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Rerailing a 20 ton Brake Van
Photos by E C Friel unless otherwise credited.

The RPSI has a small collection of goods wagons, of types no longer seen in operation in Ireland. Financial pressures mean that they cannot be maintained to the same standards as our passenger carrying trains. However, a group of young members are being encouraged to take on the restoration of one of the wagons, an ex - GNR(I) 20 ton brake van.


Whitehead Works Image
During World War II the Great Northern Railway (Ireland) replaced some of its older brake vans. Photo by Duffners, Dundalk. 
Van No.4 was built to diagram 158A in August 1943 by Dundalk Works. It is seen here in ex works condition, complete with personalised lamps. Photo by Duffners, Dundalk. 
Whitehead Works Image
Whitehead Works Image
The starting point: Brake Van No.81, identical to No.4 above, derailed in a rough shunt sometime in the last decade. No attempt was made to rerail her at the time and she vegetated out of sight and out of mind at the back of Whitehead Yard. She suffered fire damage in the arson attack of 1996.
The brake van's floor was completely rotten. To reduce the possibility of someone falling through it, the youngsters removed most of it. At least now workers in the van can stand on the structural members.
Whitehead Works Image
Whitehead Works Image
The remaining roof was in the same state as the floor, although in this case it was removed to prevent the loose timbers holding moisture against the steel roof girders.
The derailed van, ironically coupled to a (unserviceable) steam crane. The trolley in the foreground was used to carry sleepers, jacks, rails and tools out to the van. No mechanisation here!
Whitehead Works Image
Whitehead Works Image
A 30 ton hydraulic jack was used to lift the van, while two 18 ton screw jacks were used to support the van when the hydraulic jack was removed to add more packing. 
After a few hour's hard work a wheel started to emerge from the earth. The rail end was still considerably higher than the bottom of the wheel.
Whitehead Works Image
Whitehead Works Image
Two of the youths hard at work, one pumping the hydraulic jack, as another follows on the screw jack. One problem they found is that the ground beneath the jacks had to be compressed before the van started to lift!
By the end of the first day of jacking No.81 looked a lot straighter - compare with this earlier picture.  In particular look at the relationship between the buffer of the van compared to the buffer of the match wagon.
Whitehead Works Image
Whitehead Works Image
 The work continued the next Saturday. By lunchtime the van was jacked level. Two of the youngsters are inserting a short length of bullhead rail for the derailed wheel to sit on once the van is traversed to the right.
Luckily a sleeper complete with bullhead chairs was sitting only inches from the site of the derailment. it would support one end of the bullhead rail section, while the other end could be supported by fishplates attached to the end of the siding.
Whitehead Works Image
Whitehead Works Image
A key was driven into the chair to support the rail, and a point clip inserted to keep the two fishplates together.
The youngsters were not making this up as they went along - advice and assistance was available from Whitehead's engineering gurus. Here, to stop the van's tendency to move further from the rail, they have set up a chain hoist attached to the near rail of the adjacent siding.
Whitehead Works Image
Whitehead Works Image
After much traversing of the screw jacks, the rear of the van was moved 4" or so towards the rail. This procedure involved taking a turn on the horizontal screw shown, and waiting for the van to shift 1/4 or 1/2 an inch at a time.
With the right hand wheel over the rail, in theory the rail under the left hand wheel could be inserted.
Whitehead Works Image
Whitehead Works Image
But the van is still lower at this corner, and the axlebox is slightly lower due to the corroded and expanded leaf spring. More jacking is needed before this rail can sit in both chairs. 
Another inch or so of height, and the rail was be moved into place. Again, track keys hold the rail in place. This time fishplates could not be used as the rail ended in the middle of the chair!
Whitehead Works Image
Whitehead Works Image
The van is lowered onto the track with rail under each wheel. As someone said at the time, "If that rail had been there in the first place then this brake van wouldn't have derailed!"
After two day's hard work, the young fellas had the brake van back on the rails.
Whitehead Works Image
Whitehead Works Image
The next weekend, a shunt was carried out to move the van nearer to electricity supplies and tools. Here RPSI ex-GSWR J15 No.186 buffs up to the short train.
 And the brake van rolls for the first time in years. 
Whitehead Works Image
Whitehead Works Image
One of the youngsters who helped rerail the van directs the shunt.
The initials "G N" can still be seen on the side of the van. The side of wood is rotten and will have to be replaced, but not before careful notes are made of the lettering.
Whitehead Works Image
Whitehead Works Image
Salvaged parts sit in the Belfast end verandah. This picture marks the end of the rerailing - but only the beginning of the restoration project!



I hope this has given you a fun insight into work behind the scenes at Whitehead.
There are many jobs like this that your help could make a real difference on.
Why don't you come and join us?



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