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M30272M - Overhauling the body - Rebuilding the apparatus end (2003)

The body brackets being painted in the "Channel Green" topcoat1st January 2003

The four body brackets that have been removed from the apparatus end of the coach are now being painted in the "channel green" colour scheme that was used on the inside of the coach. Here the brackets are seen just after painting.

The body brackets back on the coach (temporarily)29th March 2003

Two of the four brackets can be seen after being placed back on the coach. These will be temporarily removed soon so that the cross members can be installed along with the wooden planks behind the brackets.

The wood for the corridor end awaiting repairThe wood for the corridor end of the coach was located today and checked over. Three sections require replacement and this wood will be ordered for delivery before the first week in May when the corridor end is planned to be erected.

The next few weeks will see each section of wood repaired, with paint being removed, nails and screws removed, holes filled using the "glue and sawdust" formula and finally a sanding down.

The wood for the corridor end being repairedHere we see two sections of the wood from the corridor end after they have had the paint removed, nails and screws removed and the holes filled.
The first of the new cross members and end bar in place3rd May 2003

First day of the May Work Week saw some of the cross members and end bar installed on the coach as well as the two lengths of bottomside made into one piece.

The rebuilt corridor end of the coach4th May 2003

Second day of the work week. The morning was spent rebuilding the corridor connector end of the coach 'on the ground', as can be seen in the picture. This was undertaken so that we could be sure that all the parts fitted before it is rebuilt on the coach. A few of the replacement (new) sections were found to be slightly out of true, resulting in some minor adjustments.

Once we were happy with how it all fitted together it was then taken apart again in the reverse order of how it will be rebuilt on the coach. This was done to ensure that we don't run into problems when it goes back on the coach, hopefully tomorrow.

All the bottomsides, cross members in placeDuring the morning Pete Silver continued to work on the bottomside, making it ready to accept the corridor end of the coach. The afternoon saw the whole team move onto the coach chassis to work on various parts of the wooden framing.

By the end of the day all the various sections were placed on the coach to ensure that they all fitted together with no missing bits or misaligned parts. With just a few minor adjustments this was achieved.

Just like the corridor end this has to all come off again to allow other parts to be fitted to the bottomside before it can finally be fixed into position.

The large section of wood underneath the apparatus equipment6th May 2003

Day four of the work week. All the flooring sections are now in place, including the large section where the apparatus equipment goes. This section (shown in lower part of the picture on the left) fitted into place at the first attempt, with no adjustment needed - a great surprise to everyone on the team.

Panels inserted into the new bottomsideSections of the bodywork were installed during the day.
the corridor end framing in placeA view of the corridor end of the coach showing a section of the side framing, the smiles at Wansford had to be seen to be believed!
Repaired apparatus pillar8th May 2003

One of the two 'large' pillars from the apparatus area. This one required a major section to be replaced due to rot; this has resulted in five sections of wood being laminated together to achieve the repair.

The pillar is that large that it is a struggle for two men to lift it, we are just thankful that this item has not had to be replaced.

Apparatus area ready to receive the pillarThe very spot where the above pillar will be located. This is the pillar before the apparatus area of the coach. Note the large section of wood behind the bottomside, this holds yet another large block of wood that has the bedplate bolted to it for the carriage net.

It should also be pointed out that the is a cross member that joins the bottomside at the very point where the mortises for the upright is cut out, making this a weak area of the coach, yet it is an area that takes most of the pounding during an apparatus exchange!

Space for sliding door has been routed outThe door section next to the apparatus area, with a section cut away for the door runner to sit in.
More of the coach sides back in place, including a door pillarMore of the coach sides in place up to and including the door pillar. The area next to the door pillar has sections inserted from the bottomside up to the first 'rail', this is where one of the lights is located on the side of the coach and one of the traductor arms is fitted.
The apparatus area starts to take shape9th May 2003

The apparatus area of the coach starts to take shape.

A closer view of the apparatus areaA closer view of the apparatus area.
Replacement door pillars10th August 2003

A new door pillar is seen on the right and will replace the old one on the left. The original one will be used as a pattern to ensure that the new one is identical.

The apparatus area after rebuilding15th September 2003

The apparatus area after rebuilding on the Monday of the September work week. Note the new cantrail above the apparatus area.

The base of the apparatus area has a "chunk" of wood that is bolted to the bottomside by five 14inch bolts.

Trial fitting of the new net lever18th September 2003

A trail fitting of the new net lever took place today. While it did not fit into the net lever pivot (center of picture) it did show that all other dimensions were correct.

The apparatus bedplate in position20th September 2003

The apparatus bedplate in position with the arm that passes through to the inside of the coach to connect with the net lever.

The apparatus area after rebuildingThe appratus area at the end of the work week showing the new door pillar on the left.

It is hard to believe that at the beginning of the year this whole area was just a painted chassis.

Overhauling the body - Non apparatus end