M59137 Restoration 2005-Present

M59137 was the vehicle in the worst condition, of the 104s preserved on the CVR, as a result of decades of unchecked water leaks which reduced the bodywork and much of the internal metal/woodwork to such a condition that it would need complete replacement. However its historical significance of being the only class 104 Trailer Composite Lavatory (TCL) to survive, plus being the only centre car on the CVR, means it is worth saving. Overcrowding on M50455/M50517 during the summer season in 2005 identified the need for an increase in seats so plans for a second 2-car set were shelved in favour of the faster option of restoring a single vehicle to insert in between the running set to produce a 3-car. The rebuild was started in 2005 and achievements so far include: a complete lower half re-skin; restoration of the main bodywork & reglazing; removal of the toilet walls and replacement of the floor at the rear of the vehicle; reconstruction of the toilet bulkheads & refurbishment of other bulkheads; full refurbishment of the heating system; much of the wooden interior pieces (both visible and non visible) remade from scratch. Plus hundreds of other tasks too numerous to mention. M59137 is by far the most comprehensive restoration we have attempted to date, and progress is still ongoing. This gallery is often updated, with the latest images at the bottom of the page. Newly added images are highlighted yellow.

2005

  1. View M59137 being cleared out ready for moving to Cheddleton for restoration
  2. View M59137 being cleared out ready for moving to Cheddleton for restoration
  3. View Internal gutter having been primed
  4. View The upper part of the vehicle was found to be in much better condition
  5. View The maze of wiring which had to be removed from M59137 for welding to commence
  6. View New steel which will replace the rotten framework that was in place
  7. View The toilet unfortunately had to be removed completely
  8. View Mark clearing the internal gutter of old stuff
  9. View Kevin clearing the internal gutter of old stuff
  10. View The team get cracking!
  11. View M59137 in "as found" condition after being dragged up from Oakamoor
  12. View M59137 in "as found" condition after being dragged up from Oakamoor
  13. View View of the first class saloon
  14. View View of the first class saloon
  15. View View of the middle saloon
  16. View View of the rear saloon
  17. View View of the rear saloon
  18. View An extreme section of the bodyside rot
  19. View Mark on door removal (very tricky)
  20. View Chris removing old lino to remove the floor
  21. View The result of one of the bad leaks
  22. View The result of one of the bad leaks
  23. View Old flooring stacked up in the middle saloon
  24. View Lower door area (once we'd prised the thing open!)
  25. View Chris getting started on an exterior door
  26. View Kevin removing rotten wooden door pieces
  27. View The actual framework (structural) was completely gone in most places
  28. View The entire floor and exterior skin of the rear saloon was rotten beyond repair
  29. View Stripping the toilet end
  30. View The end that would be a cab if it were a driving vehicle during stripping
  31. View The end that would be a cab if it were a driving vehicle during stripping
  32. View Roger sealing vents into the night...
  33. View With the doors off hardboard covers were made as a barrier from the weather
  34. View M59137 now fairly well stripped

2006

  1. View Seat frames after being painted off site
  2. View Door dismantling, which took weeks...
  3. View General view of the unit after entering the shed for a lower half re-skin
  4. View The first bodyside panels are removed
  5. View New hardwood window "grippers" being made
  6. View The rear Saloon is now well underway with new steel now appearing
  7. View Toilet End after the rotten floor had been removed
  8. View New steel panels after painting. Note the cut outs for the bottom of the windows
  9. View Buffer beam rubberised paint before sandblasting
  10. View Worksplate "revealed" after sandblasting
  11. View One of the many steel panels being clamped in position ready for welding
  12. View The "other side" taking shape
  13. View Brand new hardwood bearers now in position
  14. View The toilet end in early 2006 shortly after we removed the corridor connection
  15. View The corridor connection awaiting attention
  16. View Toilet interior during stripping
  17. View The rot opposite the toilet
  18. View Chris & Kevin busy removing a corridor connection
  19. View Paul dismantling a corridor
  20. View Roger starting the metalwork
  21. View Kevin continues with the exterior doors
  22. View Showing the removal of one of the steel sheets
  23. View The toilet mid strip
  24. View The rear saloon without its wooden flooring
  25. View The toilet during stripping
  26. View Roger & Kevin happily pulling bits off the vehicle!
  27. View Roger & Kevin happily pulling bits off the vehicle!
  28. View Roger dealing with corroded sections
  29. View Lots of wires travelling up a rotten piece of steel
  30. View M59137 now in the shed for the re-skin
  31. View One of the horrors that were revealed to us
  32. View As we chipped away the floors filled with rust...
  33. View This was once used to channel heat into the saloons
  34. View Kevein working on the "internal gutters"
  35. View Paul removing heater ducting
  36. View Kevin dealing with window pins
  37. View Mark replacing a smashed window
  38. View Chris dealing with window pins
  39. View Some brand new pillers going in
  40. View Hardwood that will run the lenghth of the saloons and support the floor
  41. View Out with the old and in with the new
  42. View The solebar that is finally revealed under all the rotten wood and metal
  43. View One of the crusty bits...
  44. View These steel "feet" worryingly support the sides & roof of the vehicle
  45. View Replacement steel "feet"
  46. View Bit by bit the bodyside from the waist down was removed
  47. View Mark preparing for the bulkhead removal
  48. View Mark removing more rotten bodypanels
  49. View The new framework goes in...
  50. View The new framework goes in...
  51. View Bits for the new framework
  52. View Round where the toilet was cut away
  53. View pane of glass after thorough (and time consuming) cleaning
  54. View Kevin removes a heater
  55. View Attention turns to the toilet filler tank
  56. View Kevin cutting away more steel
  57. View Kevin protecting the new steel frame
  58. View Chris testing that the filler tank holds water
  59. View Mark cutting away at a door frame
  60. View Chris painted the newly repaired heater ducting
  61. View More surgery
  62. View A crusty window corner (which ones weren't?)
  63. View Kevin loading up the sand blaster
  64. View The centre car during Sand-blasting
  65. View Kevin blasting the battery box
  66. View Roger takes on the solebar
  67. View Starting to look like a 104 again!
  68. View Nice shiny bodywork - no rust!
  69. View Roger welding new panels in
  70. View Richard protecting the panels post welding
  71. View Chris continues with glass cleaning
  72. View The end for 2006, and Roger still has more metalwork ahead...

2007

  1. View Kev getting stuck into windows in January
  2. View Kev getting stuck into windows in January
  3. View Whilst in storage the toilet bulkhead was snapped
  4. View Once the new steel was in the sanding and filling began
  5. View The rear saloon steelwork, 25.2.07
  6. View April 2007, first class welding in the first class saloon!
  7. View M59137's front saloon framework being completely replaced, March 2007
  8. View M59137's bodyside receiving green paint in April
  9. View Z600 M59137 R''tion 2007
  10. View More of M59137's bodywork in July
  11. View M59137's bodywork taking shape in green primer, 25.2.07
  12. View Lower Half re-skin progress in March 2007
  13. View Lower Half re-skin progress in March 2007
  14. View The vehicle pulled out of the shed almost showing a before during & after effect
  15. View Paul attending to some rotten wood
  16. View Pillar replacement had now reached the far end of the vehicle
  17. View The framework of the first class area, which was last to be done
  18. View Mark & Chris cleaning gutters in April
  19. View Gutter restoration
  20. View The "ceremony" for the generous lino donation
  21. View The framework of the first class area, which was last to be done
  22. View View of the end which had to be totally reconstructed
  23. View Retrieving doors from stores
  24. View Dismantling Class 101 doors in May
  25. View Dismantling Class 101 doors in May
  26. View Dismantling Class 101 doors in May
  27. View Dismantling Class 101 doors in May
  28. View May: One of M59137's partly stripped doors
  29. View M59137's stripped doors in June
  30. View Chris & Frank cleaning door droplight scissors
  31. View Paul & Chris sanding down the bodyside of M59137
  32. View Kevin protecting the framework of the north end
  33. View Kevin undertaking more bodywork
  34. View M59137 after receiving a top coat of green at one end in late 2007
  35. View The vehicle was moved into the carriage shed for 2 weeks to be glazed

2008

  1. View M59137 out of the shed, exterior restoration now quite advanced
  2. View "This Door is not in use"
  3. View Heater ducts taking shape in M59137
  4. View M59137 glows in the dark (the lights are unrestored despite how it looks!)
  5. View Door frames
  6. View Corridor connection "scissors" ready for restoration
  7. View The scissors after being cleaned and painted, hanging up to dry
  8. View The area of roof at the toilet end. This area was rebuilt in 2008
  9. View The toilet window, boarded up till the frosted glass can be sourced
  10. View Rotten hardwood "plinth" that forms part of the floor in M59137
  11. View Gap where the heater port should be to bring hot air into M59137's saloon
  12. View View of the back area which has recently been fully protected with paint
  13. View Fully protected ceiling in M59137's rear saloon
  14. View Restored toilet tank supports
  15. View Z174
  16. View General view of M59137's first class saloon
  17. View Chris putting heater ducts together
  18. View Replacement part for the sealant "gun"
  19. View Window runners (fit inside M59137's doors) soaking
  20. View Various door "innards" having been gloss blacked (BR gave them no protection)
  21. View One of two original door skins which will be reused on M59137
  22. View One of the class 104 doors which has been modified to fit a class 104 frame
  23. View Kevin busy altering the curvature on a class 101 door to fit an M59137 frame
  24. View Various parts of heater ducting which have been glossed (some will be visible)
  25. View Terry Essery helped the group cleaning internal runners for M59137's doors
  26. View Flattening the edges of the 101 door skins as they'd been pulled out to fit
  27. View Light shades: before & after
  28. View Light shades: before & after
  29. View Light rings: before & after
  30. View Light reflectors: before & after
  31. View First complete door for M59137 (front)
  32. View First complete door for M59137 (back)
  33. View Kevin working on M59137 doors
  34. View Kevin protecting a door frame
  35. View New wooden surrounds for heater ducts in M59137 complete
  36. View Buxton Poster from M59137 - still there 25 years on...
  37. View M59137 middle saloon now protected
  38. View New hardwood battons running the length of M59137
  39. View New hardwood batton under a window in M59137
  40. View Toilet bulkhead during a test fit before the toilet reconstuction
  41. View Kevin busy working on window surrounds
  42. View New wood for toilet bulkhead to secure to
  43. View Framework in the toilet area coming together
  44. View Toilet Door during stripping
  45. View Chris finishing off the heater ducting
  46. View The toilet area showing progress with the framework
  47. View Chris spotted on M59137's roof!
  48. View Clamping one of the unusual angles that form the five sided area
  49. View The toilet walls secured in place after nearly 2 years of absence

2009

  1. View An under-door heater duct for M59137 being weatherproofed with insulation & tape
  2. View An under-door heater duct for M59137 having been weather-proofed
  3. View An under-door heater duct for M59137 with the corner "ports" test fitted
  4. View M59137 being shunted down the yard
  5. View M59137 being shunted in the yard
  6. View Two corner ports than channel the heat under the door linking the saloons
  7. View M59137's middle saloon
  8. View Bolting heater ducts together
  9. View M59137 in its new home at the bottom of the yard
  10. View Luggage rack back in "as found" condition
  11. View Luggage rack back in after refurbishment
  12. View A refurbished luggage rack back on the right & a badly damaged one on the left
  13. View The first section of bulkhead to be varnish stripped
  14. View Colour comparison of stripped (right) and untouched (left) bulkheads
  15. View 16 refurbished lighting rings, now in store till the ceilings are fitted
  16. View M59137 in the evening sun. Work on the interior continues steadily
  17. View M59137 at Cheddleton
  18. View M59137 is shunted into a new position in the yard
  19. View M50517 passes its future partner vehicle
  20. View Varnish Stripping a First Class Bulkhead
  21. View Part of M59137's underframe now in black
  22. View Restored GRP vestibule heater duct cover
  23. View Restored GRP saloon heater duct cover
  24. View Restored GRP Passenger Communication Valve Covers
  25. View Restored GRP Heater Control Box
  26. View Jumper Cables before & after cleaning
  27. View A Jumper Cable after priming
  28. View More wooden battons being fitted to M59137
  29. View A sanded bulkhead on the left, and a stripped one on the right
  30. View Kevin sanding a bulkhead
  31. View By September both the overhauled saloon heaters had been fitted to the vehicle
  32. View Close up of the exposed and sanded wood veneer present in second class
  33. View An unsanded section of second class veneer below a sanded section
  34. View Close up of the exposed and sanded wood veneer present in first class
  35. View A second class bulkhead partially varnished in this comparison view
  36. View The toilet bulkhead is like a mirror after its first coat of varnish
  37. View Kevin carefully varnishing. Note the reflections in the surface
  38. View A comparison of a sanded bulkhead on the left next to one that's been varnished
  39. View Varnished on the left and just sanded on the right in first class
  40. View Kevin varnishing a first class bulkhead
  41. View Heater ducting now in position
  42. View Luggage rack backs now in position
  43. View Luggage rack backs now in position
  44. View Internal ceilings under restoration off site
  45. View M59137 at Cheddleton

2010

  1. View Chris fitting insulation in January
  2. View Fully insulated Rear Saloon in January
  3. View Insulated Rear Saloon roof in January
  4. View Insulated Middle Saloon roof in January
  5. View Work continues internally in M59137 at Cheddleton during the snow in early 2010
  6. View Wooden battons now fitted with the insulation during February
  7. View Hand made ends to the heater ducting
  8. View Fitted hand made ends to the heater ducting
  9. View Chris fitting battons during February
  10. View Wooden battons now fitted with the insulation during February
  11. View Where the heater ducting will cover the battons
  12. View Where the heat for the toilet will emerge from
  13. View M59137 showing the old roof paint on the side (May)
  14. View The untreated roof showing the vent plates (May)
  15. View Top of the toilet tank (May)
  16. View Close up of the side that had the most BR paint left (May)
  17. View Iain & Chris scabbling and sanding the centre section of the roof (May)
  18. View Chris & Iain scabbling and sanding the centre section of the roof (May)
  19. View Iain scabbling the centre section of the roof (May)
  20. View The toilet end now cleaned up and smooth again for the first time in many years
  21. View Chris primes the centre section of the roof after it had been cleaned (May)
  22. View Chris the great roof explorer! (May)
  23. View Chris Scabbles the east side of the roof (May)
  24. View The north two thirds of the roof cleaned and in primer (May)
  25. View Four weeks in and the whole roof was now in primer ready for the special paint
  26. View Four weeks in and the whole roof was now in primer ready for the special paint
  27. View Chris rollers on the special roof paint (May)
  28. View The vehicle, now complete, with grey roof (May)
  29. View The vehicle, now complete, with grey roof (May)
  30. View The vehicle, now complete, with grey roof (May)
  31. View New door frame components have now arrived having been made specially (May)
  32. View New door internal gutter (May)
  33. View Kevin drills drain holes into the bottom piece of one of the door frames (May)

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