'Ivan' Restoration 8 (May - July 2007)

In 2006 a group of young members were encouraged to take on the restoration of GNR(I) 20 ton brake van No.81, affectionately known as 'Ivan'.

Early June and the landside ballast tanks are nearly cleared out of their cargo of damp swarf and decomposing cast iron.

Adam and Mark celebrate the clearing of the ballast tanks.

A loaned brakevan stove to copy for IVAN. Here Edward tries desperately to convince himself he's cold enough to require warming up! It was very hot in direct sunlight on this day.

New vacuum pipes have been delivered so IVAN can be fitted with a through pipe.

The Belfast end drawhook has been refitted, with the (new) protoypically badly fitting drawbar pins. We can't believe they're meant to be like that either.

A huge amount of shot-blasting was performed by a helpful shot-blaster. Here James has just finished painting the beautifully cleaned components.

Edward and James worked to adapt the springs to fit IVAN's axleboxes.

This fork on the end of this long pull rod has splayed out. It was heated to red heat before being hammered back into shape.

Phillip paints the recently refitted safety loops at the Belfast end.

The completed Larne end underfloor section.

Time to refill the ballast tanks - this time without reams of swarf to retain moisture!

IVAN was moved out to be refilled with brakeblocks which had been stacked outside.

Whitehead workers rallied to the cause! Many tons of ballast is being replaced.

A perfect fit on 131's superheater! But it was worn out in 1945 - so it's little use now. Back in the ballast tank it went.

Philip, James and Edward have been working on fitting the vacuum through pipe. Here they are cutting a pipe to length.

The middle part of the vacuum pipe has been assembled for a trial fitting.

James trial fits the end of the pipe, with vacuum bag already attached.

The vacuum bag will be unobtrusively behind the buffer beam, similar to the arrangement on the Guinness engine.

Underneath the van, Michael and Edward were drilling upwards to fit the clips that the brake pipe secures into. Here they realise that they are halfway there.

Three of the four springs are now ready for refitting.

A view through the roof down to the now refilled ballast tanks.

The master stove has been given a coat of red oxide primer to protect its shot-blasted surfaces from moisture.

The completed vacuum pipe was painted in the charcoal grey undercoat, and the next day was painted gloss black.

On 12th July 2007, the Guinness engine shunted Ivan for the big spring refit day! Here, the unsteady van is brought to the heavylift area. No.90 came along for the ride. The new vacuum bags were secured on top of brake strechers.

The van needed careful positioning under the shear legs so that the chains could lift straight up past any obstructions.

The wooden blocks which had supported the van for six months or more were removed. Mark is brushing rust out of the gap where the spring will sit. The spring to be lifted in can be seen leaning against the shear leg's guide rail.

Phil and James strain to lift one end of the spring. Bob was lifting the other end by himself! We didn't weigh them to find what mass they were, but it took four men to lift them any distance.

Phil and James try and keep the spring upright.

The new nuts and bolts are screwed together after a heavy application of grease to protect them from corrosion. The new fasteners go together very easily.

Seven happy men! The van is now back on its springs - all 4 fitted!

The Guinness engine, which had been doing some shunting while the van was being resprung, took IVAN for a test run.

Bob and Edward held on tight as IVAN's newly suspended wheels negotiated the pointwork. They reported that the ride was smooth as far as vertical movement was concerned, but shuttling against the Guinness engine's big softly sprung buffers was a problem.

At the platform for the first time since restoration began, Edward as shunter prepares to give the signals for IVAN to move into the carriage shed.