M59137 Restoration (Still In Progress)

M50455/M50517 had been in service at the CVR for less than one season before the railway showed concerns about the 2-car set’s capacity. Originally, we had intended the DMU set to be used at the start/end of the running season, operating an off peak service when a steam locomotive could not be justified. However it soon became apparent that the DMU’s role was to run during the very busiest of days as a second train on the line.

Therefore rather than the original plan of the restoration of a second 2-car set (formed of the next two vehicles in the best condition), the decision was taken to start the restoration of the vehicle in the worst condition, centre car M59137, which would enable a 3-car set to be formed upon completion, and boosting capacity of the 2-car set by more than 50%.

The project started in August 2005 when members went to Oakamoor storage sidings to both assess and clear out M59137.

During the autumn the interior of the vehicle was cleared of the debris we’d left during the vehicle’s time as a restoration workshop. In October 2005, the vehicle was moved to Cheddleton for stripping to commence.

The floor was removed from the rear saloon after the entire area was found to require replacement; such was the extent of the water ingress. All of the following items were also removed for later restoration: heater ducting, seating, panelling, all interior timberwork, ceiling panels, insulation, heater controls and all internal and external doors. By winter the vehicle was practically a metal shell on wheels, this was deemed necessary as the steel bodywork was so rotten the vehicle would require re-skinning its full length with substantial sections of the steel framing also requiring replacement.

As the vehicle’s eventual (long term) condition was to represent the 1980’s, the roof vent apertures in the roof were not to have vents so were plated over to make the roof watertight.

We also started dismantling the exterior doors for restoration inside as the winter set in.

Much work was completed on the doors, with about 50% of the exterior frames being completely rebuilt. All the door “fittings” and mechanisms were also removed for full restoration. Batteries for the vehicle were prepared (ex Mk2 coach) and the battery boxes restored ready.

Attention then turned to the interior of the vehicle, which of course by now was completely missing. The new heater ducting was designed, steel delivered and assembled ready for fitting. The interior lights were all stripped down and lovingly restored to an immaculate appearance over several months! Two saloon heaters were sent away for refurbishment and were refitted to the vehicle. The mountain of interior hardwood strips, of which there are many in all shapes and sizes, was started by Kevin who usually leads all things wood. A lot of time was spent repairing and sanding the sections to bring them back to an almost original appearance ready for refitting to the vehicle. The toilet framework and bulkhead was also refitted to the rear saloon.

Much of the summer was spent away from M59137 as group members temporarily joined the restoration team of the 4-Vep Electric Multiple Unit 7800/7851 (previously numbered 3822) two coaches of which was being restored in time for the diesel gala. The team also saw distraction in the autumn organising our second Railcar Gala.

Work on the interior continued throughout 2009 with the first parts of the under floor heater ducting being fitted. The “luggage rack backs” (large sections of alloy that join the ceiling to the tops of the windows inside the vehicle) were all rebuilt and their appearance improved using industrial cleaner. The jumper cables were also restored.

The hardwood interior mission continued with further repairs being carried out. Woodwork inside the vehicle included the stripping, sanding and varnishing of the saloon bulkheads which had to be done very carefully as the veneer itself is less than 1mm thick. Towards the end of the year the first coat of protective varnish had been applied, transforming their appearance.

Distractions for 2009 included the assistance in the mechanical restorations/repairs of a Wickham Trolley and the Permanent Way Department’s Ex-Class 101 DMU which had arrived in September 2008. The team also had to contend with several major engine failures on our running vehicles which at times tied up 75% of the group.

Much of 2011 was spent on other projects including the stripping of the departmental Class 101 for spares and the restoration of GUV W86500. Consequently little work was completed on M59137.

However the exterior doors edged ever closer to completion, with more skins being attached to frames ready for eventual fitting.

This update is correct to 27/7/11. More information will be added as the project advances...