The E&G Buffet Car undergoing major bodywork rebuilding during the Winter Woolies Work Week - February 2012

With the 3 car Ayrshire DMU virtually complete and in fairly regular service on the branch, attention has turned to the fourth and perhaps most historically significant of our vehicles, the ex Edinburgh-Glasgow Buffet Car Sc79443.

As can be seen, we are undertaking a complete rebuild of the bodywork of the vehicle. The corrosion suffered is extensive, but localised to the lower bodyside and the areas below the windows where water can leak into the vehicle.

The old panelling is completely removed over most of the body to reveal the framing. The framing is is cut out and replaced as necessary (generally all the lower sections). New sections of curved frame have been formed in jigs by cutting and welding straight sections of "Top Hat" and "Z" section steel pressings - a laborious process, but our normal supplier was unable to supply pre-formed sections of sufficient quality in time.

At the lower 9" or so of the bodywork can be seen the fabricated "Box Section" that firmly joins body to the main frames and makes the bodywork a stressed part of the coach (compare the left and right hand sides of the coach to see the construction).

Here we see the new body panels being mounted to the repaired and primer painted frames.

The panels are made according to the original construction drawings for the trains and, as with the three "Ayrshire" vehicles our goal is to complete the restoration to as near as possible completely original condition using the same materials as the original.

We have still got quite a long way to go with this vehicle, but we're getting there....

Restoration Working Days at Bo'ness: 8th, 22nd April, 6th, 20th May 2012: