...the wooden 'filling' was glued (epoxy, ta) to the outer buffer beam after the buffers had been fitted (modified LGM castings.) [The buffer stocks have had a small collar soldered to the ends to improve appearance and the locating tube removed from the rear. The buffer heads are held in place by soldering a small washer to the stem and trimmed as appropriate. the buffer movement is contained in the wooden portion of the buffer beam.]
Final assembly of the rear beams was done on the chassis. The inner beam was soldered to the end of the chassis, checking for squareness in all planes. The outer assembly was glued into place, again checking alignment very carefully (I used a 1.7mm drill through the coupling hole to help.) The wooden portion had a notch cut in the top to allow access to the locating tab with a soldering iron tip. Soldering adds much more strength to the sandwich. Angle iron strengtheners, as prototype were, added. The designer had kindly added etchings for the triangular gussetts (hero,) also added.
The slots in the front buffer beam etchings are in the wrong place. The frames are wider at the front of the loco than the rear and the slots are to suit the rear only. It's an easy fix though. I had to make some locating tabs like this, from material the thickness of the chassis plate;
and assembled the front buffer beams by soldering the locating tabs to the rear beam and glueing and soldering the front assembly in place. I added a strip to disguise the locating tab as the angle iron strengtheners thus;
The slots are in the wrong place by a distance equal to the thickness of the chassis plate (x2) so the front beam can be easily soldered in place now, again carefully checking alignment.
The coupling hook on the rear of the loco is very long, as when the loco was rebuilt the original drag box was used. This necessitated a very long hook to reach it. It was fun to build prototypically.
It'll be at Telford on the Modelling Competition/Sunday Display stand all weekend for inspection. See you there?.......