Sorry bit of a break as I thought the post might be too long in one hit .....
These are the irons I have been using and generally it seems that the old school Solon is best, it is not as powerful 65 watt instead of 75 watt, but it seems to do the job with less distortion .
To reinforce the buffer beams I cut down some square tube into angle, it was a bit thinner than the angle I had ! After some drilling and filing I soldered it and the buffer bodies sandwiching the thin buffer beam . The top flange of the angle I drilled so that it could be screwed to a 10mm ply floor . So hopefully all the draw gear forces would be separate from the thin bodywork .
So came the assembly of the 'big bits' , I decided to tack the solebars in place first as they would hopefully hold it all straight and then the doors would just slot on after. Good plan except .....
the perishing solebars were too long. I took it apart and corrected the length . Put it back together, the bit behind the door was too wide now. Back a part again... It took three goes before it all fitted right, and I had to do it that way because with everything being so thin and floppy, the solebars were the only thing keeping everything straight, and to alter them they had to be off the model .
Bit of a jump ahead now, floor and other reinforcement in place .
New improved running gear coming together ....
Starting to look like a wagon at last .... Suggestions for how to fix the roof on, on a postcard to the usual address .