It is now the turn of the driver's side to be stripped back to bare metal. The cab side was showing signs of the paint finish delaminating, some new metal was required. The trail fitting of the driver's cab side window and handrail has taken place. This can be seen in the photo on the right as well the repair work to the cab side.
Door 3 (as it has been called) frame surround has been rebuilt with new metal. Just the new bit of roof to form and weld in now, then on with the door linings and door hanging! The door bumpstop was causing the usual rot behind and has been removed. The affected steel was cut out and renewed. The rest of the body panel was suffering from a pop where it has been distorted and so has been slit vertically, then welded back to eliminate this. The next bit of bottom edge was also cut off too. We will now inspect the framing, repair as required and then fit the new panel with the correct edge profile.
The picture on the right shows the gangway shroud which Swindon fitted has now been removed. The shoebeams have also been fitted.
May- December 2016
Despite the lack of updates progress has been steady at Eastleigh. The major noticeable difference is that the body skins have now been fitted to the frames (which can be seen in the photo on the right). While the body skins were being fitted a hole was found in the roof where the cant rail meets the roof, which over time has allowed water to enter and cause damage.
This has been separated from the body pillar and the roof section has been removed. The cant rail repair has now been completed with new material and the door portals have had the studs for the van packing on the inside added.
There was quite a lot of corrosion on the handbrake cab side which has now been cut out, in the front corner 100% of the original metal remains and it was nothing more than surface corrosion. The trail fitting of the cab window and handrail has also taken place on the handbrake side. On the driver’s side top corner the metal work was bulging. The old metal work was cut and repaired with new steel.
The body supports /floor bearers were rotten, so new floor bearers were made up and welded to the existing ones. New angle strengtheners were also made and fitted along with the replacement top hat body pillar bottoms. The new metal work can be seen in the photo to the right of this text.
A selection of images from a week of intensive activity is shown above. In the far left image the first curved 'Z' pillar is welded in. This is the pillar which the longbolt luggage door is to be hung from. Much care has been taken in observing drawings and using the witness marks left by Swindon Works to ensure that accuracy is high. If this pillar is positioned incorrectly, then the two double doors could not meet properly! The next shows all the new curved 'Z' pillars in and a start made connecting them with the straight, horzontal 'Z's. The function of these is to tie the whole fabriation together and provide ridgidity. Following on from this the next photo shows the van side panel framing complete along with new bottom horizontal angle. At this stage all of the necessary repairs had been carried out to the in-swinging door pillar and its supporting outrigger. The original outrigger was considerably wasted and with little persuasion was removed from the underframe, a replacement being fabricated and welded into postion. New handrail mounting points have been welded in place to take the new, original design, full length handrail. Upon refurbishment the CEPs received new shorter handrails which were also mounted further apart; inkeeping with 1963 stock. A personal view is that the shorter ones offered less assistance exiting the coach and were almost dangerous as there was effectively no upper portion. The completion of repairs and alterations to this door pillar has allowed the body skin reinstatement to commence and can bee seen here. The windscreen washer filler and recess has also been removed from behind the Driver's window. The last photo shows the completed framing with primer being applied prior to the body skin being fitted which should take place imminently.
Progress on the Cep has been a little slower than hoped due to Motor Luggage Van 68002 requiring extensive renovation in time for SouthEastern Trains' Family day at Ramsgate Depot at the end of August. It can be seen 'on the juice' (on the 750v third rail - inside the yellow plastic covers) at Ramsgate alongside SouthEastern's new 'Javelin' Class 395 EMU below.
Back at Eastleigh we have completed all the cleaning down and priming of the underframe in the vicinity of the brake van. Painting into gloss black is now well under way and is nearing completion. Once this labourious task has been completed, we will turn our attention to the construction of the brake van side framing and body skin. A temporary wooden floor will be laid over the underframe for this stage to alow a safe work area to be established.
The newly fabricated Driver's desk, power and brake controller support/mounting bracketry has been received from our contractor and is in store, ready to be trial fitted once the brake van sides have been constructed. The two sets (one for each motor coach) can be seen laid out in the photograph right.
The brake van floor framing members have seen much progress with cleaning and priming. Along the way it has been found that the Left hand side conduit for the side lead (the cable from the shoe fuse to the power junction box) had corroded through where debris had built up around a mounting bracket. This has meant that the affected section of conduit has been removed to enable its repair. As can be seen from the picture (left) an exciting transformation is now under way with the recent delivery of the traction motor access covers and their support frames. Trial fitting of these has been carried out successfully, a credit to the fine limit work and skills of our principal metal working contractor, PAG Sheet Metal of Hanwell, London.
The picture right shows the progress made to date, the side lead out of its conduit is visible in the foreground resting inside the vehicle on the centre section of floor.
Progress is being made on the cab with the framing members to support the Master and Brake Controllers. We are near to placing the order for these.
Cab stripping out has now been completed and we are now looking at working on cleaning up the sub floor on the driver's side to remove built up debris and rust. Another task completed is the removal of all the 1980's additions in the brake van area along the cant rail and solebar. The windscreen washer filler cover along with full height corroded body skin adjacent to the driver's side inward opening door has been cut out in readiness for replating, the area is clearly visible in the photo (right) of 7002 undergoing refurbishment at Swindon after the new, primed metal had been installed.
The new steel for the bottom of the body side repair around the perimeter of the entire vehicle has now been delivered to site, as has the blanks for the new traction motor hatch covers. Each of these blanks will be drilled, countersunk and tapped to accept their four captive securing screws which are currently on order. The new corrugated steel for the brake van sub floor has now been ordered, as has the framing supports for the traction motor hatch covers.
Work on reverting the vehicle wiring to pre refurbishment design has commenced with the removal of the 'Mickey Mouse' switch and shed socket from beneath 61229, behind the motor bogie on the driver's side. This has been temporarily replaced by the original 'knife' switch and shed plug socket in the cab auxiliary cupboard. The panel on which the 'knife' switch is mounted, although original has been altered substantially upon refurbishment and so will be renewed to original design in due course.
The same view as the January photo a couple of weeks later with the control desk and remaining fittings removed (left). We have since removed both sliding windows which have been refurbished and now await refitting. 7105's original route indicator was badly damaged when we purchased the unit, a replacement being recovered from Cep 7117, hence the number on the route indicator door being 61317 rather than 61229.
Work also progresses on removal of all the post refurbishment metal brackets that remained on the Cant rail and solebars in the vicinity of the new brake van. The picture shows the cleaned up plate with two outriggers attached ready to receive the new side framing.
The heater conduits are being removed for renewal, a start has been made on the handbrake side under the brake van area (in the photo right). This will also allow better access when needle gunning of the solebars commences. Removal of the remaining coach heaters has now recommenced to allow the vestibule and saloon flooring to be taken up. This will be renewed as it is widely rotten on the coach side edges. Where sections have already been removed it has been discovered that the steel corrugated sub floor below is in excellent condition.
2015 has got off to a good start with work on the cab of 61229. Just before the end of December we were given the oportunity over two days to remove the driver's bulkhead from a similar 1957 EMU, Motor Luggage Van (MLV) 68010. MLV 68010, in the private ownership of an EPB Group member is very similar to 7105 before refurbishment. This acquisition will prove invaluable to returning 7105 to original design in two ways. Firstly, one of the original drawings available for the bulkhead is in poor condition and is difficult to read in places. This has made manufacturing two new bulkheads for 61229 and 61230 from the drawing alone almost impossible, thus this acquisition will enable us to make a copy for 61229 from it and then restore it for use in 61230, saving both time and resources. It will also be nice to know that another piece of Kent Coast heritage will return to the main line, albeit in a different unit. We are very grateful to the donor unit's owner for their assistance with this.
We have removed the refurbished driver's bulkhead from 61229 (pictured above) along with the TWPS equipment fixed to it. Much of the ceiling panelling has been removed from the cab and a start has been made removing the equipment and case from above the driver's window. We will shortly turn our attention to removing the control desk and the last of the longitudinal bulkhead.
Bodyside window frame removal has now been completed along with the removal of doors 4 and 7 to allow door portal repairs to be carried out and due to their hinges being fixed on top of the adjacent window frames. Refurbishment of replacement window frames for 61230 continues off site now that all the frames for 61229 have been completed.
Right: The recovered bulkhead laid out side by side. The two will be installed back to back to make up the door pocket for the sliding door.
November / December 2014
Over the last few weeks we have made good progess with 61229. The two inward opening doors for the Guard's van have gone away for refurbishment and will revert to their original internal design of traditional casement boards. After much planning, we are now at the point of placing the order for the Guard's van floor Traction Motor hatch support frames and hatch covers. This along with preparation of the underframe will see a significant transition from 1980s design back to as built design.
Give 7105 a Christmas present?
Please consider setting up a standing order or making a donation via the Donate page and with your help we will get 7105 back on the main line quicker.
Along with further interior removal we have also made a start on hopper window frame removal with only four more to do to complete the task. Recovering the remaining good glass has taken more time than if scrapped, however we hope it will find use in another preserved unit.
August / September 2014
Over the last few weeks we have made much progress with 61229. As you can see from the above photo, the cutting out of all the Swindon replacement seating bay side panelling has been completed which gives a see-through appearance. Only tidying up of the edges remain outstanding which means our attention now turns to floor removal. All the plywood floor in the old seating bay has been removed, the floor supporting timbers removed along with insulation. The next items to order will be manufacturing of the traction motor access hatches and their frameworks, the first steel floor sheet has now been removed in readiness for this. Underframe cleaning and preparation will commence once all the sheeting is removed and then follows the welding in of the floor supporting framework for the new corrugated sub floor. We have uncovered some of the remains of welds where the old fittings were secured, which along with drawings will aid refitting the new 'old' style floor. Interior stripping out is now well advanced as can be seen in the photo (left). Part of the vestibule to saloon bulkhead has now been removed in readiness for the previously mentioned cant rail replacement over door 3.
Off site, window frame refurbishment continues as well as priming of the four sets of gangway spacer sets as seen in the photos in the previous entry below. The labourious task of window frame refurbishment is now fortunately well advanced for 61229, with only three more frames to do to complete it. Then 12 large side lights and four quarter lights to do for 61230! The four nose end upper steps have now been finished up to top coat, wrapped up and put into storage awaiting refitting in due course.
If you like what you see then please consider visiting the donate page where you can help us get this unique project completed and back on the Mainline. As mentioned above we will soon be placing the order for the traction motor access hatches - can you help? Many thanks in advance.
Saturday 26th July 2014
We have now taken delivery of the brand new gangway components to return all the gangways on both motor coaches 61229 and 61230 to as built condition. The current metal clad gangways are to be removed and replaced with the original hardwood mounting set and steel spacer set. The original rubber bellow as per the later Phase 2 Units will be used to recreate an as built appearance. All outer end and internal gangways will be so treated and will be finished by the reinstatement of the step above. 61229's front end will be the first treated after the brake van work is completed.
Friday 11th July 2014
The time consuming task of cutting off all the Huck bolts securing the cab end section of gutter to the cant rail has now been completed on the Driver's side of 61229, the sealant has all been cleaned off, the gutter labelled and put into storage. This is to allow the cutting out of the first passenger bay side as the gutter seals the roof to side interface.
Both vestibule doors have been removed and placed into storage to allow the hinges and door surround cover stips to be removed. On the Driver's side all three hinges need to be removed so that the Swindon installed side sheeting can be cut away. Although the door and partition Z section pillars will remain, renewing the whole side sheet will enable a neater finish to be achieved on the new brake van panel. On the handbrake side the door surround cover stip has been removed and the side sheeting has been released from the door and partion Z section pillar and just awaits careful removal. The rest of the side, along with the inward opening door pillar and redundant partition pillar have been cut out completely.
Shortly a start will be made on removing the second vestibule bulkhead partition so that access can be gained to the corroded cant rail above the handbrake side vestibule door's top hinge. To enable this, the saloon ceiling will need to be taken down. This 1970's design lowered ceiling will be scrapped and replaced with traditional harboard ceilings.
Wednesday 28th May 2014
Removal of the last remaining components from the new Guard's van has now been completed and a start has been made on the cab panelling. This has been removed to gain access to the rivets securing the gutters to the coach side and also as it will need to be replaced with the correct style of panelling for the unrefurbished unit. The section of gutter on the second man's side has been removed in readiness for the removal of the coach side between the cab and first passenger door. Both hopper windows, the doorway reinforcing mouldings from this side and the bodyside lower edge reinforcing strips from the cab end of the coach have all been removed. Some corrosion has been found above the first passenger door which will require some localised cant rail and roof sheet replacement. Poor flame cutting during the removal of the old brake van door pillar by Swindon Works saw a hole being made in the roof sheet. This has over the years seen water ingress cause some corrosion in the cant rail and so this will also need localised replacement. Both cabside ventilators above the sliding windows have been removed due to severe corrosion. Whilst the cab side metal work is redeemable, the cast ventilators are in need of repair/replacement. We are very grateful for the kind donation of a couple of sets of ex CIG seat units which will be valuable in providing a source of spares for the unit upon fitting out. If anyone has ex Phase 1 CIG/BIG or pre-refurbishment CEP components that they would like to donate to the project, then we would love to hear from you. Similarly we are always on the look out for old photographs, espicially those of the interior of the original CEPs. Please get in touch via the Contact page.
Monday 19th May 2014
Both motor coaches have now been moved inside into the workshops at Eastleigh. 61229 will be dealt with first which has seen an immediate start being made on clearing out all the stored items from inside it, which have been put into storage prior to refitting. The next task has been interior removal with all the seats now being cleared and palletised for scrap. The IC70 seating from 61230, which is in far better condition than those in 61229, are now available to purchase; so if you are after that unique or just different gift for you or someone special, why not get in touch today? See the Contact page for details.
Saturday 12th April 2014
Whilst we are awiting our turn to enter the Works at Eastleigh we have been busy renovating the replacement ex 4CIG window frames which will replace the hopper windows in 7105. The CIGs were fitted with Deans and Light Alloys frames from new, the CEPs having Beclawat and Hallam Sleigh ones. A lesser known fact is that Deans and Light Alloy frames are not uncommon to CEPs as when refurbished by Eastleigh, 7153 had all its sliding Beclawat frames removed and Deans and Light Alloy frames installed. Repeating this act will once again take place at Eastleigh, but this time it will be 7105 which became 1537 on refurbishment as so the same digits but in a different order!
The restoration of the frames is a labourious one with intitial strip down being hampered by steel screws not wishing to part company with the aluminium frame. Having to be drilled out and the holes retapped is the norm, with the original hole positions being reused albeit sometimes repaired with Helicoils. All the old paint is then stripped off along with the old sealants. Each individual part is then cleaned and polished to bright aluminium and the mounting flange primed. Temporary reassembly is performed to ease storage prior to fitting to the vehicle. A total of 24 large sidelights are required for the Motor Coaches along with 8 small sidelights adjacent to the central doors.
The upper front end step plates from both Motor Coaches were removed soon after arrival at Eastleigh as small projects like these are easily completed at our local workshops. The plates at the top in the picture are from 61230 with 61229's below. At first it was thought that they would be a quick job comprising being grit blasted and painted by our contractor with one plate known to need a small hole welding up. How wrong can you be? Well 61230's at the top left has had a large area of wasteage due to corrosion on the underside built up with weld and a small hole welded up. The other from 61230 on the top right has had a large piece of corroded plate (shown below the plate) cut out and a new piece of chequer plate welded in. 61229's on the bottom left was in the best condition and only required a small hole to be welded up. 61229's driver's side at the bottom right didn't require any welding but was badly bent and twisted so has had to be straightened along with the mounting brackets using oxy-acetylene. The plates are now being prepared for paint and will be stored prior to refitting.
Friday 3rd January 2014
The day of the move which saw 33029 pull 61229, 61230 and 99545 out of Stewarts Lane Depot and into Battersea Loop. Here the loco was detached and run around the train for the journey to Eastleigh. 33029 carried our headboard along with Bachmann's in recognition of their support given to the Cep Project. Running as 5Z02, via Clapham Junction and the Hounslow Loop, the train ran on time and arrived at Eastleigh at a little after 3pm. On entering the Depot, the loco was released by 08794 and saw 99545 shunted off to outside the shed and 61229 and 61230 to the yard. The 33 then departed for its return journey to Southall Depot. Both Cep Motor Coaches performed perfectly on the trip, testamount to their rugged, reliable design.
Thursday 12th January 2014
Today both motor coaches were marshalled with VSOE's Baggage Car 11, 99545, by West Coast Railways' 33029 in readiness for their late morning departure tomorrow for Eastleigh Works. We have been fortunate enough to get the Cep coaches on the rear of the train for photographic oportunities. It has been almost ten years since 7105 (then numbered 2325) was last on the mainline and tomorrow will see her return, hoped to be the first of many. A big thank you to everyone who has helped us get this far. Please help us to make its return jouney in fully unrefurbished form, hopefully under its own power by visiting the Donate page.
Thursday 12th December 2013
Over Wednesday 11th and the early hours of Thursday 12th December 61229 and 61230 moved from their home on the East Kent Railway to Stewarts Lane Depot, London, the first part of their move to Arlington Fleet Services based at Eastleigh Works, Hampshire. Once at Eastleigh, the first stage of the rebuilding work will commence which will involve the reinstatement of both Guards Vans behind the driving cabs. We urgently need your help in raising money towards the second stage of work which will involve reversion work to the gangway connections, crash pillar repairs and general bodywork repairs. Please help us reach this stage quickly by visiting the Donation Page. With your help we can get an original condition Bep back on the Main Line.
Tuesday 3rd December 2013
61229 and 61230 have now passed their fitness to run examination which means they can now run on Network Rail infastructure. Preparations are well under way for their road move to Stewarts Lane Depot, Battersea which will take place on Wednesday 11th December.
Friday 15th November 2013
61229 and 61230 have now been re-registered on TOPS and have been allocated the new numbers of 99229 and 99230 respectively. This is what they will now be known as by Network Rail.
Wednesday 13th November 2013
Due to capacity problems at St Leonards Depot we have now awarded the contract for renovation work to Arlington Fleet Services at Eastleigh Works in Hampshire. Work will include reinstatement of the brake vans in the motor coaches 61229 and 61230 and subject to funding full renovation to Main Line operating condition. Work completed so far includes the successful passing of an Ultrasonic Axle Test on the entire unit today. 61229 and 61230 have now been shunted out and marshalled back to back in readiness for their Fitness To Run examination next week. They will then be moved by road to Stewarts Lane Depot in London where they will continue on to Eastleigh by rail. This double move is necessary because the EKR is not yet connected to Network Rail and it not being possible to bring a 63ft vehicle into Eastleigh Works by road.
Wednesday 4th September 2013
The unit's home is at Shepherdswell on the East Kent Railway; however, shortly the first coach 61229 will be departing for St Leonards Depot in East Sussex where the heavy rebuilding and conversion work will take place.