RTW335 at BusWorks

Emergency exit - rebuilt

2012-01-26T18:42:00.004Z

As reported in the last posting, the Emergency Exit framing was partly rotten and this has now been rebuilt by our specialist joinery contractors. It has now been returned to us and will allow the relevant parts to be refurbished and refitted.

Emergency - Exit!

2012-01-13T12:53:00.002Z

Another example of one of the many restoration jobs that ends up being a time-consuming task. The Emergency exit framework was rebuilt last year before the rear dome was refitted but now it is time to tackle to exit door itself. The timber is partly rotten, a steel section is severely corroded and the whole door has had to be stripped for rebuilding. With the exception of the glazing, some of the component parts are visible in the picture below.

More pieces of the RTW jigsaw

2012-01-13T12:28:00.006Z

Over the last month, more pieces of the RTW jigsaw have been progressed in preparation for a reassembly onslaught once some other significant BusWorks' projects are completed (including conversion of some Big Bus Olympian buses for export and a double deck Limo bus).

We have commissioned some cant-rail 'drip' moulding that was once such a feature of bus bodywork in the 40s/50s in particular at a cost of £2,758 - but as usual with these things, the minimum order is enough to do about 10 buses!

Other work has included the preparation of parts that we want to get sprayed in LT red before re-assembly, allowing some of those 'difficult' to get to areas to be treated with paint. This includes the engine bonnet and front panelling, some between deck corner panels, the cab door & battery box panel

Sorry for the delay....

2011-11-24T17:44:00.004Z

One of the unfortunate problems with blogs - is that you are expected to keep them updated. I offer both the blog readers and RTW335's owners sincere apologies for the failing to do this over the summer & autumn months. I am sure many will be well aware that the BusWorks was affected by the effects of both the recession beginning to bite - and staff shortages resulting from previous recruits returning to Optare.

Anyway, back to RTW335. Following the resumption of work early in October, we are focussing on the reassembly of the upper deck interior. The restored aluminium window cappings are now being refitted and the new ceiling panels are back in - following a coat of Chiswick Cream - and likewise the aluminium cove panels with light fittings. Readers will recall that this follows the complete renewal of the roof timbers and aluminium panelling. The slatted timbers for the centre gangway are prepared, but await fitting - and the cork flooring for the areas underneath the seat frames are on hand.

Are biggest head scratching for the exterior - which impacts on the top deck - is the rubber gasket required for the new RT window pans. This is ongoing because neither the traditional RT rubber appears not to fit. We need to resolve this before finalising the fabrication of the non-standard front & rear window pans. Watch this space!

Finally, several specialist panels - carefully rescued when the bus was stripped down to its main frame - have been dipped to remove paint and will soon go away for respraying in two-pack London red prior to refitting.

Picture: Dave our coachpainter prepares the front interior roof dome for painting after returning from being dipped to remove previous layers of paint.

Please state your destination!

2011-06-11T21:48:00.003+01:00

We've had a good month on RTW335 during May, with many tasks that have been in preparation suddenly coming together and resulting in some good visual progress. For starters, the new roof panels are now refitted and the repaired rear roof dome, looking as good as new. The new stair treads are now in place on the rear platform after a complete rebuild. Visually though, the face of RTW335 looks a bit more complete by the refitting of the destination panel - restoring a part of the characteristic RTW frontal appearance. Next job - the cab framing!

Platform comes together

2011-05-06T20:11:00.006+01:00

Firstly, apologies to readers for the lack of posts. This is partly because your writer has been splinning too many plates - and partly going through a phase of laborious but not very interesting work on RTW335. Anyway, this week some of those efforts have resulted in something worth photographing!

After rebuilding all the platform steelwork - that was heavily corroded - and the platform riser, a newly fabricated platform bulkhead has been fitted (no small job in itself) and work is now progressing on reboarding the platform. This view captures coachbuilder Jim Howard finishing off the perimeter timberwork around the platform framing.

Window pans arrive

2011-02-27T19:16:00.005Z

The arrival of the first batch of specially fabricated steel window pans has allowed a big step forward in the restoration project. Four new units have been fitted to the lower deck, thanks to Rob Duker who had the units commissioned.

Other progress on the specialist timberwork continues, with the offside headlamp surround (illustrated) being one example of the joiner's work. Further joinery work has been completed at the rear end and both the rear wheelarches.

Emergency Exit rebuild

2011-02-11T20:40:00.002Z

The emergency exit timbers have been rebuilt this week, which means the rear roof dome and new aluminium roof panelling can be fitted. Other work has involved rebuilding the rear platform bulkhead and fitting all seat fixings and brackets on the lower deck. Good news also that some RT window pans are ready and we hope to collect these next week - then we really will start seeing some progress!

Panelling progresses

2011-02-03T20:58:00.002Z

Whilst work progresses on the lower deck, fitting new seat brackets and the rear emergency exit timberwork is rebuilt, further between deck panelling is in hand. Once the emergency exit timbers are replaced (which is quite complex), the rear roof dome can be refitted and the roof panelling completed. Still waiting for some window pans which would really transform RTW335!

Back with the dome

2011-01-22T17:10:00.002Z

RTW335's rear dome has arrived back after a few weeks of TLC having the dents knocked out of it and now looks as good as new. It has been prepared by a company that was formed by a small group of staff that were formerly employed in the TVR Cars panel shop at Bispham in Blackpool. The specialist shaped timberwork around the dome and emergency exit is being rebuilt (more rot having been found), but the roof panelling is now ready for refitting.

Also returned recently has been the window parts sent away for re-chroming - again all looking as good as new. All we need now are some window pans - these are being fabricated under the car of Routemaster owner Rob Duker.

Dome of discovery

2010-12-04T21:55:00.007Z

Ok, I know exactly what you're thinking - one step forward, two steps backward. Why is the roof panelling now off?

Well, this week we removed the front roof dome off RTW335 - it is completely shot. This resulted in two discoveries. The first was that it wasn't one dome - it was two! The outer panel was battered but this was actually a replacement dome with the layer underneath even more battered. Our other discovery was rot in the timbers underneath the dome. The roof panels on the RTW are solid riveted and overlap. To remove the front dome, the first roof panel had to be disturbed and some soft (but not rotten) timber was discovered. In the interests of RTW335's long term conservation and undertaking a thorough restoration, it was therefore decided to repanel the entire roof and replace the timber inserts. The ceiling panels have been taken down - although these were only loose fitted. Other developments are the fabrication of new seat frame supporting brackets and the top securing bolts so characteristic of the London RT and RM classes. Whilst new timbers for the front between deck area are awaited, the back board for the destination box has been replaced with new bulb holders and new wiring.

Plenty of seats on top!

2010-11-30T19:23:00.002Z

We have been busy fabricating the original style seat fixing brackets and this has allowed a trial refitting of the RTW seat frames. We have also made an interesting discovery - the seat backs from a Routemaster will (with a slight modification) fit RTW seat frames. RTW335 returned from Germany without seat frames, so the use of standard RM/RML backs will save having to fabricate from scratch.

Other progress includes removal of the front and rear domes - which are both badly dented and not fit for re-use. A local company will make new, using sister bus RTW467 as a template.

Fabrication of new window pans is in progress and the re-fitting of these will make a great visual appearance to RTW335's extensive restoration.

All that should glisten

2010-11-11T17:17:00.002Z

Not the most exciting of photographs, but one that illustrates one of the many tasks in bus restoration - one of the tasks that are taken forgranted. The photo is of the component parts of the wind-down half drop windows from RTW335. The units have been stripped down and separated from the glazing ready for re-chroming. Screws were seized, gears were seized or covered in years of solidified grease and rubber gaskets have perished - all need restoring to form their part of the many pixels that will become the fully restored picture of a London RTW.

RTW467 at BusWorks too

2010-11-02T11:25:00.002Z

As previously reported, RTW467 is currently at the BusWorks for some mechanical work and MoT submission - but also to have its seats completed retrimmed. We have taken the opportunity to take lots of detailed pictures of this vehicle to inform the detailed re-assembly of RTW335.

More from the blog roll!

2010-10-29T17:34:00.004+01:00

Other work in hand is the rexine covering of the internal window cappings on RTW335. If you scroll through the back pages of this blog, you'll see the condition of the interior with its cracked emulsion paint - the condition which 335 arrived to us. Despite the years stored outside and the generally damp interior, the aluminium window cappings are in good condition and fit to re-use. We are therefore stripping off the emulsion covered rexine, cleaning them up and fitting new green and cream rexine. The picture is not of a before and after - but of a cleaned up capping and one with new green rexine applied.

Back & blogging

2010-10-29T17:25:00.002+01:00

Steve Newman at Ensign reminded me that it has been over 3-months since any fresh news on RTW335 appeared on the blog. I know this is unforgiveable but I can only use the excuse of a very hectic summer, day-to-day life at the BusWorks being very busy and frankly being a bit 'blogged out' with keeping track of events for the Blackpool tram 125th anniversary and the projects I was managing as part of this once in a lifetime celebration. Anyway, enough excuses - I apologise!

Although visually work on 335 does not appear to have progressed as far as I would have hoped by now, work is still progressing. The rear platform was stripped down to reveal to usual corroded rear step riser (which is now being replaced) and timberwork around the rear end has been replaced (see picture). There is still a reasonable amount of timberwork to replace around the front & cab area which is one of the next jobs - our specialist joiner has been laid up in hospital for two months after a big operation - but he is back part time now.

Other news to report is that sister bus RTW467 is now with us - and we have photographed it to death! Ironically, 467's body used to be on 335's chassis! We will be using the sister bus to create patterns over the next few months to rebuild parts of 335.

Panelling commences

2010-07-21T00:25:00.003+01:00

Repanelling commenced today on the RTW, another major step forward in the restoration phase. Next major obstacle, is tackling the corroded step riser and platform bulkhead area and getting window pans fabricated. Certainly the pictures of RT8 now completed by Ensignbus is an inspiration - we look forward to seeing RTW335 alongside RT8 when its own restoration is complete.

New floor fitted as re-framing progresses

2010-07-03T14:46:00.002+01:00

A new lower deck floor has been fitted to RTW335 this week, whilst continued good progress on re-framing continues. The offside is now 90% complete and the nearside around 70% complete. There is still a lot of work to tackle around the front and rear ends, but it is proposed to start repanelling between the decks over the next few weeks.

Reframing makes more progress

2010-06-10T23:29:00.003+01:00

There are times at the BusWorks, like with all restoration projects, when work appears to progress rapidly and we all smile with satisfaction, and other times when either jobs stall or visual progress (well, lack of!) gets us frustrated. RTW335 has suffered this over the last two weeks awaiting timber from our specialist joinery contractor after we overwhelmed them. Also, Andy Ashton (the lead coachbuilder on this project) has just had a well earned holiday.

Anyway, suffice to say more shaped timberwork is now arriving and Andy is once again progressing well with RTW335. See picture - ok not the most inspiring but every step brings RTW335 closer to the day it will come back to life.

We've also had good news that RTW467 may be up with us by the end of the month and we look forward to crawling all over it for the detail for RTW335. I found out from Nick Agnew (one of the owners of RTW467) that it carries the body originally on RTW335 - now there's a great coincidence!

Lower deck floor out

2010-05-14T23:26:00.003+01:00

Work on RTW335 is again making good progress this week. The lower deck floor has been stripped out for renewal revealing the chassis underneath which is in excellent condition.

This can be attributed to 335's history with Hywema Lifts in Germany - the bus was used to demonstrate the vehicle lifts to potential clients so keeping the underframe in good clean condition was important. The floor will be replaced next week.

Lower deck re-assembly

2010-05-05T20:01:00.002+01:00

The gap in posting updates has been twofold - partly a brief diversion of the team working on RTW335 to other projects and partly because in bus restoration there are many jobs which are laborious, unglamouress and for which there are no great picture opportunities. This describes much of the tasks of recent weeks which has seen rewiring of the lower deck and fitting of some more complex shaped timbers between decks.

Anyway, to make amends here is a view of the lower deck now with ceiling panels and aluminium cove panels refitted.

Lower deck stripped for restoration

2010-03-25T22:38:00.002Z

We have now started work on the next stage of the build programme for RTW335. The lower deck has been cleared and stripped with all ceiling panels and fittings removed.

It is intended to now concentrate on getting the lower deck to the same stage as the upper deck, which will include all timber replacement, rewiring of saloon lighting, new stress panels and a new floor.

Great progress on upper deck

2010-03-21T15:05:00.002Z

The basic re-assembly of the timber and steel stress panels on the upper deck of RTW335 has made great progress this week as seen in the accompanying photograph. The next stages for the upper deck would be refitting mouldings and window cappings - but it is more likely that we will now start stripping the lower deck to get it to the same stage before the detailed finishing work commences.

Because RTW335 was devoid of much original interior detail when it arrived at the Busworks, we really need another RTW to refer to. Sister vehicle RTW467 is earmarked to make the journey north to Blackpool during the Spring allowing us to extensively photograph the bus and apply this to the restoration of RTW335.

Timber!

2010-03-18T20:34:00.003Z

Work has now started on replacing the framework timbers on RTW335 as shown in the picture opposite. New between-deck stress panels are also being fitted to complete the basic assembly of the upper deck.

We are hitting the ceiling with RTW335!

2010-03-14T16:16:00.002Z

Yes, we really are hitting the ceiling with RTW335 this week. New ceiling panels, already covered with primer and a first coat of gloss have been fitted. Also fitted following paint stripping are the aluminium coving panels, refitted now that rewiring of the upper deck saloon ceiling has been completed.

Machined timber, based on the originals used as templates, is now on hand and will allow further re-assembly of the upper deck over the next few weeks.

Factory finish for aluminium pressed panels

2010-03-09T00:23:00.002Z

Another batch of aluminium pressed panels has returned from a commercial metal paint stripper after dipping in a bath that removes all paint but leaves the metal with its as-new factory finish. Included in this latest batch are the destination screen panels and the characteristic RT-style panel below the driver's windscreen (illustrated). Just another piece of the RTW jigsaw!

Upper Deck floor goes down

2010-02-24T01:03:00.002Z

Forgive me for the lack of posting in recent weeks. This has not been because no work has been taking place (far from it!!) but because the work has no visual output to communicate on this blog. The effort has been on the thankless tasks of cleaning up and repairing specific areas of framework and also some rewiring tasks - none of which make for exciting photographs!

Anyway, the photogenic tasks return with this view of the new upper deck floorboards fitted and ready for fine tweaking and then securing down. Another milestone achived!

A strange view of the cab!

2010-01-30T11:25:00.002Z

As part of the rebuilding of the front end and upper deck floor, the cab ceiling panel has been removed giving this unique view of the cab from the upper deck. The ceiling panel was in poor condition and like the rest of the interior it had been painted with household emulsion paint which was badly flaking - it was decided to be faster to replace than prepare the old panels.

Rebuilding of upper deck front commences

2010-01-24T10:30:00.004Z

In addition to the tasks in hand on the upper deck such as rewiring and re-flooring, this week's focus has seen the destination equipment stripped out for overhaul and a start made on replacing corroded framework around the front end. This includes the horizontal steel sections below the upper deck front windows which have been fabricated from scratch - the area was so corroded there wasn't anything to make a pattern to!

Let there be light!

2010-01-18T07:41:00.002Z

The removal of the ceiling cove panels gives full access to the lamp units and wiring and the opportunity is being taken both to replace any dodgy bayonet fittings and rewire RTW335 where necessary. This view shows the work in progress with all bulbs illuminated.

Other progress has concentrated on the lower deck offside where the horizontal stress panels have now been replaced. We are also fabricating the steelwork to replace badly corroded sections at the front of the bus and around the destination box.

8th January - New Year Progress

2010-01-08T16:56:00.002Z

The UK is experiencing the coldest spell of winter weather since 1963 - 47 years ago and a year when RTW335 was still in service on the streets of London!

Despite the cold weather our two guys dedicated to the restoration of the RTW continue to make good progress. This week the brackets securing the upper deck structure onto the lower deck have been cleaned up and painted if they are in good condition - or new ones made to replace those that were corroded. The upper deck floor panels have been lifted to reveal the lower deck roof structure which is in good condition, but needs a coat of protective paint before it gets hidden again. The nearside panelling has also now been stripped to the basic frame.

The floor will be replaced as part of the next phase of work and this represents a milestone in the project with the upper deck moving from dismantling to re-assembly stage - not bad progress after just 5 weeks in the workshop!

24th December - Progress Report

2009-12-24T15:16:00.005Z

Good progress continues on RTW335 and prior to the Christmas holidays, a template for the lower deck horizontal stress panelling was fabricated and fitted. The existing stress panels, which are welded to the vertical steel frame, are all badly corroded and replacements will be in zintec metal sheet.

We wanted to get the offside of the vehicle stripped down as far as possible prior to christmas, allowing replacement steel and specialist timber to be ordered whilst keeping the nearside frame intact at this stage. The upper deck plywood ceiling panels have been removed for replacement and early in 2010 the upper deck floor panels will be replaced. This will give the staff dedicated to the project a clean sheet from which to start the re-assembly of the upper deck, whilst also being a visible milestone for the project.

The interior aluminium domes will be paint stripped and the offside cove panels have already been sent away for paint removal.

See Leon Daniel's own blog for the account of Leon and others saving RTW335
http://leondaniels.blogspot.com/2009/12/story-of-rtw335-tale-for-christmas.html

19th December 2009 - Progress Report

2009-12-19T18:26:00.000Z

By 19 December, all exterior panels and mouldings have been stripped off and work is focusing upon the offside of the vehicle, removing rotten timbers and steelwork beyond repair. The timbers and steelwork removed have been labelled and stored for use as templates - and the most common sections are now being fabricated by a local specialist joinery company. The removal of the timbers has allowed access to the steelwork which can now be treated with red oxide paint.

The plywood ceiling panels have been removed and these will be replaced with new. Although the ceiling panels were in poor condition, the framework they concealed looks as good as new!

More stripping!

2009-12-19T11:31:00.000Z

This view, taken on 12 December, shows RTW335 stripped further with all the corroded steel window pans removed. Although some specific parts removed can be re-used during the restoration the majority of panels and mouldings will be scrapped and replaced with new. With the exception of one window pan, which will be used as a template, all are others are severely corroded. It is planned to make a fibreglass mould from the good one and use this to make new units - but this is a way off yet!

Stripping commences

2009-12-19T11:09:00.000Z

The BusWorks team lost no time in getting RTW335 into the workshop and stripped down to its main frame - but not before the whole bus was extensively photographed as a record for the future. There is considerable interest in the work on the RTW and to examine the all-Leyland construction in comparison to the standard Park Royal, Weymann and Metro-Cammel examples.

Because the type had a relatively short life in London, the class was never extensively overhauled or repanelled unlike the standard RT class, many of which survived in London service until the 1970s.

Stripping of RTW335 has revealed that the type employed the standard Leyland "patented metal construction" with a basic steel frame with timber inserts. But stripping has also revealed that all the timber is essentially rotten, whilst much of the high quality steel used is still in good condition - although there are areas of corrosion - particularly around the rear platform and cab area.

About RTW335

2009-12-18T23:15:00.001Z

The RTWs had the distinction of being London's first 8ft wide motor buses with 500 being introduced in 1949 on modified Leyland Titan PD2 chassis. Originally they were banned from Central London, and from anywhere with tram tracks, which limited their scope somewhat. The Metropolitan Police were only prepared to admit them as suburban buses until trials took place that allowed them into central areas from 1950.

RTWs had a relatively short life with London Transport with withdrawal commencing in 1963 after the last trolleybuses had been replaced by the conquering Routemaster. Some survived in use as driver training vehicles, others were sold to small UK operators whilst a large number (279 of them) were exported to Sri Lanka.

RTW335 ended its service career with London in 1965 and was exported to Solingen, Germany and latterly used as a demonstration bus for Hywema vehicle lifts. It was stored outside for many years where it's condition deteriorated until rescued by two prominent preservationists in 2004 and returned to England.

In 2008 it passed to Ensignbus for future restoration to join their heritage fleet and in October 2009, Ensign commissioned the BusWorks to rebuild the bus. It arrived in Blackpool on 24 November and will be fully restored to operational condition over the next 12-18 months.