Renovation

The refurbishment programme of the cliff railway by Torbay Council is completed.  Passengers travel in the new carriages resplendent in the near as pssible original maroon and cream colours embellished with Torbay's coat of arms on either side of the centre panels.  See: Recollection page: Babbacombe Cliff Railway, Council Refurbishment.

The refurbishment of the cliff railway commenced in perfect weather conditions sunny blue skies although the prevailing easterly wind was bitterly cold.  A few days later the weather conditions changed see website: www.stmarychurchdag.co.uk  see: Out and About 'A Winter Bay' 25th November 2005 

The pre-planning by all involved in the Babbacombe Cliff Railway lifting operation on 23rd November 2005 ensured that it ran as if it were a military exercise.  At 8.15 am, the Torbay Seaway crane began the process, extending its massive hydraulic lifting jib to enable the lift to commence.

By 8.30 am, the two straps attached to chains were securely in place beneath one of the cars.  After the removal of the last pin holding the first car to its bogie slowly, the car was lifted off and carefully manoeuvred onto a flatbed lorry.

The remaining car, two bogies and two diverters lifted during the day and taken to a holding point in Brixham then onto large loader and transported to London for refurbishment.

The lifting operation covered by the press and TV although not as many of the public as anticipated attended.

The years of salt air had taken its toll on the outer carriages shells tests on the cars whilst at the London engineering works concluded they were beyond repair.

There was no alternative other than scrap the cars and construct new ones.

Photographs progress of work on refurbishment at Embankment Engineering Limited, London.

In mid March 2006, the two fully refurbished bogies were transported overnight from London to Babbacombe.  The first day’s six-hour installation went well and to plan Torbay Seaways crane lifted the 3.2 tonne bogies off a flatbed lorry onto the track.

However, on the second day whilst winching one of the bogies broke free and collided into the bottom boarding station causing extensive framework damage to the bogie and had to be sent back to London for repairs.  There were no visible signs of damage to the bottom station a structural survey to find out the cause and extent of the damage was carried out. The London experts assessed the damaged bogie was extensive and repairs would take time therefore the railway was not ready for the celebration on April 1st 2006.

Fortunately, a full risk assessment for all involved in the lifting operation and precautions were in place no one was hurt.  The many inbuilt safety devices ensure when functioning under normal operation this would have been impossible.  The railway has been running 80 years and there has never been a serious accident.  A major disappoint and setback for all. One of the newly refurbished carriages with some of the original vertical poles and handgrips restored and retained was on show for the April celebration day. 

25th May 2006 again the weather changed from previous days of rain and wind the conditions were perfect.  The lorry with its loads had to reverse down the cliff road into position near the bottom station a tricky manoeuvre to undertake.

Torbay Seaways lifted the bogie onto the track the lorry then left to collect the second carriage upon returning with its load it was placed into position on the bogie.


There followed a month of fixation of cabling, adjustments and testing of the whole system to ensure it was fully operational and complied with all regulations.
 


Engine room top and bottom stations.

The old motor room engine equipment removed.

Teams from Earlswood specialist manufacturers Dagenham installed the new folding doors at the top and bottom stations.

 

The folding door panels were pre-formed from flat sheets of galvanised sheeting (a long lasting protection for steel from corrosion) and folded independently and assembled separately on a bench.  The panels were then sent away for powder coating.

  

Jimmy, James, Darren and Brian a lively, happy and extremely efficient team ‘Paddy, Noddy, Kojak and Not Brian’ their suggestion) throughout the days whilst fitting the doors kept up a continuous banter of good humour and songs.

   

Must have been the sea air!

Powder Coating,  electro-forritic application of powder coatings

The component first under goes a pre-treatment cleaning preparation process of degreasing rinsing, stabilising and drying to enable the powder to adhere.  Then suspended (earthed) and an electrical charge is passed through which attracts the negative powder (a mixture of fine particle of solid resin, pigments, charge agents and additives). Then the component is placed in an oven and baked, at a high temperature 200C where the powder particles melt fuse and bond to the metal surface which form a corrosion resistant and durable film with a life expectancy of approximately 15 to 25 years.

Powder coating is a fast growing finishing process environmental friendly due to minimal impact on the environment.  Many firms use powders containing no Triglycidyl Isocyanurate as per the current personal Health and Safety and Environmental legislation.

Due to the location and the corrosive effect of salt water to preserve the durability of the doors regular maintenance by cleaning with warm water and mild detergent will help. Abrasive cleaners must never be used.

Photographs courtesy of David Cooper, Norman Drew, Peter Aunger, Nick Hallam & J.M.L.

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