How to make paper gangways for ‘N’ gauge

All too often, we ask our model passengers to jump an impossible gap between corridor coaches when walking down a train. There is a simple way to fill the gap between gangways on coaches, especially those which are operated through sharp curves.

CLOSE coupling cams have done much to eliminate the unsightly gap between coach gangways, at least when trains are sitting on a length of straight track. There remains a lot of well detailed stock with no form of close coupling, and closing up the gap by fitting couplings closer to the coach body brings the problems of buffer and gangway locking on sharp curves, especially those found on ‘N' gauge layouts.

So, how does one remove the unsightly and inconvenient gap (for our passengers and train crew), which can be as much as several scale feet wide, without having to make significant changes to the model?

Simple concertina gangway extensions or replacements can be made in a matter of a couple of hours using inexpensive materials.

For this rolling stock fine-tuning project you will need black 20-thou styrene card and a sheet of 100gsm black or dark grey art paper (colour choice depends on the stock being fitted). Superglue gel, a very sharp scalpel, together with a steel ruler are also essentials.

The projects

A set of five Graham Farish Mk.1 Super BGs, run as a rake on the editor's ‘N' gauge layout in a semi-permanent formation, is the perfect subject for gangway extensions as a precursor to a reworking project to detail them. They are not equipped with close coupling cams and being required to run on the layout's minimum radius curves of 10 inches, the resulting gangway gap within the train was visually unacceptable. Other Graham Farish models suffer from the same problem: the Class 150 for example along with older Mk.1 and Mk.3 coaches.

Whilst the original bogie mounted couplings could be used with the methods described in this article, the inner couplings were replaced with better-looking Micro-Trains buckeye couplings. Furthermore, additional weight was added to reduce a tendency to bounce on turnouts. The new couplings transfer coupling forces through the coach frames, significantly improving the performance of the train.

A second project found suitable for gangways using this technique was an EMU conversion using older Graham Farish Mk.1 coaches and Electra Railway Graphics overlays. The need to avoid gangway locking on 10-inch radius curves still produced unacceptable gaps between the cars.

It should be noted that fitting

gangway bellows extensions to models is not entirely prototypical unless the vehicles being treated have distinct bellows such as pre-nationalisation designs or modern stock such as ‘Voyagers’ and ‘Turbostars’. BR-built coaches have bowed ends which means the actual gangway structure is not pronounced except on Mk.1s.

Assembly method

The project Mk.1 coaches have moulded gangways measuring 15mm in height and 8mm in width. Note that the flexible gangway on Mk.1s has a rounded top which is concealed by a fabric cover. The buffing plate does not have the same rounded top and is taller, with a flatter top which supports the fabric cover. How the top is represented is a matter of personal preferences. Adding the fabric cover might impede the action of the paper bellows extensions even if something as thin as tissue paper is used. Shaping the top of the paper bellows to match the flatter profile is an option too.

A strip of black paper was cut

16mm wide and then measured along the long edge at 8mm intervals to mark out four panels (the number will depend on the type of vehicle being equipped). Two are needed for each coach end. More panels can be incorporated to extend the length of a set of bellows if necessary, but four seems to be optimal. Precise measurement is not necessary and they can be trimmed to length.

The 8mm marks are repeated for the opposite edge so fold lines can be scribed very gently in to the card at right angles to the edge. The middle line (or alternate lines) is scribed on the opposite side to the two outer lines before the four panel piece is cut from the strip. It should be possible to fold it up to make a concertina shape, in the same manner as concertina doors.

Open out each pair of concertinas and lay them flat on a cutting mat. Cut a vertical line half way up each panel of the first one from the bottom. Repeat for the second one but from the top to the mid point or just beyond. Open out the cuts a little by running the scalpel blade up and down then cut a couple of times, but carefully!

The two concertina pieces slot together, with one reversed, to

create one set of gangway bellows. Gently push them flat and the shape of a sprung gangway is the result, measuring about 2.5mm thick when fully compressed. Once folded up, shape the top to match the shape of the model’s moulded gangway using a very sharp scalpel blade to trim paper away, using photographs of the rolling stock for reference. In ‘N’ gauge one is talking about paring away tiny slithers of paper – literally! Finish with a rub with wet and dry paper with the bellows pressed firmly together and remove the resulting dust.

Gangway rubbing plates

A gangway plate is needed for each set of bellows. This is cut from 20thou styrene and shaped to match the model’s gangway outline. This is gently glued to the paper bellows with tiny amounts of superglue gel and left to dry overnight. The plates are fitted to the outer face and should be free of burrs, allowing them to move smoothly against the gangway plate of the adjacent coach when the train runs over junctions or into curves. They must not lock together or a coach will be flung off the track when entering a curve. A 20-thou rubbing plate adds at least 0.5mm to the thickness of a set of compressed gangways. Therefore two, one fitted to coaches coupled together, will occupy at least 6mm before allowing for the extension of the paper bellows.

Fitting them to the model

There are several options for fitting gangway bellows to the coach. A temporary fix is possible using black bath sealant, just in case the conversion has to be reversed. Alternatively, use PVA glue, double-sided adhesive tape or matt varnish, taking care not to seal up the concertina action. Ensure that there is sufficient flexibility in the gangways when the coaches are coupled together and that a gentle springing effect is the result. A very slight gap of about 10-thou between the rubbing plates is

fine. The four panel gangways can be cut back by a panel on each side of a gangway pair or increased by a panel at a time depending on the gap. Once finished, the paper gangway bellows can be gently weathered with care to retain their flexibility.

Advantages of using paper gangways

That’s it for a simple improvement to

‘N’ gauge coaching stock and multiple units, which is a pragmatic compromise. In ‘N’ gauge, there is considerably more compromise needed to ensure trains run smoothly compared to larger scales. The benefit is a better appearance and a cushioning effect on the slack between couplings, even the Micro-Trains ones fitted to the project coaches. Furthermore, the extended gangways improve the visual appearance of mail and passenger trains when seen from normal viewing distances.

They cost little to make and take just a few hours to equip a rake of coaches once the technique has been practised. ‘OO’ gauge modellers are not missing out either: the same approach works in 4mm scale too, just that everything is correspondingly larger and more panels per set of bellows may be required.

Many current ‘N’ gauge coach models are not fitted with close coupling cams, including the Graham Farish Class 150s and its Mk.1 Super BGs. Older models have no coupling mechanism either, resulting in unacceptable gaps between coaches. How can this visual problem be fixed?

Kits and conversions also benefit from working paper concertina gangways such as the Class 310 conversion seen alongside Graham Farish Class 150 No. 150123.

The method shown in this article will suit a variety of different coaches, including the Mk.1 Super BGs. This shot shows the shape of the top of the gangway when the top cover is removed.

Class 310 and Graham Farish Super BGs as fitted with the gangways. Whilst not strictly prototypical, they are a practical compromise that are easy to make.

Whilst precise cutting is not essential, some care is needed to allow the two parts of each bellows to fit together and work along the fold lines (A). They slot together (B) along the cuts made in the paper at (C).

The bellows pieces are cut and folded using 100gsm art paper whilst the rubbing plates are of 20-thou styrene card.

They are a modelling compromise which will help improve the visual appearance and operation of a train. The basic design can be improved and adapted for almost any application. The same technique also works with 4mm scale stock.

Wet and dry paper used dry is used to refine the shape of the bellows gangways and remove any burrs that will prevent them from working correctly.

Gangways are made up in batches and can be shaped before slotting together or afterwards. They can be cut overlength and trimmed to the desired length.

The bellows method described in this article will suit a variety of ‘N’ gauge models including the Class 150.

The dreaded gap – necessary to prevent buffer lock on 10-inch radius curves. The same gap is present when the original bogie-mounted couplings are retained.