Building a DMU
Part Three: Body Sides and Ends
Images seventeen to twenty-six in the booklet show the body sides and ends being added to the underframe. Some contemporary text describing the body construction:
The cars have been designed to resist an end compression load of 200 tons in the same way as standard locomotive drawn corridor stock. Unlike the existing standard stock, these cars have been designed on the "stressed body" principal, the underframe, body sides and roof combining to form a welded steel structure which resists all bending, compression, and draft stresses. This form of constuction is particularly useful for Diesel Cars, since the underframe is completely free from conventional trussing, and provides the maximum space below the floor of the car for the suspension of the diesel and auxiliary equipment and for its subsequent maintenance.
The coaches are of all-welded construction, the underframe being fabricated from rolled steel sections on to which is welded a corrugated steel floor of special section, which considerably increases the strength of the vehicle in its restistance to end shocks. The body sides and ends, formed of pressed steel framing members, with outside panelling of 16 B.G. steel are jig-built in sub-assemblies, when all the sub-assemblies are welded together into a complete vehicle, forms a continious structural member extending the full length of the coach.
"Body Side Erection"
Negative 5C43
Taken 17/11/55. The white frames fixed to the underframe will allow the top of the body sides to be fitted with the correct spacing for the roof. The body sides were made separately, one can be seen hanging to the right ready for fitting.
"Lifting Body Framing from Jig"
Negative 5C70
Taken 15/12/55. The body side framework was welded together in a jig, a completed side (inner end closest) is seen being hoisted out of the jig.
"Body Side Framing coming off Jig"
Negative 5C71
Also on 15/12/55, the next step for this body side will be to have the outer panels welded on. They have already been welded together into a complete vehicle length, seen behind the men. Note that under where the windows will be there is just one vertical 'z' rail. At some point this was changed to two 'z' rails under each window (as discovered on buffet car Sc79443 at Bo'ness) and all the later Ayshire Inter-City vehicles had two.
"Panelling on End Frame"
Negative 5C69
Two vehicle ends are seen under construction on 15/12/55. On the closest, we see the inside face (the outer panels are angled upwards) of the panels being welded together without any framework. The second has been turned over and have the footsteps fitted it will form the inner end of a vehicle. The hardwood packing for the gangway is also in place. Behind is the jig for the body sides, to its left is the jig for the body panels.
"Body Side Erection"
Negative 5C44
Taken on 17/11/55, this is the inner (toilet) end of a DMBS. Both body sides are now in place.
"Body Side Erection"
Negative 5C45
Also on 17/11/55, this is the cab end of an intermediate DMBS.
"Assembly of Drivers' End"
Negative 5C55
On 24/11/55 a pre-built cab of an intermediate DMBS is being manouvered into place.
"Drivers' End Erected"
Negative 5C56
The cab in the previous image now clamped into place.
"Side & Ends Erected"
Negative 5C54
Another 24/11/55 image showing all sides and ends now in place. Note the corrugated sheets to the left of the vehicle, these will form the floor.
"Non Drivers' End Erected"
Negative 5C57
The inner end of the intermediate DMBS on 24/11/55. Note the roof hanging above the wooden coach behind, ready to be moved over and fitted.