![]() |
![]() |
![]() |
Having decided to
copy the style of cab
from the full size Bagnall 'Sir Tom' there was a lot of planning
to do before starting to cut any metal. For a start it was
obvious that if any imagined driver was going to fit between the end of
the cab side plates and the rear roof support struts then the footplate
would need extending rearwards. The width of the cab had to
be
carefully matched to that of the existing cab side plates, the front of
the cab had to line up with the proposed safety valve output pipe
extension, and most importantly the driver (me) had to be able to see
the pressure and vacuum gauges. The first step was to build a cab and roof from cardboard and to see how visible and accessible the controls and gauges were with it fitted to the loco. After a few adjustments I finally settled on a set of measurements, but even with the two gauges set as low as possible and on opposite sides of the cab (see Gauges and Safety Valve) the roof still had to be 2 inches (50mm) higher than I would have liked. The next step was to very carefully measure the dimensions of the existing cab parts and features, with special reference to the position of the safety valve outlet. These measurements were then used to create a CAD drawing of the cab end of the Stafford over which I could design the new cab and roof. The width of the cab was set at 1/4" (6mm) narrower than the internal width between the existing cab side plates so that a 1/8" (3mm) spacer strip could be fitted between the front cab struts and the existing cab sides to ensure that the new struts were clear of the existing cab side beading. The intended cab was to be fitted to the Stafford using three 2 BA bolts in each front strut through the existing cab side plates and a single M6 bolt each side passing through the footplate extension and screwing into blocks fitted inside the rear struts. The CAD package also predicted that the finished cab assembly, footplate extension, and steps would add 11 pounds (5 kgs) in weight and that all of this would be well behind the rear axle. So as to not unbalance the loco I decided that I wanted to add ballast to the front, which is why the front dumb buffers ended up being filled with lead ballast until they weighed almost 6 1/2 pounds (3 kgs) each. As you can see this cab conversion was a package of planned changes rather than an assortment of piecemeal additions. |
![]() Having failed to find a company who could roll the angle sections for me I considered fabricating the sections using a laser cut face and welding on a strip of metal to form the roof support. The problem was that I didn't think I could weld such an item without a lot of distortion, so I approached what I now consider to be my local equivalent of a blacksmith. This two man company undertakes all sorts of bespoke welding projects from gates, to vehicles and fuel tanks; and they had previously welded the aluminium body of the new lubricator that I had built for my Stafford. To my surprise they offered to roll some angle for me, and within a week I had two perfectly rolled lengths of angle that exactly met my requirements. Now the work on the cab could actually commence. |
![]() |
![]() If you look closely at the photo you will also see the two 4BA tapped holes in the front face of the roof arch that eventually attached the safety valve extension. Once the cab frame was removed from the jig it could at last be offered up to the Stafford to check that it would indeed fit, and to see what the finished cab would look like. All that remained was to make the roof skin and bolt it down, but that wasn't as easy as it sounds. Despite being told that aluminium has no place on model steam engines I decided to use 16 SWG aluminium for the roof simply because it would be soft enough for me to bend without any suitable metal forming tools. A sheet of cardboard was cut to fit the cab frame with an extra 1/4" (6mm) on each side to form the gutters. Having cut the aluminium to match the cardboard pattern, each side was clamped between two lengths of steel angle so that the gutter edges could be bent through 90 degrees using a hammer. The various hammer marks were then sanded out using Wet & Dry paper. The roof now had to be "rolled" to match the arch of the roof, with the outer ends forming ever decreasing radius curves. That isn't exactly easy to do, but eventually I managed it by hand bending the aluminium sheet over various bits of scrap tubing (actually water pipe and scaffold pole) and "forcing the bends" by compressing the curved sheet between my hands and the floor. For once the television had taught me something useful as I had previously watched similar techniques being used to form an aluminium car body in the series "American Hotrod". Once shaped the roof was clamped in place on the frame and all the holes drilled through for the mounting screws. |
![]() Throughout the manufacture of the cab, footplate extension, and the safety valve extension nothing had actually been bolted in place for a trial fit simply because I never had the time between runs to partially dismantle the loco (and because I didn't want unused holes in the model before the cab was complete). Thus I was very relieved when everything fitted into place without any fettling being required. The final photo shows the view through the cab while my Stafford 'Gentoo' is waiting for a Birthday Party event to start at my home "Pinewood" track. Although the drivers eye view is a lot higher than that of the photo the cab assembly does not in any way inhibit the drivers view of the controls and relocated gauges, nor do I find it to cause any problems when driving. As every comment has so far been very complimentary I am very pleased with the outcome of this package of modifications. However I do carry a copy of the 'Sir Tom' photo with me to satisfy those people who say that Bagnalls never had cabs or chevron painted dumb buffers. |