Having decided that the outline drawing in my last post was pretty close to what I wanted to achieve on the Kato bogie chassis, last week I slowly started to gather the materials required to start work. Immediately I was taken back a good few years to the early days of my O9 modelling, finding odd bits here and there that would become something other than their manufacturers intended. One sign of real progress is that some of these parts were actually intended for O9 rather than other scales.
From the spares box came the good side from a pair of Avalon line coach sides that Peter Ledley (of Clee Valley Railway fame) had passed on to me. This was cut either side of the centre door, the solebars removed and the cut ends made good with styrene strip. A pair of Chivers O9 coach ends were cleaned up and spare seat backs from the same source cut down in height to 7.5mm to be used as seat supports.
The floor piece is from 40 thou styrene, 22 x 70 mm with a cut-out for the Kato chassis. Plank lines are scribed on what will become the balcony ends. Solebars were cut from 3.2mm Plastruct channel, actually the second attempt as the originals were 3.2mm deep 60 thou Evergreen strip, but looked too plain and would have been set quite far back behind the Avalon sides. They were re-cut as strip to go above the solebars between the seat ends.
The floor, ends and solebars were assembled, followed by adding the seat end pieces, re-purposed as seat fronts to hide the Kato chassis under the seat. I hesitated adding the pieces planned along the top of the floor between the seat fronts as I realised they might make adding the bulkheads between the balcony and saloon a little more difficult.
After cleaning up, the Avalon Line coach sides were modified by adding a central window divider in each of the windows, using a length of 60 x 40 thou Evergreen strip carefully cut to length and superglued in place. These dividers would align with the bulkhead/partition pieces, which would be scratchbuilt parts. The new dividers were marked out on 20 thou styrene, with 10 x 40 strip used to make the window frames, very much in the manner that the masters for the Avalon coach kit were made (maybe in this case with a little less care...). Once set overnight the windows and lower cutout were cut out, then the pieces cut from the sheet. At this stage the top edges of the 20 thou sheet had been marked out to use a Dundas VoR roof for the project, but as can be seen, the final profile of the 40 thou material backing the parts is rather different...
Which brings us to story of the roof. When I had drawn out my concept drawing I had planned to keep the overall width to that of a Chivers coach kit, which just suited the Dundas roof. When cutting the floor piece and all the other parts that would sit between the sides, I forgot to take into account that the Avalon Line sides are a good 0.5-0.75mm thicker, i.e. there should be a rebate in the floor... I was also starting to think a flatter roof profile would be bit more "tram like" and to cut a long story short, after rejecting an already-converted version as being too narrow, I pinched a new roof from a Dapol Railbus kit. It was cut to length, oddly the length between sets of ventilators was just right, and then narrowed. I miscalculated here taking 6mm out, then having to take a further 1mm from each side. Glued together with a strip of 40 x 156 thou Evergreen strip below the joint, it was set aside to dry.
Whilst that dried I fitted the bulkhead partitions into place on the floor unit, having carefully measured their location in relation to the sides. The lengths of 60 thou x 3.2mm strip were further cut down to fit in-between and add strength to the central section. In between the partitions and the seat fronts I added squares of 40 thou styrene that will eventually support the balcony seats, but also add extra support to the bulkheads.
Just visible in the shot above is the construction of the rear side of the bulkhead partitions, a 40 x 40 thou strip runs from the motor cut-out, through the window divide and right up to roof level, with panels of 40 thou sheet in either quarter above and below the windows. This was a neater way to get the strength required in these parts. As some of the lower pieces are visible through the side windows they have a planked effect scribed in to represent the seat backs.
More soon, this is progressing well...
Colin
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