Toplight Coach Group at the Swindon and Cricklade Steam Railway

GWR 7545 Toplight Coach Group News

Mar 2006

by James Faulkner

Since the last report, work has been continuing on the frame repairs including two of the worst rotten parts of the coach around the toilet area and bay 6, Both had very badly rotted because there has been no glass in the window whilst the coach had been stored outside, but have been fully repaired by patching and using completely new material.
We have also fitted some more of the Bolection window mouldings and will be ordering some more in the near future from Peter Milnes.

Ken Hapgood has been making and fitting mouldings for the coach end and a section of one side. These have been made from Utile or Brazilian Mahogany which we usually buy in planks 1.5" inch thick and then cut on the circular saw into rough panels, which are then fed through the thicknesser so that the panels are smooth and exactly 3/8" thick.

The straight pieces of moulding are just cut using the circular saw and then the rounded edge is put on using the router table, but for shaped sections we first need to carefully mark out and make a pattern the correct size and shape from plywood or MDF approx 3/8" thick. We try and use an original moulding (or impression on the old body panels) that have been saved to make sure the pattern is the same. The pattern is then pinned on the utile panel using panel pins cut off so they don't stick completely through. The pattern also ensures that the mouldings are the same on each section of the body.

The next step is to roughly cut round the pattern on the band saw leaving a bit spare, so the pattern and the finished moulding a pinned together in a sandwich. The moulding is then trimmed all the way round, flush with the pattern on the router table using a straight cutter that has a small ball bearing race on the end.
The ball bearing race is the same diameter as the cutter and so the ball bearing follows round the pattern and the cutter cuts the moulding so that it ends up exact the same size as the pattern.
The final step is to use a rounded cutter again with a ball bearing race on, this cuts the moulding so it has rounded edges. Sometimes mistakes are made or the wood will split across the grain so this means you have to have another go!

Once made, we carefully draw lines in pencil on the coach body so the mouldings will line up and then the moulding is pinned onto the body using panel pins spaced approx 1 inch apart. These are then punched below the surface and filled. We tried using polysulphide sealant under the mouldings but this proved to be a bit too hard so we have reverted to the traditional putty and linseed oil, often old lead paint was originally mixed with putty.
Once the corner/shaped mouldings have been pinned on then the straight pieces are carefully cut to fit in between and are very slightly longer then necessary so they can be bent and "sprung" into place between the corner mouldings ensuring a tight fit with no gaps.

Incidentally Ken was first putting mouldings on Toplights and Clerestory roof vehicles (nicknamed "Top Deckers") when he was doing his apprenticeship in Swindon works in the1950s. At the time they were still being repaired for accident damage etc and you could go to a rack and just pick up finished mouldings already pre-made to each type, ready for fitting. It helps having someone who has done it before to show you what to do.

Congratulations for Andrew Creasor, he has been busy, first he has recently "created" a new son, We know what you've been up to! Do I need to explain why the new son is called Thomas?
Anyway apart from this he has been busy making new panels for the inside of the top of the doors, using a combination of original and new bits, The panels originally contained an advert for luncheon baskets and we shall have to get some new ones printed at some stage, The advert was originally covered with glass, but for the restored ones acrylic is being used instead so it won't crack.

Andrew has also been working on four interior panels for the two first class compartments. These hold the luggage rack brackets and compartment pictures. They are made from American Walnut and would have had a gold leaf band which partly survives. We had two originals in the one surviving compartment, one of which had had some chunks cut out in departmental days, which have been restored and the other two have been made from scratch, again with the exposed sections made from American Walnut.

Andrew, Nick Bailey and Tony Davies have also started dismantling the frame, removing windows and doors on the compartment side of the coach, in preparation for the frame repairs which will be started soon.

Mike Bradley has been working on the battery box supports, getting new sections welded in where they had corroded. These straps are entirely surrounded by Tufnell blocks and washers so they are completely electrically isolated from the rest of the chassis.
He has got some new Tufnell to make some replacements for some of the washers and blocks that are damaged.

Mike has also be removing, painting and then replacing some other parts off the chassis, including the vacuum pipes, There is still lots of needle gunning to be done, any volunteers ?

Richard Wade has been working on the toilet Bolection moulding, getting it to fit.

I have been working on panelling, frame repairs, and have also refitted the restored door number 5 which was restored earlier.

Nick Bailey has been putting in the preparation for obtaining grants for the restoration of a 4 wheel grounded body that has been at Blunsdon on the SCR for some time. We believe this to be a Taff Vale Railway body, A BR CCT van has been purchased as a possible chassis donor and has recently arrived at the Swindon and Cricklade.

He has also been offered by a local farmer a 6 wheel passenger brake body which is also definitely ex Taff Vale, we know the number to be 277 which was condemned at Swindon works in 1934 and there is no other like it which has survived, again a 6 wheel chassis has been identified for this which may be suitable.
If these projects get the required funding to go ahead then they will both be owned by the Swindon and Cricklade Railway itself and restoration and modification of the chassis's will be carried out by an outside contractor. I will probably write a separate web page giving details and photos in the near future.

Fancy getting involved? Much of the work is easy such as sanding and varnishing, wire brushing etc. We would desperately like it for more people to get involved as the main limiting factor in any of this is a shortage of skilled volunteers. You can contact us James Faulkner Tel 07715 322241 or email James75452000@yahoo.com or Nick Bailey on (01242) 604522.


	GWR 7545 Toplight Coach Group News Mar 2006 by James Faulkner Since the last report, work has been continuing on the frame repairs including two of the worst rotten parts of the coach around the toilet area and bay 6, Both had very badly rotted because there has been no glass in the window whilst the coach had been stored outside, but have been fully repaired by patching and using completely new material. We have also fitted some more of the Bolection window mouldings and will be ordering some more in the near future from Peter Milnes. Ken Hapgood has been making and fitting mouldings for the coach end and a section of one side. These have been made from Utile or Brazilian Mahogany which we usually buy in planks 1.5" inch thick and then cut on the circular saw into rough panels, which are then fed through the thicknesser so that the panels are smooth and exactly 3/8" thick. The straight pieces of moulding are just cut using the circular saw and then the rounded edge is put on using the router table, but for shaped sections we first need to carefully mark out and make a pattern the correct size and shape from plywood or MDF approx 3/8" thick. We try and use an original moulding (or impression on the old body panels) that have been saved to make sure the pattern is the same. The pattern is then pinned on the utile panel using panel pins cut off so they don't stick completely through. The pattern also ensures that the mouldings are the same on each section of the body. The next step is to roughly cut round the pattern on the band saw leaving a bit spare, so the pattern and the finished moulding a pinned together in a sandwich. The moulding is then trimmed all the way round, flush with the pattern on the router table using a straight cutter that has a small ball bearing race on the end. The ball bearing race is the same diameter as the cutter and so the ball bearing follows round the pattern and the cutter cuts the moulding so that it ends up exact the same size as the pattern. The final step is to use a rounded cutter again with a ball bearing race on, this cuts the moulding so it has rounded edges. Sometimes mistakes are made or the wood will split across the grain so this means you have to have another go! Once made, we carefully draw lines in pencil on the coach body so the mouldings will line up and then the moulding is pinned onto the body using panel pins spaced approx 1 inch apart. These are then punched below the surface and filled. We tried using polysulphide sealant under the mouldings but this proved to be a bit too hard so we have reverted to the traditional putty and linseed oil, often old lead paint was originally mixed with putty. Once the corner/shaped mouldings have been pinned on then the straight pieces are carefully cut to fit in between and are very slightly longer then necessary so they can be bent and "sprung" into place between the corner mouldings ensuring a tight fit with no gaps. Incidentally Ken was first putting mouldings on Toplights and Clerestory roof vehicles (nicknamed "Top Deckers") when he was doing his apprenticeship in Swindon works in the1950s. At the time they were still being repaired for accident damage etc and you could go to a rack and just pick up finished mouldings already pre-made to each type, ready for fitting. It helps having someone who has done it before to show you what to do. Congratulations for Andrew Creasor, he has been busy, first he has recently "created" a new son, We know what you've been up to! Do I need to explain why the new son is called Thomas? Anyway apart from this he has been busy making new panels for the inside of the top of the doors, using a combination of original and new bits, The panels originally contained an advert for luncheon baskets and we shall have to get some new ones printed at some stage, The advert was originally covered with glass, but for the restored ones acrylic is being used instead so it won't crack. Andrew has also been working on four interior panels for the two first class compartments. These hold the luggage rack brackets and compartment pictures. They are made from American Walnut and would have had a gold leaf band which partly survives. We had two originals in the one surviving compartment, one of which had had some chunks cut out in departmental days, which have been restored and the other two have been made from scratch, again with the exposed sections made from American Walnut. Andrew, Nick Bailey and Tony Davies have also started dismantling the frame, removing windows and doors on the compartment side of the coach, in preparation for the frame repairs which will be started soon. Mike Bradley has been working on the battery box supports, getting new sections welded in where they had corroded. These straps are entirely surrounded by Tufnell blocks and washers so they are completely electrically isolated from the rest of the chassis. He has got some new Tufnell to make some replacements for some of the washers and blocks that are damaged. Mike has also be removing, painting and then replacing some other parts off the chassis, including the vacuum pipes, There is still lots of needle gunning to be done, any volunteers ? Richard Wade has been working on the toilet Bolection moulding, getting it to fit. I have been working on panelling, frame repairs, and have also refitted the restored door number 5 which was restored earlier. Nick Bailey has been putting in the preparation for obtaining grants for the restoration of a 4 wheel grounded body that has been at Blunsdon on the SCR for some time. We believe this to be a Taff Vale Railway body, A BR CCT van has been purchased as a possible chassis donor and has recently arrived at the Swindon and Cricklade. He has also been offered by a local farmer a 6 wheel passenger brake body which is also definitely ex Taff Vale, we know the number to be 277 which was condemned at Swindon works in 1934 and there is no other like it which has survived, again a 6 wheel chassis has been identified for this which may be suitable. If these projects get the required funding to go ahead then they will both be owned by the Swindon and Cricklade Railway itself and restoration and modification of the chassis's will be carried out by an outside contractor. I will probably write a separate web page giving details and photos in the near future. Fancy getting involved? Much of the work is easy such as sanding and varnishing, wire brushing etc. We would desperately like it for more people to get involved as the main limiting factor in any of this is a shortage of skilled volunteers. You can contact us James Faulkner Tel 07715 322241 or email James75452000@yahoo.com or Nick Bailey on (01242) 604522.