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Rebuilding Gresley Buffet 644 - Chapter 21

chair back jig

As well as having to replace 5 chair seat bases, 5 backs had to be made. These are much more complex than the bases. Two vertical trapezoidal pieces are fitted to two curved struts to form the basic frame. Don & Chris made a jig so that 4 thicknesses of thin ply could be glues together to make the horizontal curved pieces. hole were drilled in the back of the jig so that the finished struts could be easily knocked out of the jig using a punch. One such strut is shown in the photo to the right in the jig during the glue setting time.

chair frames

After removal from the jig, the curved struts were stored as in the photo on the left. A brake block was placed on the struts to make VERY sure that there was no tendency to revert to straight as the glue finally cured.
A further jig was made up to assemble the backs which were glued and screwed together. After setting, Chris cut out plywood sheet backs to complete the assembly. Between cutting out the backs and assembling, the plywood sheet was held in a curve with several brake blocks on top to try to force it into a curve prior to final assembly. This seemed to work OK as Chris had no problems with the final fixing to the frames which were then tidied up and sent off to the upholsterers.

saloon door draught strip

The west saloon door has been fitted with black draught proofing felt as is shown in this photo. The felt was glued to a narrow strip of thin formica to give a nice smooth finish. The formica was then drilled an pinned using glimp pins to the edge of the door as you can see. The east saloon will be similarly dressed when access to that end of the coach is clear of the decorators.

Reg varnishing

Not much more happened visually to 644 during the autumn of 2008. But quite a bit of work was done.

Several more coats of varnish were applied to the exterior panels - this photo shows Reg Parsons hard at work in September on the SW corner of the vehicle. More lining out was done on the north side and Dave Simpson spent a lot of time tarting up the kitchen door, a glimpse of which can just be seen behind Reg in this photo.
A very kind gentleman called Mike Trice has sent life-size prints of the lettering required for the exterior which he created in 1991 while on a reaearch project at the NYMR while 641 was being restored. These will allow Dave Simpson to trace "BUFFET CAR" and "LNER" much more easily on to the long horizontal panels of the coach.

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