Thursday, 29 November 2018

Wednesday - stabilisation

With all seats taken in the mess room we must have 24 in attendance. So between resolving all the issues of the world except Brexit we got a lot done.

Despite there being 24 of us John Hill was the  lone member of the upholstery team in and while he claimed to be making some new head rest pads we have a sneaky feeling he was just practicing ready for the turkey at Christmas.

The last 2 thresholds were cut prepared and put in place on 21092. so the floor re-laying can now be completed.

at the north end of the carriage David was preparing and painting the gangway door.


Back in the woodwork shop Colin was busy making several other wood sections most pof these for 34929's new windows.

They were soon in the paintshop for a protective coat of varnish although I think they will need some colouring to a darker shade in the next coat.

A little warning message in case we get carried away painting these window sliders there are some springs and guide clips need fitting. The bottom springs are missing here

while this has a broken guide strip.


With more painters than usual in on a Wednesday we took the opportunity to get a fist top coat on many of the window frames on 4986. We don't usually do this in the workshop these days but there wasn't any serious sanding or dust creation going on so we could.

Craig was sorting out a rebate on the door 1 of 4986 for the capping strip to go back on while was doing something similar on door 6.

In the woodwork shop again here Paul and elsewhere Mike were fitting the panelling to some of the doors.

In the past if you had been working in the barn at this time of year you would have been off your trolley. However, since the roller shutters went up things are notably different. Its still chilly but the driving rain and wind are firmly shut out and its not bad to work on a platform trolley in there now.

Ken was also in the barn cleaning the threads on the gangway connector studs. This one will go onto the north end of 21092 when complete.

So just why was 4867, the newly arrived TSO shunted into the barn? We knew the crash pillars had been cut out at for replacement at the south end of the carriage before it came to us. A carful inspection showed signed the roof at that end was sagging. Hence both toilet windows were broken.

So the first after further inspections and and some careful measurements by Nick and Ken the end was jacked up by over 20mm to re-establish the correct height.

Nick then set about our usual repairs an new base plat, being cut here.

While Gerry and on the other side John Varley cut out the outside ends of the old base plate


More double checks later, the new base plate and crash pillars sections were welded in place as were the first side rigger bars,


on both outer corners. The centre section and centre pillars will be prepared for repairs next week. This carriage is going nowhere until the end has been totally stabilised!

Tuesday - Whoops

Before we get to Tuesday those wide awake followers with have noticed there is no post for Saturday!

As both I and Dave were involved in meetings for most of the day we left everybody else to get on with it and we didn't take any pictures either. So you may have to guess at what was done on Saturday by spotting great leaps forward in progress and the positioning of things in the workshops.

and so to Tuesday.


With 15 names signed in, now a typical number for the attendance on a Tuesday (even with 3 away), we made some good progress as well a wonderful blooper!

Beginning with the second GWR trolley which is now well underway. With dowels being inserted, Derek was soon gluing the base frame together.

Into the Barn with Bob Mac stripping off loose roof paint and clearing out the gutters on TSO 4867. Full gutters mean rainwater pouring down the sides, so we need to keep them clear as far as possible.

(did you spot something from Saturday? - yes this carriage got shunted into the work)

The Malvern side centre door was a trial to open, but liberal use of WD 40 was enough to free it. Obviously this will be attended to properly when the coach eventually comes in for its full restoration.

I missed Richard Stone and Dennis working on the LNWR van, but the roof is now completely stripped of the old planking (now neatly laid out in the skip). Some of the beams are not securely clamped at the sides and it is likely that this caused loose fixings which penetrated the canvas, which in turn helped to cause the leakage problem.


Great to have the trestles back for all the odds and ends for painting and varnishing. John gives a second top coat to some sliders from BSK 34929.

TSO 4986 further progresses with Ainsley undercoating more of the Malvern side.

While Pat completes the black glossing of the north end of the coach. Once the capping strip is on we will tape up that end of the coach ready for the cream and brown undercoat on the green primed corner section.

Second top coating on BCK 21092 with Cheryl, Stu and Richard Hoy painting well. While the Paintshop was nice and cosy, it was very cold outside with a biting wind, hence the woolly hat on Cheryl.


At the north end Richard Fairhurst was repairing the bottom of the corridor connection sliding door. The door will now have a good sand down and coat of undercoat cream.

It was a very different story at the south end with the sliding door sticking badly. Dennis lifted off the door and then removed the metal strip for cleaning up. The boarding underneath was also improved.

Various other tweeks were made and the result was a nicely sliding door. This will also need a repaint.

The corridor ceiling was half top coated by John. When completed all the ceilings will have painted.


Guards doors are always a pain when painting because they open inwards, and it's easy to see why this happened. Both the line taping and painting were no doubt done from the inside with the door open so it wasn't obvious that the line position was out. Give it a few days to harden and we will gently sand out the incorrect area, apply new tape in the correct position, and then repaint.

Report by Dave Clark

Thursday - Hot and cold

With 19 in we were as usual scattered about with plenty going on outside on an initially very chilly day. The contrast between this and the Paintshop was quite marked!

 It was nice in the sun, but a different matter if you were working in the shade. The Maroon Rake has been partially pulled out of the platform to allow access for battery changing .

Richard Bates fitting one of the new gel batteries to RMB 1876.

The big chunk of filler that fell off the corner of BSK 35308 was forever being mentioned to me. The split bits both above and below were also dug out, the whole lot sanded and then coated in red oxide.

Although very cold, both the red oxide and subsequent layers of filler soon dried, and the result was painted in undercoat Madder. It certainly stands out now, but another dry working day should see this top coated and then lined out.

Good to get back into the warm Paintshop to find Jeff enjoying some white lettering at the north end of BCK 21092. Alex will be wishing he was here instead!.

A nice bit of teamwork beginning with Rob plasma cutting a strip of heavy grade metal sheet in the Workshop..

This was destined to be the new threshold base plate for the north end passenger doorway on the Malvern side of 21092. Nick and John Varley plan the next step.

Gerry steps in to clean up a bit more of the area.

All is as good as can be leaving Nick to weld in the new piece.

The completed job ready for the fitting of the new wooden threshold

With the white lettering completed Jeff removes the old carpet from the disabled (former luggage) area of the coach.

He is later found sorting out more of the weird striations shown up by the gloss painting on the north end of the coach by carefully rubbing in filler. When initially coming to the Railway, 21092 was covered with these, particularly on the Cotswold side which resulted in most of the paintwork being removed and a fresh start being made. The Malvern side wasn't as bad, while it looks as though the ones here escaped our notice until painted.

More ceiling top coating care of Bob K. I think just the corridor is left to do. At first we thought we could leave these as they didn't look too bad, but as usual a closer look soon changed our minds. Once done the difference is very obvious.

Richard Hoy spent the day on the gutter level panel around the whole coach, initially giving a light sand before applying the second top coat to most of the Cotswold side.

Pat and Alan staining and then varnishing internal window framing for 21092. Oh have we missed the paint trestles - it's good to have them back


Bob back on varnishing and being a professional painter for over 50 years what a super job he does. I think these are from TSO 4986.


I later found him in the north end vestibule of 4986, top coating the ceiling.

 In the centre vestibule Bob Slater was stripping off the old varnish.

Ainsley was back on the Malvern side of the coach sorting out more areas needing filling. The undercoated centre panels show the progress on this side. It won't be long before this is also fully undercoated as far as currently possible

Pat Cleary worked on the north end of 4986, initially cleaning up the various parts before giving everything a coat of undercoat dark grey.

Derek applies glue to one of the two heavy planks that will be for the rear axle of I believe the second GWR trolley that will be made.

Clamped up to dry. This will then be cut to shape.

Finally a much needed tidy up of the metal working area. Well done John and Rob!
Report by Dave Clark