Saturday 24th - Bending metal

 A very busy day on the trains, which was great to see. More passengers hopefully means a healthy bottom line.

In the works it was equally busy. After a bit of a practice last week, and a slightly more heavily engineered jig, John, James and Andy got going straight away on the new plan for bending new handrails for the Mica.

A substantially chunkier piece of plate to hold everything on, James temporarily welds it to the trestles so it's rock solid.

Rather than pegs this time we went with slivers of 2 inch tube to help give a smoother radius. James applies the heat, the top bend has already been done by Andy, now to the main arc with John doing the pushing.

And the final result! As the warning notice says, it's a bit hot! But a nice smooth handrail, well done chaps. All 4 were bent up to this stage. Next week there's a joggle in another plane to do to take the handrails over the end vents, then a tight loop and sharp right hand bend at each end for the terminations.

On the wagon itself Paul did a bit more chiselling to the old wooden corner posts so our new planks will fit snugly behind the steel corners. We just need to sort out holes for the end steps then we should be able to plank this lot.

SO 4790 is virtually ready for top coat now; Phil and Martin sanded down the last of the undercoat in 320 grit in readiness, along with a few bits of final undercoating that had been left behind.

Robert went round doing more minor woodwork repairs, a pleased look of satisfaction as the bottom of this door is now fixed to the rest of it again.

With the major sanding done Paul did a vacuum round inside. Any more sanding we're under strict instructions to keep the windows shut!

The FK is seeing some concerted activity on the door front which is good. Hopefully this will be about ready to finish painting by the time we've finished 4790 in a few weeks?... Anyway, Ben and Dave get to grips with the capping strip on the Cotswold side at the South end...

And at the North end.

Also at the South end Dave was doing some painting in readiness for Ken to finish off the corridor connection.

I popped into upholstery quite early today along with Andy and didn't get a chance to visit again, as they exclaimed when I walked in "We haven't got started yet!" Sorry! Looks like DFR seats were the order of the day for Laura and Helen. 

Last but not least (or saving the best 'til last?!) the RBr. I had to have a wry smile at the comment on the previous post about the RBr being a 'labour of love'. Well, labour of something anyway... Chris is removing the middle hinges on the pelmets, for some reason they weren't quite swinging right, and 3 hinges with 6 screws each is a bit overkill for a small plank of wood anyway.

Pam was back inside the servery with more varnish on the oak beading.

Dave went round fitting the now painted footboards.

And Dave captured Pam putting a final coat of black on after fitting.

Thursday 22nd - Busy and varied

In a recent comment from one of our readers the question was asked, "What is the purpose of the skids". A separate article "Skids and how we use them" immediately follows this post.

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Another busy and varied day with 18 attending.

Many thanks to Paul W. for two photos taken in BCK 21272.

Following on from the aforementioned article on the skids, inside 1675's pantry Phil, Nicole and Richard I review the connecting up of the water heater to the water pump, steriliser and filter.

Richard II updating the folder holding all the electrical records for 1675.

Inside the control panel for the lighting throughout 1675.

The water heater skid now connected.

Phil setting up more pipe connections for 1675.

Meanwhile Richard II was building the gland plate for the main in and out cables in the main control panel located in the electrical cupboard at the south end of 1675.

Robert attaches the final bit of window frame in the servery.

The pile of 1675's cleaned up heating pipe covers thankfully now far exceeds the pile awaiting to be done. 

Moving on to progress with SO 4790, many of the windows needed some fresh sealant, something made more obvious when the cream undercoat has been put on. Martin begins the job on the Cotswold side of the coach.

Alex tidying up some of the bodywork at the north end on the opposite side.

Bob progressed with the first top coating along the Cotswold side of the roof and completed it. 

At the south end of 4790 Robert retests the fitting of the new back panel which Alex varnished late on Tuesday.

Job done - that's better. A rub down with 240 paper and a second coat of varnish, and a top up of the black paint on the door lock, will finish it off nicely.

A final shot at the end of the day. It's all coming along well.

Into the Barn where at the south end of FK 13326 Dave is fitting a new section of capping strip on the new door liner fitted the day before by Ainsley.

On board BCK 21272 Paul and Dennis were doing more internal cleaning.

[Photo : Paul W]  In one of the First Class compartments Dave and Paul were refitting loose carpet under the table. Aluminium strips along each seat base hold the carpet in place.

[Photo : Paul W] Aluminium carpet strips have also been fitted in two or three places across the corridor to prevent raw edges being kicked up when 21272 becomes operational.

In RMB 1808 Roger and Alan continue internal window frame repairs, trial fitting a base section.

Later in the day I stained the prepared section  using the same dye as used recently on the window sections for 4798, one of which I placed next to it. The new piece compares well, especially with a coat of varnish just applied.

Derek enjoys the better weather while doing the seemingly endless repairs to the planking on the Monster van.

With the vacuum pump chugging away, Stu tests the working of this vacuum cylinder. We keep a supply ready in a fit-to-use condition so that they can be immediately available to replace any that become faulty.

2807 steams into Winchcombe Station.

Skids and how we use them

SKIDS AND HOW WE USE THEM

In a comment from one of our readers was the question "What is the purpose of the skids?". So here is the answer and how we are using the two skids as set up in the restaurant/buffet coach RBr 1675.

Many thanks to our electricians Richard I and Richard II for the following information.

A skid is basically a framework on castors which enables it to be pulled out for easy access to its contents when maintenance or upgrading is required.

The two skids in 1675 have been included to support physically the heaters for the pantry and kitchen.

The large skid was originally intended to house the water heater and pump/filter/steriliser in the pantry area, whilst the small skid is for the water heater in the kitchen area.

Since orginally constructed the large skid has been cut into two. The bit that contains the pump, filter and steriliser does not need to move and so this half has been "de-castorised". The other half containing the water heater is now in effect like the small skid.

The water heaters need to be accessed easily so as to be able to change the heating element or thermostat, or simply for general maintenance.

The temperature of the heaters will be pre-set to either hand wash or pot wash pending their position. Mains supply to each will be applied during the night time, with additional manually selected back-up through the inverter from either the battery or LPG generator as required during daytime running.

The small skid awaiting fitting

Under the kitchen sink where the small skid will be connected

The cut off part of the original large skid which is now in permanent position with castors removed

The remaining part of the large skid - sawn off to enable independence from the plumbed in part.

Wednesday 21st - A slow start

 It was a slow start, with a bit of inter team conversation. Eventually it all started to happen …..

Not so in upholstery, Eve is cutting foam for the seats for 4798 .....

.... and Laura is cutting the moquette for 4798 seats.

Ainsley is all smiles, in hand a door liner which he has had to adapt for a rather troublesome door fit.

Steve was asked to make a frame for another department, here he is measuring ready for cutting.

Then tack welded ....

Very happy John and Steve, both busy with bench work.

Simon is making precise fitting panels for vestibules on 13326.

Rex is on holiday, so Bryan has progressed with 4798 windows, he has measured some new bolts and I welded captive nuts on.......

Bob put down the paintbrush and joined in with Bryan.

Ben and Dave are discussing positioning of a capping strip on 4798.

..... Stuart is checking all is good.

Ken is working on a vacuum brake cylinder.

A quick flashback to 4798, the window frame in position.

and finally Alex is applying undercoat to 4790, at least I think it is undercoat ( I am not a painter ).

[Yes, it is - undercoat Madder. Dave C]

Many thanks to Gerry for the photos.