CONVERT A HAWKSWORTH
This step-by-step sequence covers the main aspects of the conversion, but I had already removed the gangways and cut windows in the ends, as well as filling two unwanted windows on one side of the coach. However, I still had more windows to deal with as both sides of the Second Class end were modified, so that aspect of the conversion is covered in the photographic sequence. Begin by dismantling the coach. The body is a one-piece shell and it is affixed to the chassis by clips which are part of the glazing. Once the body was off, I pressed out all the glazing. It was glued in place, but it was easy to break the glue joints.
On the corridor side, right-hand end, I needed to remove a section containing one large window and a toilet window. Using a sharp razor saw I made the vertical cuts where the door edges would be.
Using a sharp craft knife, I cut along immediately below the rivet line. The Hornby plastic sides are thin and I was through in three passes. The door and toilet window will be reused, so cut with care.
The big window opening needed to be filled and this was done with 30thou styrene sheet, secured in place with Deluxe Materials’ Plastic Magic. I placed the styrene flush with the outside surface.
The second cut was made at the point that would become the edge of the guard’s door. I avoided cutting into the gutter at the roof edge and the row of rivets immediately below it.
I temporarily tacked the door in place, but soon realised that the saw cuts had left the pieces slightly short; some fillets of styrene would need to be inserted to fill out the width again.
The section removed cleanly. I cleaned up the edges with a flat file. On the other side of the coach you can see my earlier method, leaving the glazing in place and filling over the unwanted windows.
The next step was to separate the door from the removed side section, using a steel rule and a sharp knife. Take care, as both the door and the window piece will be reused.