Category: Updates

Hello everyone and thank you for joining us for another update from Quorn. Work on the Catfish progresses, with more bodywork attention and new skills learned in making safety loops. First though, I’ll cover some work on B954268 by Nick and Tom. The cladding on the East side of the van has rotted, so is being removed to be replaced.

Richard, Dave and I started by removing some safety loops from DB993560 to use as a template. Catfish have 3 safety loops per axle, and these serve as secondary retention for the brake bow girders and pull rods. In the unlikely event that a pin fails in the brake rigging, these safety loops prevent any loose components dropping down causing damage to the wagon, or event derailing it.

DB983393 arrived on site with none of its safety loops, so we’ve had to manufacture them. Dave found some steel stock which was suitable, and between himself, Richard guided by Ernie got cracking on heating and bending.

I worked on the Catfish. After reviewing the time taken trying to cut and close up the stretched material, we decided that it would be quicker and easier to cut out the damaged material and weld in new.

I got the first bit cut out, and decided to cut out a section of the bigger panel. Dave managed to catch the panel mid drop.

Richard, Dave and Ernie made good progress and got the two centre safety loops and one ‘outer’ loop made.

Encouraged by progress on Saturday, Dave and I with various assistance continued to make the rest of the safety loops.

Nick, Mark, Tom, Dan and Oliver processed our other lorry sheets, getting them ready for use on some of the vans. They cut the rivets hold the straps into the curtain and removed the straps. The sheet was then folded and cut in half.

By the end of the day, we’d made all safety loops required for DB993560. The next stage on these is to weld prepare some bolts to weld to the top of each loop to mount them to the wagon.

Thanks for reading everyone, join us next week were we should be trying to weld bits in to the Catfish and finish the safety loops. Join us then!

Welcome to a sunny June weekend update from the team at Quorn. This weekend we’ve been doing some heavy metalwork on the Catfish and finishing the last few jobs on Palvan B781908.

Saturday started with Tom and Dan doing some oiling of the brake rigging on the Palvan.

Oliver helped Nick replace the vacuum brake hoses on both ends of the Palvan.

I removed and tested the fuel lift pump on the Test Car; all was good so this was re-fitted.

Ernie and Ross concentrated on cutting, welding and grinding of some more of the gouges imparted by digger buckets on the Catfish DB983560.

Thanks to Mark for bringing along some provisions for a BBQ lunch; prepared by head chef Oliver who was helped by sous-chef Charlie, and of course Tom (being a Grade 6 food techie) had to supervise.

After lunch there was some more cutting, welding and grinding.

The Test Car’s cannister oil filter was also removed and cleaned out.

Then there was some more welding and grinding.

Sunday and more sunshine; Ross fitted a few missing split pins that we noted during the previous wagon inspection we did on the Palvan.

I did some measuring up in readiness for preparing the templates for the forthcoming signwriting on the Catfish wagons.

Nick, Ross and myself then got the vacuum test rig started in order to look into the train pipe leakage problem on the Palvan.

The vacuum hose end seal on the south end was noted to be leaking so that was replaced.

A small leak was found on the cylinder piston rod gland so that was removed and inspected; the seal was slightly damaged so this was replaced. It was also noted that the cylinder release was not a smooth or as quick as it should be. On closer inspection the piston rod itself was seen to be slightly bent, so a ‘straight’ replacement from stock was cleaned up and fitted.

With the leakage problem and slow release still persisting we decided to drop out the inner cylinder and piston to check the ball valve and rolling ring.

The rolling ring was inspected and noted in very good condition, therefore it was re-fitted to the piston. Some muck was cleaned out of the ball valve and a little dust in the inner cylinder hoovered out before refitting back into the cylinder dome. The die-nut was run down a couple of the dome cover stud threads and one stud re-fitted further into the dome. The release valve was also swapped for another overhauled one.

A replacement hose for connecting the test rig to the wagon was fitted as we noted some collapsing of the old hose. The branch pipe clip was also replaced with a slightly smaller one to try and get a better seal here.

Finally we managed to achieve a respectable vacuum train pipe leakage rate for the Palvan.

This completes our restoration work on B781908 which started back in November last year; here’s the before and after. The wagon will now be handed over to the Carriage & Wagon Department for final inspection and sign-off; however we will also carry out a running assessment / inspection during its in-train first operation.

Thanks for reading, all the best, Dave

Hello everyone and thanks for joining us for another update. This weekend we’ve managed to find a dry enough spell to paint the Palvan roof, investigate the Test Car’s fuel tank.

Tom has been doing some work on B954268 during the week while its in the shed having its suspension looked at. A new roof sheet has been laid over the van to re-waterproof it.

I started off by finishing connecting the new batteries in the GUV with crimps ordered in the week. Its a pleasure to be in there without the hum from the charger running all the time as the power supply. I finished the modification off with a Voltmeter to show us the battery volts inside the vehicle so we can monitor the charge level.

Dave made a start by looking at the fuel pick up and return lines into the fuel tank on the Test Car. The pipe fittings were welded to the top of the tank, so looking at them became a little more tricky. The fuel was drained out so we could check for sludge at the bottom of the tank. we found the end of the pick up tube nestled in the tank’s drain bung, so it was just a case of cleaning out the drain bung, rather than the tank.

In a dry spell in the afternoon, we used our new oxy-propane heat gun to look at the sides of the Catfish. The gouges imparted by digger buckets were slit with the grinder and then heated and whacked to flatten the crease. Its all trial and error at the moment, and we’ll have some welding to do at some point, but we’ve made a start.

Sunday was by far the drier day so much so, we got the roof painted on the Palvan! That now only leaves the 2 vacuum hoses to replace before the acceptance exam. Tom, Mark Dan and I hit the roof with the PVC canvas paint and quickly got it covered. Dan carefully painted the edges and above the doors, and did the same with bauxite once the roof paint had dried. Nick used the bauxite brush to touch in some of the body.

With the Palvan requiring minimal attention next weekend, we’ll hit the two Catfish, continuing with how we’ve started the first. Thanks for reading!

Hello everyone and welcome to another update from Quorn. Work has focused on the small bits to get the Palvan ready to run, though with the list dwindling, some work was done on the GUV too.

Nick and Charlie continued with Operation Grass Cut, finishing the section between our two coaches and the running line. Once completed, the newly prepared chalkboards were fitted to the Palvan.

Ernie concentrating the under-frame details and touching in the black, including scraping and painting the bottom side of the headstocks.

I disconnected and removed the current batteries in the GUV. It was thought the cells were life expired, however, one of the cell connections had corroded and broken, so there might be hope in them yet. However, with some new batteries sat there waiting to go in, the decision was made to replace. We can then look at the others at our leisure. I made up new connection tails, and am just waiting for the copper tube terminals for the cable ends.

On Sunday, being that it was just the two of us, Dave and I treated ourselves to breakfast on the train, not before we surveyed the van train to get an idea for the work needed on the vehicles in it. Some new ply sheets and some new planks to do, so we’ll get those planned. For the most part its a sand and a repaint for several of the vans, which is positive.

After a quick look round at Loughborough, we went back to Quorn and got on with the signwriting. Dave on the wagon plate, and me on the vacuum release chord star.

With the paint drying, we shuffled the vehicles back down and started the formal brake test of the Palvan. The brake test was mostly good and functioned correctly, though the leakage rate is not up to spec.

We also recovered a set of our steps from the yard using ‘George’, it reminded me a cut price version of the steps you have for aircraft!

With that done, the last job to tick off on the Palvan is painting the roof, which hopefully will be done next week. Thanks for reading!

Hello and welcome to our first June 2024 update. The team at Quorn have been busy again with the needle gun on the underframe and signwriting brushes out for the east bodyside of the Palvan.

Saturday, Nick and Charlie removed the remains of the original D plates and bolts; these had been snapped off many years ago but the remains and the bolts need to be removed so we can signwrite new D plates.

Ernie went round the underframe with a black touch-up brush attending to any areas missed and also where the D plate remains were. He then did some bauxite touch up along any edges that got missed with the spray gun.

Some new chalk boards were cut then primed and undercoated by Richard.

I got stuck into the Palvan east-side chalking-up and signwriting

The bodyside number, load, wheelbase, tare weight and XP were completed and the 2024 paint symbol added to both sides of the wagon.

Nick and Charlie tackled some of the long grass to the west of the mess coach with the lawn mower.

I also completed the Palvan lettering and Return to Port Sunlight text on the east side.

Both east and west Palvan bodysides are now complete.

On Sunday Oliver and Nick continued with the chalkboard painting in undercoat followed by black gloss.

The Palvan was rolled out of the dock so we could access the east side underframe where Tom got stuck in with the needle gun.

Dan continued work on the west side underframe completing the signwriting of the D-plate and vac release star.

Mark and Tom applied primer to the cleaned up east side underframe.

The end is in sight now for the Palvan, join us again next week, all the best, Dave

Hello, and welcome to this week’s second May Bank Holiday update from Quorn. We’ve worked around the weather and got the Palvan into its second coat of gloss, signwritten, and the underframe painted in black.

Saturday saw Jack and Dave continuing the work on Madge, getting more stripped off of the vehicle including all the wiring and petrol tank. Dave also cleaned off the wheels and got them painted into primer.

Jack removed the levers in the cab and refurbished them on the bench.

For me, the main event was spraying the gloss on the Palvan. I had a few issues with the pressure pot initially, but once working and with Ernie’s help I got the two ends and both sides coated in the lovely bauxite colour we know so well.

Sunday was fairly damp, but to continue sign writing we improvised a shelter from the LOBO scaffolding and an old gazebo Dave dug out. This enabled Dave, Dan and I to get the doors mostly sign written.

Initially Dan worked with Mark to paint the underframe into black, and they made good progress on the accessible side.

Dave took care of the vehicle number, while I applied the PALVAN lettering. Dan started applying the “Return to” branding on the van. Unfortunately the weather closed in before this could be finished.

I finished off the branding, and applied the XP, wheelbase and tare mass to the other end of the van.

Nick got the black paint back out and painted both headstocks, and the north wheel pan on the west side.

The light is very much at the end of the tunnel with the Palvan, the other side needs sign writing, the east side underframe a scrape and paint, and then its details, details, details. Though we shouldn’t forget about that pesky roof!

Thanks for reading, and see you next time.

Welcome to a Bus Rally Weekend update from the team. Despite the distraction of some fabulous buses and the sunshine, Nick, Ross, Mark, Ernie, Tom, Dan, Oliver, Charlie and myself have progressed the Palvan nearer to completion and Jack joined us to get stuck into some work on Madge.

There was also some grass cutting done, and some chairs were washed !

The needle gun was used to finish off cleaning up the remaining metalwork on the Palvan. Undercoat was then applied.

Madge’s rear wheels were removed and pressure washed, the left hand wheel taking a few minutes longer to remove as scratched our heads, eventually working out that the left side wheel nuts are left hand threaded.

Some sanding of the previously painted panel work on the Palvan was done in readiness for gloss painting (hopefully next weekend weather permitting).

The needle gun found it’s way into the garage and was put to work cleaning up the Madge’s hubs, brake drums and areas of the frame now accessible following removal of the wheels.

The brake adjusters on the rear drums were fettled to dress the burrs and checked for operation. The handbrake and footbrake were applied checking each drum in turn; the effectiveness seemed very good.

The fuel sender was removed as it has never worked reliably, thankfully it seems to be just a stuck needle. The fuel tank was also removed so we could get access to the frame behind.

The exhaust has at least three holes, a torn bracket and blown gasket, so this was removed. We’re hoping to get a new one made up locally using this as a template.

Some engine cleaning was done and the cooling system drained; the somewhat tired radiator hoses were removed for measuring up for replacements.

Some red-oxide primer was applied to the areas of Madge’s underframe cleaned up.

That’s it for this week, join us again next time, all the best, Dave

Hello everyone and welcome to another warm weekend from Quorn. The push on the Palvan continues, with primer being applied and more paint removed simultaneously.

Oliver, Mark and Dan made a start by applying undercoat to the framework that Nick and I prepared on Bank Holiday Monday.

Ernie applied red oxide primer to the west side under frame, and was joined by Oliver and Mark once they’d finished with the undercoat.

Tom was gainfully employed with the needle gun tackling the north end framework and the east side metal work, getting them ready for primer.

Barry and I decided to remove the fuel pump from the Test Car’s generator so it is ready to take for testing or maybe even rebuild. Dan assisted by removing the belt guards and inspection plate to allow the pump to be disconnected from its drive gear. We also cleaned the engine with some degreaser, so its easier for us to see future issues.

Dan finished off by cleaning up the belt guards and applying some etch primer to them.

Nick and I finished off preparing the iron work on the Palvan. Nick scraping and me spending the day applying primer to all the uprights and north headstock.

There is a little bit of needle gunning still to do on the east side, put we are firmly in paint territory, although there will be some keying to do on the glossed woodwork to ready it for a second coat. Thanks for reading!

Evening folks, and welcome to another update from us. This weekend has been another one where we’ve opened the Test Car up for everyone to come and have a look and learn about how and why rolling stock was tested. For those that visited its been a pleasure to talk to you!

Dave was at the NEC with West Hill Wagon Works, which left Barry, Richard and myself to give Test Car tours, and the rest of the gang to man the sales stand, all of which helps to put money back into the wagon fund.

Mark, Tom, Dan and Oliver did really well on the sales stand, though also found plenty of opportunities to get snaps of all the diesels running past the Test Car. Dan found some time to give some of the yellow vehicles a wipe over as well.

Sunday ended up being a very quiet day due to the weather, so the team started to find ways to amuse themselves. Some went on a ride on the trains, others started to investigate features of the Test Car, including swapping one of the speaker boxes, investigating the reed switch on the Slip Brake Application handle and seeing if we could find the other end of its cable to re-use it as the remote start on the Time/Speed/Distance Unit as was the case when slip brake testing. Another thing that was dug out and measured was the spare tachograph, which we are cooking up some plans for…

Given the weather, Nick also looked into the rebuild container to check for any leaks. Aside from around the door, all seems to be well and dry.

One of the visitors was PurpleVision who came through on the Sunday once the weather had cleared.

We’ll be back to wagon work next week, so back into the normal swing of things. Join us then where we are planning to pick up with where was left off on the Palvan. Thanks for reading!