Replacement roof for a Paya 987 coach

This weekend we had a few hours to saw, shave and sand a rough roof mould for the missing Paya 987 roof. I used old pine as it is hard enough to be rigid and soft enough to work it into the required shape. Furthermore, we have a full shed of pieces of old pine wood. The plan is to sand the mould in an even better shape and then to use it as soldering mould and make a new roof from either new tin plate or brass plate. Well anyway, a start has been made and I am quiet happy with this rough mould.

Last Saturday, I went to Peperkamp to get a brass sheet of K&S (10 x 4 x 0.01 inch) for a reasonable price. First, I cut and folded a paper roof to measure all the distances on the roof mould. Then I started to cut the metal sheet. To get the four right angles in the brass the most difficult part. But my vice, hammer and fat iron ruler were perfect for the job. Now I just have to bend the more gentle curves in the roof and solder it together.

Last evening I started to shape the rounded corners of the Paya roof, by making incisions with a pair of scirrors, hamering the shape in the roof and soldering the lot to form a roof with nicely curved lines. Well, there is still a lot to do: filling the holes, sanding, grinding, polishing! Afterwards the curves will get smooth finish by soldering a thin strip on the bottom rim of the roof curves.

The roof replacement is now largely formed; all the major shapes are formed. It just has to be made beautiful still.