British Rail 12 ton vented wagon conversion

[Wildefalcon]

The last bit of steel for this repair is curved.

I don't have any fancy tooling, so I improvised.

 

[Wildefalcon]

I'm also going to bolt up the existing repair to ensure it stays somewhat straight.

20 x 16 mm holes. I like step drill bits.

 

[Wildefalcon]

And, some fettling later.

Ready for the hot steel melting machine.

 

[Wildefalcon]

I have a new in box RS Pro threading set, not cheap though, I would be looking for £30

Yay!

@Robotstar5 Thank you!

 

[Wildefalcon]

And some good, for me, welding, and some crap welding. One and the same?

 

[Wildefalcon]

All (exterior) evidence of pigeon droppings removed. And bolted together, tacked and ready for rivets welding in.

 

[Wildefalcon]

The lower seam isn't as bad in some respects, and worse, in others. But as I'm fed up with this heat, I'm going for an expedient approach.

There's about 5mm of rust between the angle and the pressing, but only a few were ballooned out. I've cut around the rivets and removed the rust. I'll weld in new tomorrow.

 

[Wildefalcon]

And an experiment.

Citric acid rust removal. Just a thick gloop of water mix for now. I'll try adding wall paper paste in the morning.

 

[Wildefalcon]

Finally, the corner of the pressing has a few holes and the edge was thin. So I spat steel into holes and along the edge.

I was able to get the thin disk up into the rust and hopefully break it out of the seam.

 

[Wildefalcon]

It looks good. Management is happy.

 

[Wildefalcon]

And the corner will grind into shape.

 

[Wildefalcon]

So, bar a bit of grinding and simple welding. It's done. I'll pause once that's all done, as I've other stuff to sort. But next week I'll go at getting the rails sorted, at one end at least.

 

[Wildefalcon]

You know I said it works be a quick session?

Well .......

 

[Wildefalcon]

I started on the rail under the pressing.

It made sense at the time.

The logic was that I found some more rot, so wanted to make sure I got it all.


The citric acid did do something, I think. But the scale is so thick it didn't do much.

I've hammered, chiseled, reciprocating sawed and wire brushed this lot.

I'll finish this, weld in new and then, honest, call it a day.

 

[Wildefalcon]

Oh, and the corner came up nice.

 

[Wildefalcon]

All patched up. Going to grind it down this afternoon.

 

[Milkybars]

I spotted this ..some inspiration

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[Wildefalcon]

I spotted this ..some inspiration

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Noooooooooo!

Inspiration equals perspiration.

 

[Wildefalcon]

Final bit of welding and grinding done. I'll pack up after dinner and that's it for a few days.

There were a few holes in the first welds, where the old material was thinner and I was too lazy to cut a new patch so spent twice as long chasing rust with the welder. So I chased the rust more, then ground it back again.

 

[Wildefalcon]

I'm looking forward to getting paint onto this.