I am returning to one of my favourite subjects, Heljan Westerns.  My sixties layout is shall we say ‘stuck in time’.  Rather than purchase the latest model shop offerings I have been backfilling some gaps in my ‘stock book’ from eBay.  Whether it is a sign of the times or just an ‘age thing’ but I have picked up a number of excellent ‘unused’ models, and in one case unopened from around ten years back.

Heljan is a particularly interesting manufacturer in that their models seem to be designed to clip together with minimal use of glue.  The upside is that models can be taken apart and repaired relatively easily.  The downside is that the models are sensitive to impact and do not travel well.

 

Western Queen – fresh from the Post.  Spot the Reporting Number in the packaging

 

Heljan 5218 aka D1040 Western Queen – missing one reporting number

 

Judging by the number of advertisements for models with missing Train Reporting Numbers these parts appear to be particularly sensitive.  A little knowledge is dangerous.  I have spare sheets of numbers which can be scanned and reused.  When a model was advertised with a missing number I thought, not a problem – I can make a new plastic window and cut a replacement number from one of my existing sheets.

 

Heljan Train Reporting Number Window

 

The little windows for the reporting numbers are a push fit and can be poked out from inside the body shell with a wooden cocktail stick.  Mine measured 7 x 5 mm and I cut a rectangle from some scrap glazing out of an old Mainline coach (I was going to use the lid of a CD case).  I don’t know the exact thickness but I used one of my wife’s emery boards to reduce the thickness to be the same as the existing. 

 

]Heljan Train reporting Number Glazing

 

The corners need to be rounded and then the plastic repolished using something like automobile metal polish.  There is an element of trial and error in the polishing and fitting process.

Time to fit the numbers - I should add that if the number needed is not already on the sheet or has been used then one way of making the replacement number is to save a scanned image of the sheet to a programme like Word and cut and paste the required number from another part of the scanned image.

 

Heljan Western (Class 52) Train Reporting Numbers

 

My model of Western Queen was missing its number ’27’.  This didn’t feature on my Heljan paper sheet so I would cut and paste a ‘7’ into the top line to make the missing ‘27’.

 

Heljan Train Reporting Numbers 5218 aka D1040 Western Queen compared to earlier models

 

Oops – I don’t know how I missed this detail.  Whilst the early Heljan Westerns had clear windows and paper reporting numbers, the newer models such as Western Queen came factory fitted with the numbers bonded to the rear of the window.  Furthermore the font type and size on the two models is significantly different – note especially the shape of the number ‘2’.  Don’t ask which is correct.  I was only interested in matching and replacing the missing numbers on my model.  (Carter’s drawing in his book British Railways Main-Line Diesels is not sufficiently detailed to estimate ‘window’ sizes and omits totally any font.)  After some trial and error I alighted on the font and size combination shown below.  Using Word it is a simple operation to insert a text box, add a black fill to the background and print in white.  (I use the same technique to make smoke box door numbers.)

 

Heljan 5218 aka D1040 Western Queen Train Reporting Number Font Size

 

I would cut out my Train Reporting Number and use some varnish to attach the printed paper to the plastic window.  It all looked very grey. 

 

First attempt using varnish for fixing compared to genuine numbers old and new

 

The numbers on Heljan Queen had a white painted backing – I would use some Humbrol enamel.  The varnish took time to dry – I would instead use some of Mr Wilkinson’s ‘Super Glue’ – it worked a treat.

 

Heljan 5218 aka D1040 Western Queen – which one has the replacement ‘27’? (I forgot to make a note)

 

For comparison I have included a picture below of Queen and I think Campaigner fitted with paper printed numbers – highlighting again the different font types and sizes.

 

Heljan 5209 aka D1010 Western Campaigner compared to Heljan 5218 aka D1040 Western Queen

 

Moving on to another unused model, Heljan 5213 aka Western Enterprise (with small yellow panel). This one recently arrived complete with signed health check dated 2010 from the Hereford Model Centre.  I am thinking that Explorer might have been one the first Heljan models to have been produced in China because there are a couple of production related issues.  Firstly and most noticeably the skirt and body shell are different colours.

 

Heljan 5213 aka D1000 Western Enterprise

 

Secondly the body shell was unclipped on one side from the chassis.  Further investigation showed that the two cab ‘open’ windows were unglued.  After not a little time I decided that surplus glue applied around the running lights was preventing the black nylon cover plate to the wiring from sitting flat which in turn was pressing against the cab seating unit, and since the seating unit is clipped to the opening side window this could account for both the window being dislodged and the body shell not sitting down correctly.

 

Heljan 5213 aka D1000 Western Enterprise cover plate and wiring for running lights

 

Heljan 5213 aka D1000 Western Enterprise – cover plate raised by wiring

 

Relative position of cab seating unit

 

As stated at the start, Heljan models are made to clip together and can generally be successfully pulled apart.  I don’t know whether the cab side window is designed to be held in place by the cab seating unit or vice versa.  I used a dab of super glue to hold the window in place before I clipped everything else back into position. 

 

For completeness the cab side window showing fixing slot for seating unit

 

Even after removing surplus glue from the wiring I was not convinced that the cover plate was lying flat and I used a file to remove some the ‘thickness’ from the seating unit where it might be contacting the cover plate.

 

Underside of seating unit highlighting areas where plastic was filed away

 

Back together it is 90% sorted - but perhaps that is as good as it will get, given that the plastic body shell has likely been sitting in the wrong position for nearly ten years.

 

Heljan 5213 aka D1000 Western Enterprise with small yellow panel

 

For comparison – a picture I took earlier.  I need to investigate some shades of Desert Sand!

 

Heljan 5204 aka D1000 Western Enterprise no yellow panel