Monday 6 November 2023

Ashover coaches part 3: Details and roofs

The instructions don't mention handrails but pictures of the coaches show them prominently, and with the steps for low platforms they are an obvious requirement. I realised that staples were slightly too long but would fit if I was happy to accept them running to the bottom of the door, lower than the prototype, and being a flat section. I'm not making an exact model so figured the precise length and bends would save a lot of time, and look better than I can manage bending wire.

I drilled all the holes (80!) with the dremel in the stand, using a slightly undersize bit as it tended to melt the hole bigger than the drill, even in short bursts (I wish it could go slower!) - but much quicker and easier than using the pin vice by hand. The staple legs were cut shorter (especially to avoid the window openings), and supergled in using a 20-thou strip of plastic for even spacing from the body. 

The brake coach had steps made up from plasticard. Those at the left (saloon) end were made to match those of the other coaches, those under the guard's compartment doors made to a similar style but longer to match the double doors, and passing in front of the frame bracing. The steps are 20-thou plastic but the upright supports are 40-thou, and with a second thickness of 40-thou between the steps to support them. 

I also added door handles. They are not very prominent on the photos and are quite slender on the frames of the sliding doors, so I just used short lengths of microstrip vertially on the outer edges of the doors, but horizontally on the brake compartment doors which are assumed to hinge inwards in the usual way.

Experimenting with roofs led me to realise that they didn't fit well to the ends of the coaches, and it seemed that the ends were too low, and the top edge sloped down to the outer edge. To avoid an unsightly gap I added a strip of 20 thou plastic to the top of the end, and filed it smooth to the front and level across the top. I also added a little microstrip to the top of the door frame. You can just see the door handle behind the left handrail here.

I decided on the drinks-can roof. The moulded plastic roof was slightly too curved and wasn't smooth underneath, making shortening and fitting complex, while fabricating a plastic roof to be a neat fit and not warp is challenging, especially as the partitions leave little room for bracing underneath. 

The metal was cut to size with a scalpel using lots of light cuts. I decided to cover the metal with masking tape to give a tarred cloth finish, it also serves to stiffen the metal slightly. I took care to roll the roof onto the tape rather than flatten it, so the curvature is maintained. The sides and ends are then folded underneath. 

To further strengthen the roof and prevent it distorting I added a couple of lengths of 40-thou plastic longitudanally underneath, the strips spaced apart with slices of plasticard then superglued to the roof. 


Some of the kits came with lamp ventilators but they didn't match, and some kits didn't. I found a load of matching whitemetal ventilators in my bits box, not sure of the original source. I think the prototypes had torpedo type ventilators rather than these "sea-shell" type, but at least all 5 coaches will have the same type. Holes are drilled with the dremel again and they are superglued from underneath. 

I'm also fitting rainstrips which, perhaps surprisingly given the doors being at the ends, curves over the whole length of the sides. The strips are tacked in place with plasticweld solvent, which doesn't really stick to the masking tape/metal roof, but holds it long enough to dribble some superglue along it. A fiddly job, 2 roofs are now done so just 3 more to complete!

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