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Rebuilding Gresley Buffet 644 - Chapter 3

Vestibule framing

The rotten vestibule framing at all four corners was stripped out and has been replaced with new hardwood framing. Patterns were made in softwood for one corner, then these were used to make the proper hardwood framing parts. The amazing thing is, the patterns made for one corner fitted all the other three corners within a millimetre or two! They sure were great craftsmen in 1937!

Work has started on stripping the rust and scale from the sole bar - this is a horribly noisy process involving a needle gun. Ear plugs all round! The de-scaled parts were then painted in primer before application of all the various undercoats and overcoats specified by the painting department. Here is Jim Ormiston hard at work with the needle gun.

Jim Ormiston

The missing main lights (3 - off) have been refitted and the BR "modification" to the main light in the kitchen reverted to the 1937 design. This unfortunately uncovered more rotten framing which has had to be replaced.

Repair Repair

All of the loose roofing boards have been repaired and secured at the gangways. Holes for BR fitted ventilators have been filled in and profiled. The entire roof has been smoothed down with a sander to remove the old lead based gunge and any sharp edges in preparation for the fitting of the roofing covering.

Roof boards

roof panels

The underside of the saloon roof was sprayed with firecheck. The top side of the ceiling panels was similarly treated and the ceiling panels were fitted. This shot was taken at the end of 2001 showing the first 4 panels in position. All the countersunk screw holes and the joints between the panels will have to be filled with filler and smoothed off before the application of lining paper.

On June 15th 2002 an SRPS Railtour ran to York and Leeds. This train was used to carry four members of the restoration team to Pickering (via a hire car from York) to have another look at 641 on the NYMR. We managed to pick the "Thomas" weekend (again!) for our visit, so didn't get as long as we would have liked surveying 641. A large number of photos and measurements were taken in 641 on the move and at Pickering station. When the train left we were given a conducted tour of the LNERCA site by Len Clarke who gave us all sorts of useful hints and tips. Of particular interest was the number of glue blocks used to secure the outer teak panels to the framing. We need to cut some more!

LNERCA coach at Pickering

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