Rebuilding Windows

Picking up where I left off last week, it was time to rebuild the windows under the end toplights

Work begins - a light sanding

First up was a light sanding and an investigation looking for any rot or bad joints. Once identified, the bad timber was chiselled away or scrubbed out with a wire brush. Once again, the damage was not as bad as I was expecting.

Top corner - bad timber chiselled out along the grain of the wood

Bottom corner - more sanding and attacking with a wire brush

The other bottom corner needed a similar treatment

The bottom margin of the windows require special attention because the timber here tends to be in bad shape due to water running down the window. Three of the four windows worked on this weekend required the old margin chiselled out (very carefully!) and a new margin added using 6mm quadrant. These were embedded into a deep layer of acrylic filler which was also squirted into the two upright margins of each window to reseal them.

A new bottom margin of the window added from 6mm quad

Then out with the Builders Bog, slapped onto the holes and exposed timber and sanded back into shape.

One window, filled and sanded, ready for painting.

This end of the carriage had simply been painted over after the graffiti attack last year. In this area the vandals had used a particularly nasty silver paint and the overlaying red had not adhered to it very well so, when I started sanding back, the red came off in sheets. So I had to sand right back to wood in most places and start the painting process all over.

At the conclusion of the weekend's work, the end of the carriage was painted with 3-in-1 Primer, Sealer and Undercoat