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I cut out two sides two ends and two internal pieces to brace the sides and support the roof. Once these were cut out, I glued an overlay of Slater's 4mm planking sheet on to the outside surfaces. To be the correct scale the planking should really be 5mm but I could only obtain 4mm, I'm not that fussy.
The outside framing was then applied using various sections of Evergreen plastic strip, mostly 3.2mm x 3.2mm. The sliding doors were made from 60 thou Plastikard and the wider 7mm planking was scribed on to these using a tile cutting tool. Further strip detailing was then added to the doors together with some 3mm angle strip for the door runners. Extra detailing in the form of rivets (Peco track pins) and a door handle made from a paper clip were also added before the sides were glued up, more angle strip was used to reinforce the corners.
The van floor was cut from a sheet of half inch ply to fit inside the body and flush with the bottom. This adds some much needed extra weight. Headstocks and solebars were then cut from strip wood and glued to the underside once the solebars had been pre-drilled to take the axleguards. The axleguards are held in place with 10BA screws and nuts.
Further strapping was then added to the van ends and the final extra detailing was added, this includes brass rivets and corner plates from Garden Railway Specialists and a working handbrake and some parts of a wagon detailing set from IP Engineering. The axleguards, wheels and chopper couplings were recovered from open wagon number 8 which has been withdrawn from service (and its body is now rotting away quietly outside the engine shed).
The roof is made up from five and a half scale size sheets of corrugated aluminium supplied by Back 2 Bay 6. The sheets were exactly the right length but the last one had to be trimmed width wise by cutting down the centre with a sharp knife. This is very easy to do and any sharp edges are quickly and easily removed by light sanding. The roofing sheets were curved to shape by sliding them between my finger and thumb using gentle pressure until the correct profile was achieved. At first I attempted to glue the roof sheets on with cyano but with no joy, I eventually succeeded by using silicone adhesive, holding the sheets in position with elastic bands until the glue set.
The van was spray painted in my usual goods livery of grey auto primer from a rattle can. The roof axleguards and brake gear were picked out in matt black. Once the wheels and couplings were attached, the whole lot was weathered with a spray application of olive drab paint. Unfortunately one side received too much weathering due to a twitchy trigger finger so I had to do the same to the rest of the van to even up the result. The van therefore looks far more mucky than my usual weathering efforts but hey it's just very dirty!