Hold the carriage firmly and pull existing corridor connection from the carriage.

Clean up the bellows of the corridor connection and check for fit to the carriage with a dry run.

Carefully carve the raised detail from the end of the carriage.

Place the bellows on to the end of the carriage and mark a hole through the hole in the bellows. Open up the hole with a 8mm drill bit.

With care this can be done without taking the carriage apart. See below.

After painting the End Plate and Concertina the parts are assembled with spring over the spigot of the End Plate. Pass the spigot through the hole in the concertina and secure it with the fixing washer.

Adjust the attitude of the fixing washer so that the End Plate is equally spaced 1mm out from the concertina.

Secure the fixing washer with a tiny amount of super glue. Then glue the corridor connection to the carriage end.

The draw bar on these carriages is almost perfect. Hornhy have done a good job here. The only problem is the coupling pocket is 1mm too far back.

If you get swarf inside the carriage after opening the hole in the end of the carriage then the carriage will need to be taken apart.

First remove the bogies by sliding a domestic smooth bladed table knife into the bogie pivot and twist it. The bogie will then pop out cleanly.

To remove the body from the chassis the clear coloured tabs at the ends of the carriage need to be eased inwards to release them from the chassis and gently ease the the chassis from the body.

There are also locating lugs half way along the carriage.

Hornby GWR Hawksworth

The Corridor Connection


Taking the carriage apart.

Close Coupling

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The Keen Systems flat plate coupler is used with a 1mm space from the coupling pocket.

 When coupled the carriages will go  round Hornby radius 2 curves.

When reassembling the carriage simply snaps back together.