Day two of the TPO conversion,

Continuing where I left off on Sunday, the first job was to finish off removing the remaining window frames. Once removed the area was all sanded back ready for fitting the new windows. Another removal task was on the doors, as it stood I had carved off half a mm from the top of the door (there was a recess above the top of the windows). In order to assist in fitting the replacement doors I have carved off a further mm of plastic so that the hole where the windows were is extended up to the roof. This should mean that there is now just a single joint which will need filling rather than two.

Next up it was time to start work on the replacement windows, looking at photos there are two potential diagrams the first batch built 1961 Nos 80309-18 (ie the Bachmann model refurbished with small windows) and a second batch built 1968/69 Nos 80328-38. It looks like the later version has the windows in the centre section equally spaced and no window on the right hand panel, whereas the 1961 build has a different spacing (a wider space between the middle two windows) and has an additional window on the right hand panel)
I am still struggling to find decent quality photos of TPO stock online especially in these number series.

I am tending towards the later build, purely because I have already blanked off the right hand window before I realised there were two designs. Though I would certainly like to see more photos of the earlier batch, especially to see if the window on the right hand panel was on the whole batch.

Back to the build, the window blank was prepared from 40 thou plasticard (approximately 8mm by 5.5mm from memory). A strip 5.5mm thick was cut and then chopped to 8mm lengths with my NWSL Chopper. The corners were then rounded off and it was glued into position on the coach (with a second piece of 40 thou glued behind to reinforce the joint.)
I now have 5 more of these easy blanks to fit before I need to start on the more involved parts that need the new window included.
I have a plan forming for these (and the doors) drawing up the blank complete with window hole on CAD and then cutting from 2 layers of 20thou plus the 10thou window frame with the Silhouette cutter. I need to check one of these window frames against the model and see how much plastic will be around it (to confirm if it is easier to just add a strip of x thou Evergreen strip around the edge of the hole and fit the new frame over the top.

The final job related to paint, having received an order containing a Vallejo paint that is a good match to the RAL shade for RM red, however it’s not such a good match to the model. Attempts to mix a shade to match have so far not met with success so it looks likely that a full respray will be needed, I will try the Phoenix shade tonight and see how it compares. If anyone knows of a good match please let me know.

A late finish last night limited the modelling time, which ended up solely spent on CAD preparing drawings for the TPO. As a result I now have a drawing for the secure window, and a plan for the window blanks that need fitting.
The drawing includes the security window along with a replacement door (which has the window hole included), I have also included a replacement panel / door for my NUA in case I cant get the replacement parts from DC Kits needed to finish it off.

This all now needs running through the Silhouette to cut out the parts, after which I can get back to work adding them to the model.

In a related not, I have also managed to find a suitable prototype for the model, better still it is an NSA (T) so satisfies that requirement from the formation document. This will be finished as 80334, it will need white TOPs numbers and a Rail Express Systems flash, I will also need a transfer for the “first class letters only” to go next to the new post box. The selection of this particular coach also means that I need to move the post box from the left hand panel to the right hand side of the centre panel.