More progress in the last couple of days. I formed up the sides and roof by hand to see how it all looks with the rivet detail, and reassembled the prototype coach with the new piece. Since then, I have been scratching my head about tools to do the job a little quicker. It turns out my friend Ed, who would be known to some in the Bassett-Lowke Society, still had his tools he had made for forming replica Exley coaches out of aluminium sheet and he very kindly offered them to me.
Since this was made I have been working on the Exley tools (the roof profile is effectively identical, which is a funny coincidence because my profile is an exact scale replica of the Spirit of Progress stock, but not quite the notional scale of the Exley K6 LMS coach profile).
The main work has been cleaning and derusting with a rotary brush, and easing some mating parts with careful grinding to make sure they don't lock together or shear off the sides if over-pressed. They were never intended for doing any large quantity of parts, so there were shortcuts involved in their welding and fabrication. However, considering how they were made they are exceptionally good and pretty accurate. I will be adding some stops and alignment features too, but I was able to finally do an end to end tryout today and it all worked.

The coach ends behind the cast floating vestibule/streamline corridor connectors are also pressed out of tools I had lasercut in slices and then pinned together. I'll post something on those in the next few days. The doors are actually folded over flaps of the ends, and the handrail knobs hold the ends on. I need to make embossing dies for the door window frames, and master models for battery boxes and air conditioner units and air cylinders, but its coming together. Oh, and I need to make dies to press seats for the compartments. I want to at least make some rough dummies of the underfloor parts to get a feel for how it all presents itself. Anyway, more anon.
Pieter