24 February 2018

COMPLETION SPECIAL: Mark 1 Covered Carriage Truck E94464


Our "Completion Special" updates are normally reserved for the completion of Gold standard overhauls, however an exception is being made for E94464 as it has spent over ten years out of passenger service, and also because whilst it was originally brought in for a Bronze overhaul, most areas of the vehicle have in fact received a Silver level of work, with some even getting Gold treatment.

E94464 is one of two Covered Carriage Trucks (CCT) owned and operated by the North Norfolk Railway. It is part of the British Railways standard Mark 1 family, but is unlike most other Mark 1 variants in many ways. Weighing 17 tons, it is a short vehicle on a fixed 4-wheeled chassis and has no accommodation for passengers. Instead there is a large open area inside for any goods or parcel traffic that may be required to be stowed. Access is either through one of the four sets of double opening doors in the bodysides, or through either end of the vehicle which is equipped with wooden folding doors and a tail gate which can be hinged down over the buffers. This latter feature allowed road cars to be driven into the vehicle at one end and along a train of similar vehicles, much in the way that the Channel Tunnel shuttle services operate today.  E94464 was originally built with folding shelves along the walls, these could be stowed upwards if cars etc were being carried, or folded down to provide additional storage for smaller packages if required. These tables were later removed but it is not known if this was done in British Rail days or by NNR volunteers. Three windows each side allow light into the vehicle, with electric lighting also being fitted. E94464 is roughly in the middle of a huge production run of 923 CCT vehicles built between 1959 and 1961 at British Railway's Earlestown works, being supplied to the Midland, Eastern and Western regions. Many were later transferred to the Southern region, with only the Scottish region having nothing to do with them. As the prefix to the number suggests, E94464 was one of 120 CCT's originally built for the Eastern region.

E94464 rolled off the production line in 1960 finished in lined out British Railway's maroon livery. being the tenth CCT delivered to the Eastern region. It was immediately put to work operating mixed goods and parcels trains as required. It's vacuum braking system and comparability with passenger stock would have also allowed the vehicle to be attached to passenger trains as well to provide extra goods accommodation. We have no records of E94464's exact allocations or travels, but there is no doubt it would have toured the country in the course of its duties. During the late 1960's/early 1970's, E94464 was repainted into BR's new corporate blue livery, losing its lining in the process.

A few odd CCT vehicles were taken out of service in the 1970's, however the 1980's were to prove disastrous for the type. From 1981 onwards, CCT's were withdrawn in their hundreds, with only a handful surviving beyond 1985. The last vehicle remaining was recorded as being withdrawn in October 1989. E94464 was one of the earlier casualties, being taken out of use in April 1981. The reasons for withdrawal en-masse are thought to be a general decline in parcel traffic on the railways and an increasing move away from older designs of stock with 4-wheeled chassis and vacuum brakes.

E94464 was not to rest for long however, being purchased by the North Norfolk Railway later that year (1981) and transported to Sheringham to begin a new life in "working retirement". CCT's were useful as multi purpose vehicles on growing heritage railways, the NNR being no exception, and E94464 was useful as both a stores van and workshop area. A whopping 74 CCT's were transferred into preservation in total! In the 1990's the vehicle was semi-permanently attached to one end of the Carriage & Wagon tent at Weybourne, and the remains of the brackets on the end of the vehicle remain to this day as a small reminder as to its previous occupation.


By the time of the early 2000's, E94464 had been in NNR ownership for the same number of years than it had been BR. This period was also to see E94464's return to regular service. A new cycling initiative was being pursued by the railway, and two CCT vehicles were attached to the Sheringham ends of the two main summer service sets of Mark 1 vehicles. However resources were limited and E94464 had deteriorated during its time as a static store. It was quickly revived and repainted into a plan (unlined) maroon colour and put into service. E94464 then operated for approximately five years running every day there was two Mark 1 sets in service, carrying bicycles and buggies as required.


Further deterioration to the doors and running gear led to E94464 being withdrawn from service once again in the mid 2000's (its place being taken by suburban brake E43357) and it was stored at Sheringham where it was used again as a store for the commercial/events department.


The vehicle lay at Sheringham for the best part of ten years until a change of circumstances brought it "back into the fold". The catalyst was the Suburban 4 project which saw four of the railway's suburbans restored to a high standard and removed from normal services to be formed as a special set in their own right. This resulted in suburban brake E43357 being lost from the main service trains, leaving the railway short of a bike carrying vehicle. As a short term measure, the M&GN Society's "Fruit D" goods van was borrowed to serve as a replacement, however after two summers it became apparent that the level of use was proving unsuitable to the wooden bodied Fruit D. A replacement was needed urgently. Early suggestions included securing another CCT from a heritage railway, however given the level of work required on a new vehicle to make it suitable for passenger services, it was decided that E94464 was the best option as it was a (reasonably) known quantity.

Brought into the workshops in July 2017, the underneath required lubrication, springing adjustment and repainting. The body was to prove much more troublesome, with terminal corrosion present in much of the vehicle. There were riveted patches all over it, and unable to dedicate too much labour to it, we had to make a decision what was to be tackled and what was to be re-patched. It was decided to keep all of the patches along the bottom edge of the vehicle, with everything above that being repaired. This included the complete rebuilding of all six of the window bottoms which had completely wasted away through window leaks over the years.


We returned all of the original features to the bodysides, including the prominent wooden destination chalk boards, such a feature of these vehicles. The wooden end doors had rotted badly so were fully rebuilt and partially replaced. They were also made to work again so it would now technically be possible to drive vintage cars once again into the vehicle! A full repaint, for the first time back into as-built fully lined and lettered maroon livery, finished off the outside.


The inside was sanded down, repaired where required and repainted into original freight brown colours. The ceiling had badly bowed with water damage so had to be teared down and completely replaced. The floor was de-pot-holed and also repainted.


February 2018, seven months after the start of the project, saw E94464 released back into service. It is hoped that this vehicle can join the main set (or "A set") of coaches which generally sees service seven days a week and which is enjoyed by the vast majority of our visitors.


Great Eastern Railway 1899 4 Wheel Brake Third 853


Sticking with 4-wheeled vehicles, the dramatic transformation of 853 featured last week has continued at a similar pace, with scaffolding being erected around the coach to allow roof work to be tackled.


Up top, the original roof, de-canvassed revealing the original boards below, was vacuumed off leaving a surface on which to work on. Thin plywood panels have been nailed onto the original roof to smoothen out all of the discrepancies, sharp edges and other age-related issues. This creates a better surface for the replacement canvas covering to be bedded down onto.


Other smaller fittings are also being progressed, by those who have no appetite for heights! These have included the fitting of the second emergency chain to the Holt end bufferbeam (used in times gone by in case the main coupling snapped). The upper foot board steps have also been bolted on permanently and are currently in undercoat.

British Railways 1959 Brake Corridor Composite E21224


Progress on all of the fronts discussed last week. Firstly, all of the areas of bare metal are now primed to offer it limited protection for when the coach goes to Bridge Road sheds later this year.


Secondly the store cupboard has moved onto the next coat of paint, a fetching pink primer!


Lastly the flooring repairs are continuing along the corridor now that the compartments are completed. Several replacement square sections have been produced and gloss painted on the backs to protect them once they are finally fitted.

British Railways 1955 Mark 1 Second Open M4372


The release of E94464 of course means we have a new project! 4372 is part of the dining train and is generally in very good condition. Unfortunately the cream paint used on the bodysides has crazed and broken down badly since it has been in service leading to deterioration and unsightly rust streaks. Whilst the underframe and interior require no work whatsoever, the exterior now requires repainting.


Irritatingly the reacted paint means that the cream will need stripping off fully which has been the first task, started this week. Several window fixings have failed so they are going to require stripping, resealing and re-securing. There is a lot of work to do on 4372 and very little time to do it in, so resources are being concentrated intensely in order to complete this one faster. It will be interesting to see over the coming weeks how fast we can move this one forwards using this approach.


British Railways 1959 Tourist Second Open M4843


The end is starting to be in sight for the Sheringham end seaward side corner. Panelwork is now being welded into position, with several complicated corner sections being tackled this week.


British Railways 1958 Class 101 Railcar Driving Motor Brake Second M51188


The railway has hired a Class 101 DMU powercar for the 2018 season to cover for the National Railway Museum (which suffered an engine failure earlier this month) and NNR (overhaul not yet completed) vehicles. It is to be used on services as soon as possible however there are several features which do not meet our service standards. This has included several doors which do not open/shut properly, although hopefully these can be solved with replacement of minor items within the hinges etc. These repairs have been started this week and can hopefully be completed in a couple of days. Other fun discoveries included mushrooms growing in the guards compartment! There is a great deal of damp in this area and two panels have had to be removed as they broke apart when prodded. These are being replaced with new examples.

British Railways 1958 Class 101 Railcar Driving Trailer Second Lavatory M56352


No progress to report.

Southern Railway 1939 Parcels & Miscellaneous Van S1359S


This van was moved from Weybourne to Sheringham at the same time as CCT E94464, so is now officially released from our workshop!


Maintenance


Amazingly, what with all of the other action going on, routine maintenance work has been able to continue. Some of the faults flagged up during C examinations at Sheringham are being tackled. A rotten ceiling from Corridor Second E25189 has been ripped down and a replacement made in the workshop, which is currently being painted. Meanwhile, an overhauled buckeye coupling has been fitted to dining car E1969 after its original was found to be worn.

17 February 2018

February News Part 3

Great Eastern Railway 1899 4 Wheel Brake Third 853


The headline news this week has to be the unification of the body and underframe following 11 months work rebuilding the running gear. The body was carefully jacked up and the completed underframe then rolled underneath. The body was then lowered slightly and carefully aligned onto the rubber pads which sit between the steel chassis and the framework of the body. The following day was spent bolting down the body which pulled it into a flat position, as it had settled to become slightly banana shaped whilst it was a grounded body. It is remarkable to note that this body now has wheels for the first time in 91 years! Quite an achievement for those involved...



British Railways 1959 Brake Corridor Composite E21224


The exterior paint preparation has been completed along the side of the brake/luggage compartment on the seaward side. This is now ready for painting, which will have to be done before the coach goes "on holiday" to Bridge Road sheds whilst the workshops are taken over by the Quad Arts later this year.

Internally, the floor repairs to the second compartment which needed them have been completed, so we now have a full compliment of five compartments with no rotten flooring! The store cupboard has received its first coat of paint, a special primer which is designed to key onto smooth surfaces such as Formica.

British Railways 1959 Tourist Second Open M4843


More metalwork has been completed on the Sheringham corridor end. A start has also been made on removing some of the apparatus on the Holt end corridor ready for welding repairs to start on that end in due course.

British Railways 1958 Class 101 Railcar Driving Trailer Second Lavatory M56352


No progress this week as the vehicle has been in use on February half term services!

British Railways 1960 Covered Carriage Truck E94464



We are nearly there with this one... Signwriting continues on the exterior, there is such a lot of it on this particular vehicle! The black part of the middle (waist height) line has also been applied.


The underframe has received a coat of black gloss finishing it off, and several smaller items have been picked out, including white handbrake handles and red battery charging sockets. Other lettering such as the white stars on the underframe (which show where the brake release chords are located) have also been added. The final underframe task, brake testing, is now in progress and we are currently repairing the several leaks that were found. The steel vacuum pipe had rotted away at the Sheringham end, and various rubber hoses also require changing.


On the inside, the Sheringham end folding doors are now painted in brown to match the rest of the walls, meaning there is now no more work to be done on the side walls. The floor has also received two coats of red floor paint which has transformed its appearance.


The last job now remaining on the interior is to paint the wooden floor boards in the four doorways and then it shall be complete.

Southern Railway 1939 Parcels & Miscellaneous Van S1359S


This has now been out-shopped, but I have yet to get the chance to capture a decent picture of it!

Other Projects


The repairs to the ex-Billericay seat continue. The front legs have received strengthening this week and the new wood has been dyed to match it with the old.

09 February 2018

February News Part 2

This week has been one of finds and treasures! Long term restoration project E21224 yielded no less than three historical finds... Under some paint on a piece of planking was the message "2 bundles - Saltley" which we can only guess was a destination for some materials, perhaps to the depot located there? The second find was more physical but less interesting. Inside the emergency tools cupboard was a fossilised pear, birth date unknown. The joys of restoration!


Finally, and possibly the richest find of all, was an empty pack of "Park Drive" cigarettes which was found inside the empty roof space above the store cupboard (ex toilet). Again this is of unknown vintage, but was a nice find nonetheless. It was certainly better than the previous find that I have personally made when restoring a carriage toilet that hasn't seen "use" since the 1980's - readers with a vivid imagination can probably work out what it was...


Great Eastern Railway 1899 4 Wheel Brake Third 853


The underframe is now almost ready to have its body put back on top of it. All of the brake gear split pins have been added properly now that the brake-gear is all tested as satisfactory. Extra leaks that were identified last week with the vacuum system were also solved. The rubber blocks which the body itself sits on have been attached to the underframe ready to receive the body in due course.


The small end-footboards, also mentioned last week, have been finished having received their top coat of black gloss. Finally, some cosmetic emergency chains to hang from the buffer-beam have been made from various stored/reclaimed items and are being painted.


British Railways 1959 Brake Corridor Composite E21224


Resources are now swinging away from CCT E94464 and back onto this coach, our Gold standard overhaul. The store cupboard reconstruction continues with the shelf brackets produced last week being screwed into position this week. The walls have now been treated ready for painting which involved sanding and also the removal of old glue residue. Also on the interior has been more stripping/sanding/priming of luggage space internal planking.


The compartment under-seat heater grills are now completed, having been painted, and await refitting.


With the CCT on the home straight, some work on the outside of the coach has been completed, although we are limited to the seaward side only as this is the area that has already had its welding repairs completed. The long task of filling and paint preparation has started from the Sheringham end working towards Holt. This is a temporary arrangement which won't be able to be fully completed as when our next project comes in (after the CCT) that will absorb this labour. However until then we can try to get as much of this side progressed as we can.


Further down the same side, nearer the Holt end, the lower skirt has had all of its old rivets drilled out (now surplus to requirements) and the holes welded up. The areas of bare steel were then coated in some primer to offer some protection for when the coach goes on holiday to Bridge Road carriage sheds later this year to make room for the Quad Art set.


British Railways 1959 Tourist Second Open M4843


No progress to report.

British Railways 1958 Class 101 Railcar Driving Trailer Second Lavatory M56352


We just about ran out of time in terms of fully reupholstering this coach before it is needed for the half term running days. However we put in a valiant effort and the vehicle will be in service, just with its seating capacity reduced by six people. We succeeded in fully fitting out the front and the middle (large) saloons with just a few missing from the rear saloon. Those that are fitted of course look excellent with the new material. To prevent any bare frames being present in the rear saloon, two seats were temporarily stolen from the railway's other DMU set to make up the numbers, these will be replaced in due course with the intended blue ones, and it will not be long before the final half dozen seats are fitted properly and the vehicle is fully ready for the season ahead. We see the two green seats as a thrilling "limited edition" which NNR passengers literally only have a few days to get out there and sample! Buy a ticket, get in there and have YOUR picture taken with them!


British Railways 1960 Covered Carriage Truck E94464


This vehicle is accelerating nicely towards the finish line. The exterior is progressing well, with the Sheringham end folding doors now fully fitted and painted on the outside. This is the end of a huge task and we are all pleased that these are now completed. Just the insides of them to paint brown now to match the rest of the vehicle internally. Now that painting is complete, some finishing touches such as polishing the windows and the door handles has also been done.


The completed exterior has been receiving its lining and lettering. So far, the top line has been applied and the black surrounds of the vehicle dimensions and main numbers applied. Towards the end of the week, this allowed the first coat of gold to be added to the main numbers, and the golding of the vehicle dimensions (of which there are many!) is ongoing.


On the interior, the floor compound has now been fully applied into all the gaps and cracks and holes in the floor. It looks odd at the moment but when the floor paint is applied it will all blend in and look much better than it did when we got to it.


In readiness for the final floor painting, the wooden timbers in the doorways have been cleaned up and painted in black undercoat. The small metal chequer plates, also in the doorways, have also been cleaned up.


Southern Railway 1939 Parcels & Miscellaneous Van S1359S


Still awaiting shunting out of the workshops, due next week.

Other Projects


The scheme to add folding lids to the tops of the book trolleys which live in the bookshop on Weybourne station is progressing once again after a break, with the lid construction being finished this week and the new wood painted in primer. Also back in the workshops is the seat donated from Billericay station two years ago, which has sadly broken and is back in for repairs. It is being reinforced along the side and along the front facing bottom edge. It normally lives in the waiting room, also at Weybourne station.

02 February 2018

February News Part 1

A swathe of illness and holidays has swept through the department this week, hindering progress significantly, to the extent that we had to press Monkey into service (see below) "on the tools" where he is normally more happy in a supervisory role!

Great Eastern Railway 1899 4 Wheel Brake Third 853


With the underframe vacuum system approaching completion, a vacuum test was conducted this week. The cylinder and brakework appear to operate normally but the vehicle initially failed its "leak off" test. This is a "right side failure" (not dangerous) in that the vacuum leaks in such a way that the brakes eventually go on. Normally these leaks are undetected as the locomotive constantly creating vacuum overcomes it, however too many in a train leads to an eventual drop and brakes dragging on so it is good practice to have all overhaulled vehicles "vacuum tight" to prevent this from happening. The leaks were accordingly investigated./ So far, a leaking joint in the new pipe and a porus bufferbeam vacuum pipe have both been identified - the porous pipe has been replaced already. This has improved the leaking considerably but there are still some more preventing the vehicle from passing the leak off test despite the registered improvement. These investigations/repairs will therefore continue next week.

As hinted last week, the successful fitting of more foot board supports did indeed allow the boards themselves to be fitted and painted this week. They now just await top coating.


British Railways 1959 Brake Corridor Composite E21224


Interior work on the store cupboard saw several brackets manufactured from scratch which will be screwed to the walls in due course and are intended to hold the shelving which will be fitted. Work on replacement flooring is also progressing well, with the new sections now cut to size and protected in primer. Other tasks that have been mentioned already in previous updates have also moved forwards, namely more interior guards van wooden planking stripped/sanded/painted, more exterior doors stripped of their old paint, and more compartment under-seat heater grills reaching the gloss black paint stage.


We have a good number of volunteers working hard on this coach at present, which is plugging the gap left by paid staffing being tied up exclusively on the other two Mark 1's currently in the workshop, allowing this one to progress. For that we are always grateful!

British Railways 1959 Tourist Second Open M4843


Further reassembly work has been undertaken in the Sheringham end saloon by the weekend team, who are now reaching the home straight with this particular task. A good hoover has made the area look a lot better and its now ready for the final reassembly work and any other sundry tasks now that is is a cleaner area.

British Railways 1958 Class 101 Railcar Driving Trailer Second Lavatory M56352


The end is now in sight for the re-upholstery, which we are doing our best to conclude before the February half term week which is when this vehicle is due back into traffic. We do try and provide coaches in service that actually have seats fitted to them! We had a count up of the number of side trims (we call them "boomerangs" or "hockey sticks" due to their shape) which had fallen off and gotten lost over the years so that new ones could be made. They are quite a simple component, upholstered plywood with some fixing blocks attached to the back, and we were about half a dozen short. Enter Chris - a new volunteer with an interest in woodwork, who spent his first day with us this week. He successfully produced the missing items and these can now be added to the pile for upholstering next week. We hope he enjoyed his day helping us out and look forward to seeing him again, if he chooses to return to us of course!


British Railways 1960 Covered Carriage Truck E94464


The exterior has now had its main bodyside painting concluded, with the application of the second coat of maroon gloss this week.


The resident painter was obviously not fast enough, judging by the intervention of (yes it's true) Carriage & Wagon's new Monkey Hand Puppet, our latest member of staff! We can't work out if he's paid or volunteer yet, but he seems to be cracking on with the brush in any case...


The completion of the painting has allowed other odds-and-sods on the outside to be painted, including the handrails, gutter strip, wagon clips and most prominently, the chalk boards that carry the destinations. We now have the task of fending off the offensive messages and joke destinations which will no doubt be added to the boards by workshop staff with too much time and chalk on their hands!


The end doors have really come on this week as well, with three out of the four folding doors now bolted into position at the Sheringham end. Completion of these and final adjusting and painting is now expected to be achieved next week all being well.


Finally, the interior has seen a good number of cracks and holes in the aging floor filled in with flooring compound. This is a "reasonable improvement" sort of job and is not expected to last forever, however we shall see how it fares in service and it already looks better than the cracks etc which it has replaced. It will also look less stark after the whole floor has been repainted and blended in all the repairs.


Southern Railway 1939 Parcels & Miscellaneous Van S1359S


Now awaiting shunting out of the workshops.