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Great Western Railcar W20 Project Report: October 2024

Great Western Railcar W20 Project Report: October 2024

Photo courtesy of Neil Edwards

This longstanding restoration project had been slowly but steadily progressing - often against the odds - for a number of years until in 2022 the volunteer team found their project not only adopted and encouraged by the Board but also fully funded. This was thanks to a £20,000 grant from the Association for Industrial Archaeology (AIA), match funded by the Kent and East Sussex Railway Board, and very generous donations from an appeal to members and the public which raised another £20,000 and more. Hence the "20 for 20" appeal slogan, with three times £20K funding streams.

This fundraising success enabled a new plan to be set in motion, with the team endeavouring to devote two days a week to progress the work. After a good start, things didn’t quite go to plan: more than once other urgent work in Carriage & Wagon meant that W20 was banished to Rolvenden thus halting the restoration and shifting back the completion date.  However, on each occasion, the team were able to assist C&W with their urgent projects to hasten W20’s return to C&W.

Despite these hiccups, progress has been considerable - as reported in previous Newsletters and the pages of the Terrier. Space here precludes a long list of the achievements, but the following will give some idea of the scope of the work accomplished to date:-

  • Engines, gear boxes and transmission overhauled and fitted
  • Wiring installed throughout the vehicle along with batteries and LED lighting
  • Pneumatic and vacuum systems installed and tested
  • Controllers refurbished and installed
  • A custom-designed heating system installed
  • Roof, side panels and guttering completed and painted
  • Robertsbridge-end cab metalwork created and fitted
  • Fireproof flooring installed throughout
  • 90% of the windows and wooden surrounds installed
  • New ceiling and lighting installed in both saloons
  • Interior painting and rexine coverings completed
  • All seats re-upholstered in ‘original’ style replica moquette
  • Luggage area fitted out and painted. Old heating cabinets refurbished and converted to create a useful storage facility
  • Vehicle lifted for final bogie and wheel examinations
Seats have been re-upholstered in replica moquette. Photo courtesy of Neil Edwards

To ensure that W20 is fit for its 21st century journeys, the team has chosen modern materials where appropriate e.g. LED saloon lighting; a new Diesel hot water heating system; ceiling material, the floor base and fireproof layers as well as the floor top covering. These will ensure longevity, ease of maintenance and, more importantly, comply with the I.C.P. requirements, ensuring the safety of the vehicle and its passengers without detracting from its heritage look and feel.

Interior refitting includes new LED lighting. Photo courtesy of Neil Edwards

One particular modification is within the luggage compartment. Due to the very narrow saloon doorways of only 1’ 8” the luggage compartment, with its large double doors, will now provide for accessibility-challenged passengers. The revised design should provide sufficient space for three wheelchair-bound passengers with seating for up to three people accompanying them. The only noticeable change to the interior will be the use of lino on the floor instead of the wooden slats and the fitting of wheelchair restraint mountings: a small price to pay in authenticity to deliver this capability.

A new metalwork contractor began work in August 2024 to fabricate two cab ends and the roof domes. With the completion of the Robertsbridge end, the task of drilling and countersink punching all of the sheets can start, in preparation to finally secure the new cab panels and dome onto the vehicle frame. Once this is achieved, the fitting-out of the cab interior, installing the controllers, and the driver’s desk can be undertaken. Also, with the cab dome fitted the small saloon can be finished. This includes: fitting the last ceiling panels, putting in the final windows, laying the floor covering and installing the seating. Then only finishing the large saloon and Headcorn end cab remain to be tackled.

Without the hard work of our volunteers and the support of a number of key people, the project work would be nowhere near as advanced as they are. Particular thanks go to: Alan Brice in C&W; Project Manager, Neil Edwards; Board Project Sponsor, Derrick Bilsby and Independent Competent Person Steve Beck, from Cambrian Transport, who ensures that all the work that the team undertakes is completed in a professional and compliant way, and most importantly, a safe manner.

Chris Mileman

October 2024