The restoration of 629/729

Nevilles routing adventure.

2010-12-27T07:07:00.001-08:00

Following on from the fun of the Laundromat Neville decided to spend another day of heritage activities without his mates and headed north to Paterson.

Regular bloggers may recall the early assessment of 629/729’s interior revealing the need to replace the old seat mount plates as most had deteriorated and were beyond ongoing use. Goodwin Alco has had these manufactured in quantity by our Oldmates at Negra manufacturing and we have now also provided enough to the TRMS for the RailCorp Heritage units 621 &721 to be also fitted with new plates and improve their seat mountings.

The day started with the usual broom tidy up of the cars as routing through the rubbish would surely blunt the blades very quickly.

The holes for the existing mounting points were also sucked out to remove debris & dirt.

To assist with the routing task Maywald Engineering International (MEI) were engaged to design & manufacture a jig to guide and limit the router movement. The unit supplied is a prototype known as the “Nana 2010” and is seen here in its ex workshop state. Like most MEI products the production version is planned to be released in “Grey Nurse” & “Verdant Blue” shades but more of that later…….

To mark out the job reference plate positions were measured and calculated & measurement screws installed in the vestibule walls to provide post lino installation references. Once these plates are installed they will disappear under the lino floor covering so an accurate plan of the seat bolt locations is required so holes can be punched through.

A blue chalk line was anchored and flicked firstly to confirm the early seat position reference

and then to also identify the point of the new installations.

With the centre lines established the individual plate and hole locations were marked out and the nut holes introduced thanks to a spade bit.

With the bolt holes drilled and cleaned out the Nana 2010 can be put to use.

With the alignment jig inserted the Nana is positioned using the drilled holes for the seat securing nuts as the alignment reference……

..and then the Nana is secured to the floor with screws.

With the alignment jig removed the routing fun can begin….

and a routeing frenzy results with shavings everywhere!

The new seat mounting plate is then trial fitted and if no adjustments are required….

the Nana is removed leaving the plate in place ready for screwing.

The original mounting positions are also being cleaned up with a quick route to ensure the plates sit flush.

At days end one mans efforts have the car (or half of it so far) ready for the floor covering.

It looks like theres only 3 days of solo routing to go, I wonder if it would be quicker with more workers???????

Boxing Day wash day

2010-12-26T03:58:00.001-08:00

With the festivities of Christmas day still limiting activity and the Aussies at 4/58 also having a lack lustre day the decision was made to at least progress some heritage work and thus made the day a real wash out!

As reported previously the original blinds sourced from our oldmates at Paterson are in reasonable general condition but carry many stains and marks which need to be removed.

After surveying the available appliances at Home (and confirming the opinion of the Minister for Domestic affairs) it was decided that a task of this magnitude required equally capable machinery.

A trip to the local laundromat found all machines available for use and so the pre wash treatment of the stubborn stains commenced.

Some of the blinds had serious marks (DNA?) so a good squirt of preen and a pre soak was applied before the blinds were pushed into the machines and the suds turned onto high!

Even though they were big barrelled, 3 machines were simultaneously required to wash the 2 cars worth of blinds.

45 minutes later the blinds were washed and due to the also soggy weather were transferred into dryers.

After another 45 minutes of listening to the deteriorating test the now dry blinds were removed, inspected and folded, their original golden glow now restored and ready to reenter service.

Stayed tuned for the next exciting episode – who said railway restoration isnt fun!

Heart of glass

2010-12-21T06:20:00.001-08:00

Following a call from our oldmate scrappy our compass was again showing us heading west for another visit to the home of Western bank engine working and preservation– Valley Heights so save more heritage items.

As we set up, the hills began to echo to the sounds of a modern day “diesel train” XPT W27 as it headed past and into the 1 in 33’s.

Whilst the cars had been shunted down to the bottom roads little little else had changed with their condition…..

….and the team soon gathered and got to work.

The windows in these Country cars had shutters rather than blinds…

..which meant plenty of screws had to be undone from the 3 sets of runner strips/both sides per window.

Even the ex fitter got the hang of using a screwdriver in the end…….

With the strips unscrewed and the 2 shutters removed

the sash cords were unclipped

and the windows removed.

The result was a clear frame, devoid of strips, shutters and windows.

Close inspection of the strips revealed the detailed construction that went into these cars with all parts being individually machined and placed.

With the saloons cleared attention turned to the end windows

and with the “bug eyes” rivets drilled out

The windows were prized from their silicone sealed placement

revealing some very ordinary timber framework.

With the car stripped oldmates posed for a last pic in the cab

And then loaded up the hire truck.

With the car devoid of glass, the scrappy and the RTM boys will have less issues to clean up after the sacrifice is complete

and before our departure a minute of reflection is held in respect for the beast unit 636/736.

After a few hours drive up the Highway, Motorway and freeway

the booty of strips & shutters…..

and window glass is unloaded at Paterson.

Whilst 636/736 will rest in peace never to be rostered again the oldmates take solace in the fact that we recognised the heritage donor potential of set 636/736 to support ongoing preservation activities and its sacrifice will benefit 629/729 and other vehicles.

The brown (and green) vinyl mission – Part II

2010-12-15T07:02:00.000-08:00

A year had passed since the last successful hunt for original brown seat hides and again we found the trail leading us to 2 cars worth of booty at the Valley Heights heritage precinct.

Originally designated as the RTM’s 620/720 set to be preserved, 636/736 had once been the subject of cleaning and initial restoration efforts by the dedicated Valley Heights volunteers. With the allocation of Newcastle sets to the core heritage collection it was decided that 636/736 had no place in the heritage collection and was stored at Valley Heights pending a decision on its future. After several years of neglect and the inevitable graffiti and vandal attacks, it was offered unsuccessfully to interested heritage parties, and then eventually was advertised for sale by tender by RailCorp and bought by a scrap merchant.

While suffering from extensive floor rot and body corrosion and having been already stripped of many fittings, 636/736 contained a full set of original brown and green stamped seats in very good condition which were ideal to complete a refit of a heritage 620/720 set - just like 629/729! A call to the successful scrap merchant resulted in a sale of the internal fittings for a price much less than the new upholstery costs being contemplated and so the vinyl recovery mission (part II) commenced.

Not only did the set contain the much sought after seats but it also retained the wooden trailer car partition which segregated the first and “variable” class sitting areas in the cab half of the car.

Over several days the usual suspects set to work unbolting the seats and other reusable non metal fittings and soon had the cars looking much more spacious.

636/736 were constructed as “Country cars” originally allocated to Dubbo working and despite their original configuration variations were constructed using components standard to all the cars. The bathroom vanities and basins would be hard to replicate so having spares in stock is a big bonus.

As is the norm for these kind of activities several “artefacts” were discovered during the stripping works and the collection below provides a culture snapshot from the last days of the sets Illawarra service. The half fare single ticket to Dapto was dated for travel in July 1995 and the Orchy bottle dated to expire in September 1996. It appears that all items were utilised well before the required limits but perhaps not within the guidelines of their intended use.

Ultimately fitted to all cars, the trailer car saloon partition was introduced to country cars to provide a segregated section of dedicated first class seats in the cab end of the trailer car. The adjoining area which was also partitioned by the wash room compartment walls, was used as a variable class area fitted with 12 seats. While normally allocated as second class, a wall mounted hinged sign was able to be reversed to denote “First” and in periods of high demand extra first class passengers could be accommodated.

In later day working Newcastle based sets had the partition removed but in the Illawarra they were left in place and cars like 736 were withdrawn with them intact.

After dismantling the framework and removing the securing screws the partition was broken down into components and will eventually be reinstated in 729.

Another hard to reproduce item is the hinged “class” sign which was fortunately still in place and will also be reinstated.

After a long day removing seats Jamie pauses with the “spanners” in the stripped cab of 736 and indulges in thoughts of the many drivers that had sat there before him.

Another day and more work to finish the job is underway.

With the seats dismantled the components are walked through the cars to load into the truck for transport to storage.

Outside the seat squabs have their centre arm rests removed to facilitate more compact storage.

In later days many cars had their armrests removed but the ones “down the coast” survived.

Two nuts on the underside hold them in position….

…and once undone the components can be stacked flat.

All the vinyl components are stamped originals and comprise of a combination of NSWGR, NSWTD, PTCNSW & SRANSW markings.

Stacked up in the truck ready to go 2 cars worth of seats more than filled the truck.

With the seats all out 636/736 is ready for its last empty car movement.

Farewell 736/636.

Off down the mountain and across the flat to the storage yard more activity saw the truck contents transferred and sorted into a container.

A 20 footer may look big but it sure fills up fast!

The seat frames and end arm rests were separated to facilitate better storage and minimise damage

…and a test polish performed to anticipate how good they’ll look.

Another hunt for brown and green vinyl may be over but the seat fun still has a way to run.

Gettin blinds

2010-11-14T04:13:00.001-08:00

While considered these days to have limited creature comforts, the 620/720 cars were equipped with all the latest features considered to be required for the suburban and branch line operations of their time. With the exception of air conditioning and a buffet service, all features offered and expected on other trains were provided including padded rollover seats, arm rests, ash trays, vestibule fans, gas heaters, Iced drinking water, toilet and wash rooms, luggage racks, opening windows and shades.

On the later country cars metal shutters were fitted to passenger windows to help minimise the glare and heat of the sun which could make passengers very uncomfortable particularly on a long afternoon branch line run. It is believed shutters were selected for the later cars to simplify maintenance tasks for the country based maintainers and as they also allowed air flow whilst in the down position with the window up and without the flapping of blinds.

In the early cars intended for suburban and outer suburban runs spring tensioned cloth blinds were fitted. Evidence exists of several colours and patterns being used and the last style in use prior to the Cityrail makeover which saw the blinds removed used a gold & tan coloured cloth decorated with a “Scout” insignia like pattern and trimmed with brown edging.

Fortunately The Rail Motor Society managed to save some blinds from disposal many years ago and via a mutual sponsoring arrangement has made some available for the restoration of The 629/729.

Unfortunately most of the blinds bear stains from their in service life and while traces of Brylcreem are rumoured to have been found most of the dirt has been identified as “road crud” which has mainly rested near the bottom of the blind cloth.

With the blinds mostly secured in the raised position this crud has fallen down through the body cavity and onto the top exposed service of the tightly wound blind. While most of the blinds are in good order, these stains mean that the whole blind has to be dismantled for cleaning as well as any minor repairs required.

Repetitive jobs like these can be best completed in spare moments at home and being away from the “coal face” a more casual approach to their completion implemented.

After establishing a worksite in the shadow of the garage and consulting the GA “GA” it was assessed that CSB (Cold Stubbie of Black) working would be the best way to get through the repetitive chore of stripping the 52 blinds required for the passenger windows.

First the bottom rods which slide in the window runners and secure the bottom of the blinds were removed. These were found to be mostly steel but a few had plastic rods substituted.

The blinds are secured to the top spring rollers with staples, many of which have rusted from exposure to moisture.

These can generally be teased out using a flat blade screwdriver but many break and the remaining pieces have to be removed by long nose pliers.

With the technique refined and the throat lubricated time flies as the rollers are removed.

One end of the roller has a fixed pin which fits into a bearing casting up inside the window opening….

..while the other end has the slotted end of the spring ratchet mechanism.

A few blinds were found to have irreparable damage including this one which had a cracked timber roller and provided a rare glimpse of the spring arrangement inside.

The labelling of various manufacturers was found including Stewart Hartshorn of Renfrew Canada (dated 1934), Tiger from Sweden….

..and a few unnamed of Taiwanese origin.

Those of Swedish origin included instructions on the correct tack size to be used and the installation procedure….

…while some also wore NSWTD branding.

With the blinds disassembled the rods have all been inspected, straightened as required and stacked….

…as have the spring rollers which now wait for reassembly.

Next the cleaning process will commence. Has anyones Mum or Aunty got a Whirlpool?

Rain, rain go away……..

2010-11-14T02:19:00.001-08:00

Life in preservation is mostly better for a vehicle than that experienced whilst running in regular service however there can be new challenges to manage to ensure reliable operation continues for many years.

Being of riveted aluminium construction the 620/720 cars are notorious for rain water entering the bodies via joins, rivets and cracks and to combat this the roof has now received 2 good coats of roof silver to seal the gaps and also reflect the heat of the sun. The exhaust and fan openings in the middle of a 620 power car roof unfortunately cant be sealed with paint so different controls are being put in place to avoid damage and deterioration.

The fan assemblies have an unfortunate design feature which captures rain water when not used. In daily service the fans turned regularly and ejected any water but when in outdoor stationary storage they become very effective water collectors.

To initially improve the situation the water was first sponged out..

…and the inside of the “bowl” scraped to remove surface rust.

The centre and surround were then wire brushed, the debris removed and the metal treated with rust convertor.

A coat of rust guard primer was applied to seal all surfaces and the bowl has been temporarily covered until the next visit when the second part of the fix will be implemented.

To protect the engine from rain water entering via the stacks exhaust rain flap covers have also been put in place temporarily pending final measurements and adjustments to ensure everything is “in gauge”.

Even with rain forecast again for the coming weeks we can rest easy knowing these 2 issues are under control.

Internal fittings

2010-10-30T19:03:00.001-07:00

Sunny warm days have returned to the preserved DMU capital of Paterson and with The 629 & The 729 stored outside it dosnt take long for workers to warm up.

With the cars divided doors and windows can be opened to cool things inside and to catch any soothing breezes.

When Cityrail removed the window blinds a cover panel was installed to cover the remaining cavity into the upper body.

As blinds are to be reinstated these covers have been removed by unscrewing and drilling out the retaining rivets.

Someone went to a lot of trouble to fold up these now useless items..

..and with a rivet back in the hole….

…all thats needed is a touch up by the painter and the original configuration will be back in place.

The collection of original Brown and Green vinyl seats has been in storage for a while and as the day for their reinstallation is drawing near the sorting and cleaning process has commenced.

These seat cushions come in several different styles, stampings and condition so they have been catalogued and categorised so we know what configuration options we have for reassembly.

One thing they all have in common is dirt….

So the washing and restoration of the A grade samples has commenced.

After lugging the seats around for cleaning the workers are keenly focussed on the day that all they’ll need to do is sit on them.

During the sorting evidence of previous history was noted including the former position of ash trays on the seat end panels…

…and a curious stamping found only on 2 seat frames. It appears that some conscientious worker stamped the car and seat position (622 – 18) on the seat frames that once adorned car 622. While this type of stamping was common carriage practise no other 620/720 seat frames have been found stamped this way.

Other seat components including the back rods….

..and the end panel screws are stored cleaned and sorted ready for reassembly.

The seat frames have also seen some attention first being cleaned and greased prior to painting.

Several different paint colours have been used over the years as shown here with 2 shades of green evident.

Pete the painter has been busy first priming the seat frames…

..and then giving the second class ones a coat of brown….

..and the first class samples a stunning coat of green.

With the paint hardening nicely these frames are ready again for a second stint of service.

Bright spark

2010-10-30T18:21:00.001-07:00

With the floor work well advanced and the interior still cleared of seats the services of former Sputnik Sparkie Ben have been engaged to ensure all electrical matters are correct on The 629 & The 729.

It was if he’d never been away from working on these cars when Ben lifted the floor hatches and got down to business on the terminal boxs.

A peek inside the above engine mounted box revealed a sorry sight with considerable corrosion and dirt around the terminal strips.

Fortunately the wiring and mounts themselves were found to be in good order under all the crud so the cleaning process commenced……

…and the wiring was soon looking like new again.

Bens next port of call was the centre control cabinets of 629 where labelling in his own handwriting was discovered still in place 10 years on.

These cabinets were also found to be very dirty and littered throughout flaking paint stripped by previously leaking coolant.

After a couple of hours of cleaning the cabinets are now in much better shape, you can even read the cable markers!

Moving onto the cab Ben got back in the saddle and after removing the controller cover..

…the throttle contact switches were checked for operation.

Underneath the car the engine control cabinets were found to need extensive work to bring them back to a suitable standard. After several hours all circuits and terminals were checked and the OK given for running tests.

With many loose connectors and again a dirty interior these cabinets will keep Ben busy for days.

Thanks Ben, come back soon!

Enter the sandman

2010-06-03T03:50:00.001-07:00

With the new floor in place and internal works well progressed the day to do the job that everyone had hoped they wouldn't be around for arrived.

While the new ply floor presented a generally good surface it is essential that the surface was made clean, level, the joints flush and ready for the vinyl floor covering.

After the not unusual problems associated with hired and generally neglected apparatus were dealt with the team prepared for the days activities.

First job: Pete arms the sander for the days work. This activity was to be repeated many times during the day as the sanding sheets clogged and wore out.

2nd job: Using the edging sander (also known as the “Back breaker”) Steve tidies up the joints to make sure all floor sheets meet well.

3rd job: Cranking up the sanding machine and attack the floor.

4th job: (an all day job) While Pete takes the machine for another “walk” Steve is seen on cord management duty ensuring nothing is damaged, delayed or electrified.

Job done: The sanded, even floor waits for the next stage and then the vinyl layers. Its a shame the efforts of all that hard work will never be seen again!

Thanks to a great team effort there was time to spare in the afternoon so Painter Pete returned to the outstanding task list and applied another coat of silver on the roof of 629.

Theres still many tasks to complete but thankfully the list is getting shorter.

Detail developments

2010-05-03T03:55:00.001-07:00

With the painter away some time has been spent tidying up some detail pieces without fear of being “top coated”.

The saloon fans in the cars were received in various states of completeness so the stock of spares was unearthed and components sorted.

Working on fans is fiddly and can be a stretch due to their position high on the bulkheads.

With the front of the cage off the motor can be checked, cleaned and the blade assembly replaced. Fans with 3 and 4 metal blades have been identified and there are even some later versions with dubious purple plastic blades. They wont be around for long!

Another reassembled fan complete with RGE badge is ready for the hot trips ahead.

The passenger saloons are equipped with an Alarm Signal box which passengers can activate to alert crew. The red and blue cover plates have seen many years service and were screwed back in place having been removed to protect them from paint specs.

Like many doors on the cars, the drinking water cabinet is secured with recessed square key locks. In later years when the unit was covered over the protective chrome opening surrounds were removed and luckily a couple were found to complete its reinstatement.

The saloon lights have obviously been the subject of attack from unruly passengers with the glass shades long gone and even the replacement plastic units broken and missing.

The intention is to reinstate original glass fluted shades throughout the passenger areas so the chrome mounts have been removed for polishing and replacement of any damaged components. The photo below shows the components which make up the mounts including a broken rubber grommet which cushions between the retaining fitting and the shade to hold it firmly in place and avoid cracking the shade.

The last of the rectangular light fittings have been replaced in the freshly painted vestibule and toilet areas with original glass domed units. This should give the painter something to mutter about upon his return!

Other original fittings were also reinstated in the Mens toilet with a NSWR mirror, new paper towel dispenser and the chrome window handrail now back in place.

More floor and fit out fun

2010-04-05T01:39:00.001-07:00

The refit of the 629 power car has made great progress due to the efforts of our hired hands “Clint & co” who provide their professional services and make the job look all so easy.

With the old floor completely removed an inspection of the floor hatches, framework, the tanks, engines and pipe work below them was had to ensure all was right before the new flooring went down.

To avoid the need for future reworks new black jacked joists were installed and rebolted back to the frame like the original installation.

As was found in car 729 some of the partition timber around the lower walls was rotted and so was also replaced.

An inspection higher up on some panels showed that this was not the first time that this repair had been done so the whole panel was replaced. Obviously the vestibule wall and floor areas used to suffer badly when doors were left open.

To help with long term protection the areas previously or likely to be exposed to moisture have received a protective coat of blackjack. Thanks to the central door locking system and reinstatement of the tread drains the moisture problem should be a thing of the past.

The steps are all now refitted and the floor restored to its original integrity.

The trailer car has temporarily become a storage area for seats and other materials.

The ladies toilet floor was found to be in very poor condition and required complete replacement.

2 layers of concrete had been laid over the rotten ply floor and had to be chipped out to get to the original timber layers underneath.

The sink vanity is recessed into the floor so the components were removed and cleaned whilst out.

With new joists, marine ply and the floor drain back in place this floor should weather any spillages well for many years to come.

To provide better work access the toilet doors were removed from their frames and repainted during the flooring works.

In the luggage area the transformation from drab grey to original cream has been completed….

….including in those hard to get at places behind the main reservoir which have to be painted from outside through the window.

With the floor back in place 629’s walls have also received their finish coats of green and fleck.

The final refit is not far away.

The final strip

2010-02-25T04:12:00.000-08:00

With 729 90% ready for floor sanding and the new floor covering almost all efforts have now turned to get 629 works to the same stage.
The seats had not been removed from 629 and coupled with the stored seats that came out of the trailer it has meant a lot of Blue vinyl and seat frames had to be moved.

The seats were unbolted and then transported for dismantling and storage. While the blue vinyl wont play a role in the 629/729 restoration plan it may continue telling the story somewhere else in the fuuture.

Dismantled seats stack up well and are now in storage for future sorting and reuse?

The open area again allowed the painter to come in and carryout the preliminary cleaning and undercoats....

before the "fun" job of lifting the lino and looking for the wet spots started.

As usual theres a lot of flooring to be replaced to eliminate the wood rot and resecure the seats.

Theres all sorts of hidden items under the power car floor including an earth cable and the fuel tanks. The hatches to access the under floor engines will also be rebuilt.

Lifting the lino in the end of the car has shown that this area is in good shape although some repairs have been done previously adjacent to the Guards doors using individual boards.

The luggage lash down ring in the luggage area is a reminder of the sets past duties, no doubt delivering dozens of parcels, the corro and probably getting the odd dog carrier box to secure.

With the chippies expected any day a supply of 1st grade Marine ply is on site ready....

... and timber for the new floor joists has been blackjacked ready to be cut to length.

Back to the attack

2010-01-31T00:52:00.000-08:00

With the repainting of RailCorp heritage set 621/721 completed the team have returned to the attack of the restoration of 629 & 729.
Although most of the body painting has been completed many of the defered tidy up jobs have been tackled including the removal of the last traces of Cityrail blue with a lick of paint around the lower window inserts.......

....a cut in of the door edges and frames......

........and the fiddly bits including jumper receptacles and air hose heads and taps.

The application of the final shaded lettering has also been commenced.

The seats are bolted to mounting plates which are screwed into the floor timber.

As the originals are mild steel and have obviously had a hard life the decision has been made to remove and replace them.

This will also allow easier sanding of the floor ready for the new floor covering to be laid.

New stainless steel floor mounts have been manufactured and are ready for installation.

Some mechanical matters have also been rectified with a radiator compartment oil leak being traced to a split in a fan motor drive hose.

Years of exposure to constant heat from the exhaust and radiators had taken its toll and the hose was so brittle that it broke completely through on removal.

The oil lines come up through the floor into the radiator compartment from the pump below and feed up to the roof mounted radiator units. With all the gear in there plus leaking oil its not a great place to work.

Thanks to some great work by the guys from Pirtek at Cardiff new hoses were made available and have been refitted ready for many more years service.

A year down the track.

2009-12-12T06:49:00.001-08:00

It seems like only yesterday that Project Sputnik commenced with the movement of The 629/729 to the Paterson home of The Rail Motor Society. The completion of recent efforts has the set on show again and highlighting some of the many tasks undertaken during the last 12 months which have transformed the cars from their ex service "Prong" Cityrail livery.

After masking up of the whiskers the final coats of body colour have now been applied to the ends.....

...and also sides of the cars to return them to their 1960's Indian Red livery.

Once again Tony Matthew's wonderful efforts have made the lettering task so much easier and authentic shaded lettering and numbers have been applied to the end doors.....

...to the centre section to reinstate the cars codes and numbers.....

......to the sides to denote seating classes.......

...and of course to the luggage area doors so the Guards will know where they have to get in.

With the tape off the cars are again looking very much like they did in their early years of service.

From across the tracks passing passengers and crew can now witness the reborn "local set" as they pass the TRMS depot although there are still many tasks inside to complete before they will also get the chance to travel in the cars.

Thanks to all our supporters during this first project year especially the board and members of TRMS for their friendship and assistance.

Horn works

2009-11-21T17:06:00.000-08:00

After many years in service the "Country" horns on 729 were found to require more than just a "tidy up". Having been hit by trees, birds and other objects the throats were extensively damaged and some parts missing all together.

These horns are a RVB 6320 -007 type and have been used on many NSW railcars for over 40 years. Amazingly they are still produced in Australia and are available from Sirens, Horns & hooters Pty Ltd in Queensland.
After removal from the car the modular assembly was dismantled and all parts examined.

The brass and copper "throats" or "trumpets" are held in with grub screws but having been exposed to the elements the screws resisted being undone and had to be drilled out and the holes retapped.

When correctly assembled these units have 3 trumpets of 3 different sizes. Each produce a different note and are listed by the manufacturer as being 420Hz, 520Hz & 600Hz.

The configuration used on the 620/720's has 2 throats facing the driving end of the car and one facing "backwards".

Fortunately some spare stock had previously been acquired so when our specialist "Horn fitter" arrived reassembly could commence immediately.

The pic below shows Jamie working with a big horn.

With the unit back together a final check of the diaphrams and air ways was conducted.

Several obstructions were cleared including a lot of grime and a hornets nest presumably established during the 629/729's period in storage.

The air line to the horns is piped up through roof above the drivers compartment and the horns are rivetted to the aluminium roof & frame.

Another job is completed ready for service and for the painters to apply their magic.

Face lift

2009-11-02T00:17:00.000-08:00

During its 46 year life the 629/729 has undergone several makeovers to keep it on track with the changing railway regimes.

As introduced to service the 2 car diesel train wore a livery of Indian red relieved with yellow lining, whiskers and end of car "eyes". This attractive livery served for 3/4's of its in service life with the only change being the removal of the above window side line.

Escaping the "reverse"era, the 629/729 was painted in the Belbin designed "Candy" livery during the mid 1980's. This bright livery which is still loved by many certainly brightened the fleet but was not to last long.

During an attempt to cheaply give the Newcastle railcar fleet a makeover several sets including the 629/729 were treated to a coat of all over brown with a single orange waist band line. Unfortunately due to the poor quality paint used these sets faded quickly and locally became known as "turds".

With commuter complaints being received about old trains in service and a shortage of funds to replace them, the remaining sets in service at Newcastle were treated to the Cityrail "Prong"livery which attempted to make them look more like their modern "Endeavour" stable mates. It was this livery that the 629/729 wore when she finished her public service career.

With restoration well advanced the painting team has now commenced the next face lift to restore the 629/729 to her original livery.

With the lower end completely covered in 2 coast of yellow 729 briefly looks like the long fallen North West railcar 403!

The original line work on the ends of the cars was extensive and so careful planning with picture and drawing references was made to ensure that the final product is correct. Greg Edwards excellent "Datasheets" drawings work well to produce 12 inch to the foot gauge models too!

The side lines are carefully measured, checked and remeasured to make sure they're in the right spot, evenly spaced and parallel.

To prevent overspray the cab windows are masked again....

While the signwriter tends to the intricate curves of the eyes and whiskers.

At the end of a tiring day the effort looks great and ready for the Indian red to be sprayed but what will the final result look like??????

Details

2009-11-01T05:16:00.001-08:00

While some may call it rivet counting, and others may curse at the extra time it takes, the attention to detail with the restoration of the 729 / 629 will ensure that the result is historicly correct and preserves the look of an era of train travel now past.
With the speckle and other paint finishes in place the saloon areas of 729 are looking like new and now require only final touch ups and the refitting of lights, overhead ribbed rack carpet and rubber before its ready for the floor covering and seats to be reinstated.

As reported previously, the iced drinking water unit has been included in the restoration program and with the fitting of original signage plates (thanks Andy) its ready for a second service career.

Even the waxed cups are back in place.

The lights in the vestibules were changed in later days with simple rectangle units being installed.

Fortunately a supply of early round fittings with original domed glass have been obtained which Bob took no time to install.

All they need now is a lick of ceiling white paint and it will be like they never left.

Left till last, the toilet cubicles in the centre of the trailer car are now at the head of the queue for a tidy up. Stripping the doors of labelling and fittings allows a thorough clean prior to painting......

....but has also revealed some labelling of the locking fittings that proves that what went into workshops didnt always come out in the same configuration.

Several components bearing other numbers including that from DEB set cars 902 & 954 have been discovered to date but the most common numbers by far are 629 & 729. The restoration team anxiously awaits finding a component off 3805.

More detail not seen for many years being prepared to be added to the outside of the cars are replica builders plates.

The counting continues........

Speckle reproduction

2009-10-08T04:31:00.000-07:00

The restoration of 629/729 is planned to incorporate the reinstatement of as many original fittings and features as possible to tell the story of the sets early years of service.
A distinctive feature of the 600/700 & 620/720 class railcar interiors was the use of a distinctive "speckle" paint on the lower internal walls. This decorative paint finish incorporated a beige/brown base colour covered by a random mixture of stringy paint speckles to produce a durable and attractive wall coating.

To prepare the wall a base coat is applied throughout the lower car.

Experimentation has derived that a special brew of 2 different "Camfleck" speckle paint mixes achieves the right colour balance. The application of the final coat is certainly not delicate being made by using a 3mm tip!

The final paint finish looks great and just like the original....

...and is only bettered when the upper walls are also painted and the dividing aluminium trim repositioned.

The painter is in.

2009-09-23T03:18:00.001-07:00

To suit servicing requirements 629/729 has been moved undercover temporarily and currently enjoys the shade alongside class leaders 621/721.

Whilst in the workshop area the opportunity has been taken to reinstate the Countrynet Satellite antenna which was removed when the set was retired.

The holes for the old securing bolts and cable were diligently covered by the techs when the antenna went and now makes replacement easy.

After a scrape clean of the surface and some Mastic for a good seal the antenna is back in place.

With the floor down the painter has been busy in 729.

White ceilings and the Alpine green upper walls are quickly taking shape with Pete rolling the big surfaces...

and then cutting in the detail bits and panels with a brush.

A nice surprise has been the discovery of the Iced water unit which was never removed, just plated over.

Watch this space for the next installment.

Progress at Paterson

2009-09-01T06:00:00.000-07:00

Clear skies and warm days have resulted in good progress with trailer 729 at Paterson.

Body preparation works have almost finished and with the undercoat applied the top coat is being sprayed onto some panels.

Everyone is looking forward to an original liveried set again but theres much less enthusiasm about the job of applying the lining!

At least on the car sides the task will be easier.

Inside our contracted carpenter has completed the first stages of the floor reinstatement.

The new timber is down, secured and ready for a sand to prepare for the floor covering.

Even the vestibule tread plate drains have been restored to their correct position, the first time in many years!

A lot of old damp and rotten timber has been removed....

... and tell tale signs of past variations identified.

Now its back to preping the walls, adding the trims and more painting......

The brown vinyl mission

2009-06-28T08:31:00.000-07:00

Whilst the visible restoration works progress at Paterson much effort continues in the background assembling the components and materials required to complete the desired end product that will be the restored 629/729.
Recently the opportunity to secure some seats covered with original brown vinyl presented itself and with the help of many oldmates including the usual Eveleigh brigade, Mario the train mover, Tony Tilt and our new mates at Valley Heights the mission was successful.
A former running mate 670/770 was the donor of the seats which have weathered many years since entering service in the early 1950's.

A walk through of the car revealed many original features including the class divider, signs and even the magic black line with its famous smoke repelling ability!

Unfortunately many of the windows had been smashed some time previously and many of the seats have suffered from water damage.

Despite the casulaties, enough seats to equip a car were salvagable and so the removal process began.

Once unfixed the oldmates removed the booty and secured them in the temporary storage container.

Here we see an oldmate resting in the early afternoon (13:50Hrs) and thinking through both the days efforts and the many years of service that the seats have provided.

A full container means a goods days effort and a lot less needle work for Matty in the future.

Not knowing when the next meeting will be with this old girl, the team takes a minute to ponder the destinations previously visited and where it will head next.
Thanks to our newmates at Valley Heights and all the very best with your ongoing excellent efforts to preserve this heritage precinct.

Long live 610/710 - 670/770!

Small steps

2009-06-05T06:46:00.000-07:00

While the marathon of body restoration works continues on cars 729 & 629 other small tasks are also being completed as time permits.
Recent reports have confirmed that the selection of 629/729 for preservation was a sound choice and it appears that the 2 engines are in good order and are not suffering like its preserved sister sets. To ensure the ongoing health of the engines a coolant concentration test has been completed with excellent results measured. To celebrate both engines were turned over with ease and the No 2 motor run for a short time. Its heartening to know that not only are the engines well but the batteries are in good order too!

The jumper recepatacles on the ends of the cars have obviously had a very hard life with the lids and casing badly cracked and damaged.

To support future multiple unit operations the decision was made to overhaul or replace them and so our oldmates at New Macey were again approached to work their magic.

The before and after shot clearly shows the excellent work that Rick and his team deliver with the rebuilt units looking like new.

With the first overhauled unit remounted in place theres a sense that its all starting to come together.

Painting progress

2009-05-19T06:22:00.000-07:00

Despite other priorities and distractions progress continues on many aspects of 629/729's restoration, most noticably being its exterior preparation and painting.
Having had its initial sand and prep painting, works are now being focussed on the filling of the many "battle scars" received whilst in service.....

....whilst also tidying up the holes left from the removal and relocation of newer body features.

The roof having been previously inspected and sealed is now receiving its final silver coat as well as the repainting of the black gutter strip to lift its appearance and the interest of the restorers.

On the rear of the car a sample section of Indian Red has now been sprayed to confirm the results of the preparation efforts and the body colour selection.

It wont happen over night but it is happening...........

Preparation is the key.

2009-03-31T07:08:00.001-07:00

Work on the 629/729 continues at a steady and methodical pace with preparations being made to ready the set for repainting into an authentic livery.

Many days of work have already been focussed on the inside of the trailer car and the exteriors of both cars with the following pics recording some of the recent prep and paint efforts to get 629 into primer.

The fog lights fitted to some cars in recent years have been removed for later repositioning and to help restore the set to a more original appearance.

Removal of the external bar saddles has revealed minor corrosion in some areas and is progressively being sanded, treated and primed to arrest further deterioration.

With prepworks complete the windows are masked.....

....a good base coat of primer applied to seal the skin.

The even finish of the grey provides a great canvass to highlight any imperfections and need for additional works.

With 629 sealed up its back to the waiting trailer car for more of the same.

New jumpers - think New Macey!

2009-02-22T04:42:00.001-08:00

For the majority of their years in service the 620/720 class railcars were equipped with Wilco multiple unit jumper cables and receptacles which were coded Red and yellow to distinguish roles.

In the late 1990's when the installation of the door and fire suppression system required additional and more reliable circuits the yellow jumpers were replaced with a higher capacity jumper system which used heads that were square in shape. These receptacles were coloured grey.

Prior to Goodwin Alco taking possession of 629/729 it was unfortunately involved in a shunting mishap which saw a "grey" jumper receptacle ripped from its mounts due to the jumper not being removed prior to uncoupling the cars.

Fortunately for Goodwin Alco, company New Macey based at Tomago near Newcastle offered to help with the repair of the jumper, cabling and connection. New Macey are electrical connection specialists and supply couplings, connectors and jumper cables for rollingstock including the RailCorp XPT & OSCAR fleets.

After cleaning up the old head....

...the continuity of the new wiring and pins was checked....

...and the wires retaged ready for installation on trailer 729.

The jumper cables also recieved the attention of an overhaul with both green and yellow type jumpers being cleaned up, repinned and tested to bring them back to " as new" condition.

Thanks guys for a great job.
If you ever need a relaible and secure electical connection contact New Macey:

http://www.newmacey.com/pages/index.php

New year attack.

2009-01-03T20:34:00.000-08:00

New Year, same job.
2009 has arrived and work has recommenced mostly continuing from where we left off - floor & body tidy ups but some roof progress has been made as well!
Bob started the day tidying up the rough edges, screws etc that were still in the floor inhibiting the progress.

The removal of the rotten floor continued and we decided that the best way forward was to take out the bottom section of the vestibule wall. It seemed like a good idea at the time.

With the lower partition section out the vestibule lino was lifted and there were no doubts that the entire floor needed to be replaced. The under wall joist in this section was some of the worst found so far.

To replace the floor joists top grade kiln dried hardwood machined to 34mm to match that taken out was ordered. After measuring up Steve makes the first cut to get the replacement floor underway.

Starting with the hard jobs is usually a sound approach. Here Steves measures the cuts required to fit in the vestibule wall joist which had to fit around remaining joists and conduits.

The first section of joists are in and the bolts test fitted down through the frame of the car.

Once finally fitted the joists were removed and given a coat of blackjack to help protect them from future water ingress. Uncle Bob demonstrated the technique....

...and then Jack took over.

The result was coated timber that should last another 45 years at least!

With the joists ready the specialists moved in to cut the flooring. After surveying the sheet requirements, the best cut strategy was determined so to minimise the wastage of the Marine grade ply wood. After marking out, the saw was again in action.

With so many obstacles the vestibule area sheets are the trickiest to cut and fit.

With the floor up and the "wood butchers" working out their cuts attention turned to the doorway entrances and tread plates.
With the flooring gone the silicone was picked out of the screw and drain holes to remove the brass tread plates......

....and the tread pulled clear of the supporting timber.

With the tread up and the timber out the old rusted bolts were removed - eventually!

Throughout the car some rivets have been found to be loose so the decision was made to drill out and replace the angle mounting section around the entrance doors.

With the metal work completed the wood men can return.

The new year attack was a 2 day effort and accommodation was booked at the nearby Court House Hotel. A "bonus" of this location was the rooms being located in former NSWGR 600/700 class railcars - the forerunners of the 620/720 sets.

Despite being "grounded" the cars still feature many original fittings and provided a comfortable bed for the night. These self contained rooms provide an ideal overnight stay. 4 rooms are available, the hotel can be contacted on (02)49385122.

Next day Kingy arrived early (!) and full of enthusiasm to tidy up the car exteriors. First the blisters got the disc treatment.....

....then the tidy up with a fine sand......

...and finally a coat of etch primer to treat the surface.

The blisters arnt extensive all over but theres still a few to do up and down the cars.

Also on the outside of the car, Bob prepared the side sheeting for painting by removing the various stickers.

After heating, peeling, scraping, peeling, polishing, peeling, scratching, peeling...... the L7 logos were removed. These were put on with good glue!

The roofs of the cars were silver throughout their lives and various colour schemes until the introduction of the Cityrail "prong" colour scheme when they were painted grey.

An inspection of the roof reveals that the CountryNet radio Satellite Dome antenna has been removed but the GPS & UHF antennas are in place.

In preparation for the full heritage repaint and to seal the roof to prevent leaking during outdoor storage Pete has now applied a coat of roofing silver. First the edges and joints get a touch up from the brush....

... and then the trusty rollers finish the job. The outcome is a gleaming, shiney roof. Lets hope it cools the car interiors down too!

This before & after shot shows the difference. 629 has now been done too.

The car end canopys are fibreglass mouldings and have suffered with the outer surface badly worn, possibly from tree damage.
To ensure they continue to serve for many years they have been given a quick buff to remove the flaking and rough edges......

....and then coated with prep and sealer coats to protect the fibreglass.

After the treatment it looks like it should be on the commissioners train.

At the end of another work attack the cars are again closer to being ready for their next move. Its amazing what a few oldmates can achieve with planning and team work. Thanks guys.

A rotten lot

2008-12-29T02:00:00.000-08:00

Day 2 of the restoration task dawned clear and bright but that was about to change.
The exterior of 629/729 is clad in aluminium sheeting which like all things exposed to the elements, has deteriorated in some areas. Fortunately the corrosion is not extensive and appears as blistering patches.

The "Clean & strip wheel" (a weapon of choice from previous restoration projects)easily cleans up the surface corrosion to reveal a shiny flat surface again.

With a quick clean up from a fine sanding disk the sheet is ready for a coat of primer and eventual painting.

Rain soon stopped our external play so works moved to inside trailer car 729 to make a start on the rotten flooring.

Previous examination had highlighted some wet areas of flooring but we soon discovered that the joists below the plywood floor were in some cases in worse condition than the timber above.

To be able to do a complete assessment the "Cityrail" lino was taken up....

...and the seat plates which had extensive rust and/or seized bots removed.

On the surface most of the plates look good but underneath is a different story.

In recent times damaged floor plates were replaced by stainless steel examples. A great initiative to avoid future problems and one we're keen to continue.

By poking and proding the worst areas of flooring were identified and so the cutting of sections commenced. In some cases complete panels have been sacrificed.

With the panels cut back to sound timber the old panels are lifted....

...to reveal the dark secrets underneath. Years of road dirt, sound deadening insulation and moisture make for a pretty grusome environment for timber. With the water held by the sponge like insulation the timber is continually wet and of course rots to the point were it breaks up with a scraper.

Not only will some floor panels need replacing but many joists will also be renewed.

Another advantage of lifting the lino is that we are learning whats underneath. The lines of the cars electrical conduit run can clearly be seen staggering their way along the car from side to middle to side.

Having cleaned out the problem underfloor areas another rain storm conveniently revealed the main cause of the water problem.

On close examination it was found that the water didnt leak through the windows as we thought. It enters behind the external upper window strip and then channels down through the body pillars, and emerging at the base of the car side, leaking directly onto the underfloor aluminium sheeting.

Now we know the problem our next task is to fix it!

A journey of discovery.

2008-12-23T02:28:00.000-08:00

Railcar set 629/729 was purchased by Goodwin Alco Pty Ltd from RailCorp on November 14, 2008, nearly 45 years after it ran its first trial trip to Katoomba & return on 26/11/63.
During its years of service throughout NSW 629/729 has undergone several changes of configuration and colours. It is Goodwin Alco's intention to authenticly restore 629/729 to an appearance reflecting its early days of service.
When received from RailCorp both cars were painted in the Cityrail "Prong" livery which included safety yellow ends and window bars to limit limb movement outside the car windows.

Inside, the cars have also been heavily "Cityrailed" with a light grey colour throughout on the walls and the vinyl seats painted blue.

Fortunately the batteries fitted to 629 are in good order and have already supported the starting of both traction engines.
To minimise movement and potential damage, some timber packing has now been added to stabilise the batteries within the battery boxs.

Electricly the cars seem to be in good order too however one of the newer type jumper receptacles requires repairs having apparently been damaged in a shunting accident.

To make restoration works more comfortable, the metal brackets which had been screwed to the window frames to restrict movement have been removed. Air flow within the cars is now considerabley improved.

It was decided early on that the blue seats "must go"! Restoration works are beginning with the trailer car so the removal of the seats has been completed.

Without the seats fitted, the car interior suddenly becomes considerably more spacious however their absense also highlights a few issues that lurk below.

In readiness for ceiling cleaning and painting the remaining original fittings are being removed or masked ready for spraying.

On the edge of the saloon luggage racks the rubber trip has been damaged and in some places disappeared. The strip has all now been removed and we're on the lookout for a supplier of the original material.

Most internal fittings are in place although a few of the saloon cooling fans will need to be replaced or rebuilt.

Due to the ingress of water some areas of the floor have been found to be in poor condition.
To keep the cars in service and the seats securely fastened, ply wood patches have been used in some areas to hold the seats in place.

The worst areas for rot are along under the windows and near vestibule doors.

The seats bolt into base plates which are secured to the floor. Unfortunately once the water gets in the metal starts to rust!

The floor outside the toilet area has rotted particularly badly - we suspect from a leaking pipe.

Near the doors the vestibule walls are subject to regular exposure to rain water, the results of which can be seen.

The upper and lower panels of the interior saloons were bordered by a aluminium cover strip.

With this strip off some earlier colours can be identified and samples prepared.