Hymek Refurbishment

Hymek refurbishment 2012

By Garry Tyso

& Mark Bradley

The Hymek was taken from site on January 3rd 2012 to Garry's workshop for its long awaited refurbishment.

The first photographs show the locomotive as unloaded 13th Jan 2012

The first operation was to remove the bogies, and strip them down, clean, check and replace/repair any broken or worn components and re-assemble. The front bogie required only superficial cleaning and adjustment and was re-assembled and sprayed in a relatively short space of time. Note, in the photograph, that the upper, un-refurbished, bogie has a dummy spring missing. There is no evidence to suggest that this was ever fitted.

It was immediately apparent that the rear bogie had a problem with one axle, as the wheel was loose on the shaft and could drift considerably over gauge. On removal, it was found that a repair had previously been carried out - possibly to correct the same problem -by pegging the Delrin boss of the gear pinion to the shaft. This had resulted in the boss breaking up leaving the wheel to float on the axle.

A new steel adaptor was manufactured which screwed to the wheel and was then pegged - using the original peg - and Loctited to the axle. The Delrin gear was bored to clear the flange of the adaptor and re-bolted to the wheel. The axle was then re-assembled.

Second instalment of the Hymek Friday 20th January

Having competed the bogie refurbishment, attention has now turned to the chassis.

The photos show the chassis prior to strip down. All electrics were removed and handed to Mark Bradley for a complete revamp.

The buffers were removed, as well as the rear towing eye and hook-on front buffer beam.
The buffer shanks were rusted solid and required considerable force to remove them from the bodies. A full clean up and re-paint followed, and they are now complete, working, and ready to be refitted to the chassis.

Third instalment of the Hymek Wednesday 31st January

Work is now progressing on manufacturing a fuel tank which will hang below the footplate between the bogies and house various fuses, switches and charger point.

The dummy fuel tank has now been completed and is fitted with a hinged front for access to the fuse box, switches for: on/off; sound; lights; together with the charger point, in addition to which it also houses two speakers for the sound system and two horns.

The chassis refurbishment is now virtually complete - all that remains is to paint it and final assemble.

Attention has now turned to the body. The following photos show the body as received.

First job was to remove all the remaining windows, the destination stickers and the fan grille.

A new fan grille was then fitted, removed and painted ready for assembly.

The lights were next to be tackled, the idea being to fit Perspex lenses, the LH light to be fitted with a white LED for night running. In theory a simple job.

A small hole was drilled through the one light, followed by a larger, 0.5" Dia., drill. However, on getting about halfway through the light, it shattered, resulting in a jagged hole in the body and a jigsaw puzzle of pieces for the light. It then became apparent that the lights were a resin casting glued to the main fibreglass body. B*****r!!

The net result was that all lights were removed, the body drilled, and new, steel, light bezels machined and fitted. This in fact improves the appearance of the locomotive in that the original lights followed the contour of the cab front panel, so they not only pointed outwards, they were in a distinctly 'dipped' mode.

The installation was then given a coat of white primer paint prior to a final yellow coat at a later date.

The next job is to machine the Perspex lenses and then refit windows.

Fourth instalment of the Hymek 29th February

After a 2-week enforced break - grandchildren!! - work has now restarted with the fitting of raised numerals, painting the red route restriction disc, fitting of new windows, and finally polishing the body sides. This took a complete tin of Brasso, but the loco now has a nice ex-works ish shine.

Guess which half of the cab roof has been polished. Cab end with new glazing fitted. Numerals fitted and route restriction disc.

Firth instalment of the Hymek refurbishment 4th March

Work on the Hymek body is now complete, with yellow warning panels, and the yellow/green body stripe being re-sprayed, new train reporting number panels manufactured and fitted, as well as the light lenses fitted.

Work then continued with wiring up the front reporting number panel and white marker light for use when night running. Plunger contacts have been manufactured so that there are no wires to disconnect in the event of the body having to be lifted off the chassis.

Finally, the handrails were refitted and overhead warning signs, BR logo transfers, and George Weedon nameplates fitted.

There is a small amount of work to carry out on the chassis before it is sent to Mark Bradley's workshop for electrical installation to be completed

Front end view showing marker light and train reporting number illuminated. Nameplate George Weedon and BR Logo.overall view of refurbished body.

The Sixth Instalment of the Hymek Friday 9th March

The Hymek refurbishment is now complete except for electrical wiring which is in the capable hands of Mark Bradley.

The chassis was despatched to Mark on 9th March.

The photographs show the complete chassis, as well as complete locomotive, which I think compare well with the photos of both in 'as received' condition.

It is hoped to have the completed locomotive back at BG by the end of the month at the latest.

Refurbished chassis from rear ( driving ) end ( Left picture ). Cross timbers are to locate batteries which have been moved to directly over each bogie to allow the 4QD unit to be mounted centrally, with the sound system.

Chassis from front end. ( Right Picture ) Contacts fitted to the top of the buffer beam are for the plunger contacts for the lights.