When I began my 3mm modelling 'career', one of the first projects that started out was the 2EPB project.
The first part of this 2-car third-rail electric multiple unit (expanation for my overseas readers and those whose aren't 'modern image' !) began life when I was doing the demo-stand at a model railway exhibition, and to keep up with my contraversial way of doing things, the basis of the model is sections of sawn-up Triang suburban coaches !
This method has become my standard way of coach building.
My method is a simple one. First, make up the roof sections in the correct length by cutting two sections with a razor saw, and glueing them together.
Now begin to assemble sections of coach and glue these to the roof sections - don't worry too much about the floor section, as this will be cut out later.
For the front of the units, I have made up driving ends from plasticard, bending to shape where required and glueing them to the open ends of the coach structure - you could always use this method to make DMU's using the Society cast ends (don't forget to add a buffer beam underneath - cut this off of the discarded end, and glue on)
We are now at the stage of having a complete coach - and once the glue has dried fully (I use solvents like Mekpak, and three days living on top of my PC monitor is long enough !), careful cutting with a sharp knife along the inside of the solebars will remove the whole of the floor.
I would now built the whole floor section with motor bogies on a flat 1mm thick plasticard plate. Seating can be built on top, and battery and equipment boxes built underneath. If the plate is an interference fit, or some protruding lugs with fixings fitted into the body to locate with the floor-plate are used, the floor section can be removed from the body for maintenance.
Finish off the bodywork with pipes, hand-rails and air-horns, and we're ready for passenger service !!
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