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plasticard coach construction

by Paul [owlpool]

My first attempt was a 3rd on an old LGB chassis - not to any particular scale - governed by the size of the chassis and plans I made from photos from various sources
next, I designed a chassis of my own from laminated plasticard, and built a 1st/3rd/brake composite
these were both 4 wheelers using LGB single "bogies", couplers removed and reversed - the arms held together with elastic on the second to prevent excessive swing, and locking
the PDR needed parcels capacity for its passengers, so to make a longer parcels/1st/3rd the NTTS carriage Company invested in some Roundhouse bogies [seen with the brake compo]
The construction which follows is pretty much the same as for the first 2 but the detail has evolved - the basic side plan is the same for all 3 but with additions. Nearly all joining of plastic to plastic is by Plasweld - easy to use with a small brush and capillary action
the sides were made from plasticard [1.5 I think]
windows cut out with a craft knife - all measured out, drawn on with pencil, scored along a metal ruler, then each cut made progressively deeper
planking scored below the waist
beading applied around windows and doors and along the waist
sliders for the luggage doors were fashioned from plasticard strip [plastruct], dremmeled at the ends
door assembled - ledge brace and frame applied - planking scribed as per coach sides
door open
door closed
chassis - 3 layers plasticard araldited together for strength and I didn't know how far the capillary action would go
strengthening where required, and stiffening by "H" cross section girders

end on - showing bogie mounts 
 body parts ready for assembly
assembly using L cross section plastruct - bulkheads for rigidity as well as compartments
and a wagon roof from GRS
assembled body and roof - the roof [above] is fixed by 2 brackets made from L cross section, drilled to meet holes in the end pieces, and hex head bolts tapped in for ease of removal 

buffer beams built up with layers of plasticard to the right thickness topped off by thin plasticard with "rivets" pushed out from behind with a tiny pozidrive screwdriver and stuck on
steps fashioned from L cross section, "coach bolt heads" applied - small pieces of plastruct strip welded on and cut square
bogies replaced
Accucraft choppers fitted - 1mm holes drilled - hex bolts screwed in
running boards affixed using pieces of L cross section at intervals
lamp bracket from spare bits, dremmeled to shape
coachbolt effect seen in relief on steps in lower picture 
roof cut down to size - acceptable overhang
painted - grey primer spray, then hand painted enamel topcoats
and transfers applied [GRS]
vacuum hoses, chains [Brandbright]
roof ventilators [GRS]
brass handrails, handles and window bars - home made from 1/32 brass rod 
the completed rake out on the track
found the photos used for some of the ideas / inspiration on the WHR historic gallery site originally, I think, but they're also in the Oakwood Press's excellent Narrow Gauge Railways in Caernarvonshire series
both from NWNGR / WHR
at Beddgelert - i think this one of the England engines -
and a train with Moel Tryfan, probably at South Snowdon
part of the inspiration was that the set of GWR transfers from GRS included some "luggage" signs - and only just enough, too, as its a long word, and kept breaking, or rolling up !
Ducket construction on the 2nd coach
"glazing" made from the cover of an old instruction manual
double sided sticky tape applied [backing still on for clarity
the holes are for the brass wire ends from the window bars etc

 glazing and duckets in place after painting