheets of ply are a slightly larger metric equivalent, which enables much more economical use of material with less waste, since the panels are just the wrong sizes to come out of sheets that are exactly 8' x 4'.The other photo is of the new wheel sets and the old one which was used as a pattern. The new ones are Southern Railway disc wheels which have been pressed onto new axles, machined to suit the LBSCR bearings and axle-boxes.
(Report and photos thanks to Jim Hewett)
Following the repairs to the underframe detailed in the previous report, the main effort was switched to the body of the van. During the summer of 2008 the base frame for the body was repaired and renewed as necessary. All the outside rails were renewed, the side rails each having to be fabricated from four pieces of timber which will be glued and bolted together when fitted to the underframe. There was a trial assembly of the base frame towards the end of summer 2008 (photo above left). The second photo above shows how the bottom side rails are bolted together.Work then commenced on the repair of all the body frame sections and that continued until mid 2009. In the meantime the new bottom rails had been prepared to accept the body frame sections. By May 2009 enough work had been done to trial assemble the whole body framework on the workshop floor (photo below) but this produced a further list of jobs to be done before the body was ready for assembly on the underframe. This occupied the team up to the end of June.
Interestingly, during restoration it was noticed that there were numbers stamped into the door pillars (second photo below) which probably refer to folding shelves as there is evidence of hinges being fitted close by. It is hoped to restore this feature.
New wheels and axles are required and on 24 June 2009 the underframe was lifted using the new electric jacks to remove the centre wheelset which was sent away as a pattern for the axles. This was the first use of the jacks, but their use on heavier loads must await construction of the proper jacking pads alongside the track between the pit and 270's plastic home.Some work has been done to restore the vacuum brakes and parts have been acquired to add air brakes also.
(Report and photos thanks to Jim Hewett)
The underframe was then stripped down, and repairs made to the ends of the timber solebars, and both headstocks replaced. The most expensive part so far has been replacement of the steel flitch-plates along the outside of the underframe, requiring many holes drilled in precise places. The inner flitch plates, shorter sections, were in better condition and have been repaired as necessary and refitted.
Since the photo above was taken in March, the progress has been on two fronts; one team is refitting and adapting the brakes for a dual vacuum/air system whilst another team is preparing timber for the base of the body.
Above left: The van in the course of being dismantled (March 2007)
Above right: The underframe after removal of the body, about to be lifted from its wheels (July 2007) (Photos: Jim Hewett)
Above left: The van's underframe - this photo shows the generally good condition of the underframe timbers (May 2007)
Above right: The solebars stripped of all brake gear, with the wheels removed (July 2007)
Below left: The new ends grafted onto the solebars (Nov 2007)
Below right: The new steel flitch plates drilled and ready for cleaning, painting and fitting (Jan 2008) (Photos: Dave Clarke)
The photos below show that the doors and external panelling have been removed, and that much of the internal planking has also been numbered up, and some of that removed.
Over the last few months the framework of the temporary building which is to house the van during its overhaul has been completed. It still awaits its external covering, but work has started on the van itself, which is still under its tarpaulin.
The Thursday Gang have removed the external doors and cleared the interior. As much evidence about the van's history as possible is being gathered whilst dismantling of the interior starts.
Funding for the project is provided thanks to a bequest left to the Bluebell Railway Trust for that specific purpose.
Last updated 2 January 2010 by Richard Salmon