DVT and MKIV Rake High Speed Impact Repairs and MKIV Underframe Corrosion Repairs

Scope: Impact Repairs and Corrosion Repairs

Customer: East Coast/Eversholt

Work scope summary – DVT & MKIV Rake High Speed Impact Repairs:

Following major damage to a DVT and MKIV Rake from a high-speed impact, the set was returned to its Home Depot at Bounds Green for repair.

  • Initial assessment and damage survey
  • Structural assessment
  • Brake system removal
  • Specialist procurement and sourcing of components and materials
  • Off-site pressure testing and certification of new components
  • Rebuild underframe panels and module cases from sourced metals
  • DVT front end rebuild from sourced metals and patterns
  • On site manufacture of all bracketry and framework
  • Through train ETS pull out replacement
  • Through train Wi-Fi jumpers / receptacles sourced and fitted
  • Final brake test and handover reports


Work scope summary – MKIV Underframe Corrosion Repairs

A high level of corrosion was identified on the Underframes of the MKIV coaches and therefore a full fleet inspection and repair was required.

Yellow Rail provided a fully managed service including the deployment of dedicated site management to seamlessly integrate the project into the depot’s operational activities.

  • 270 MKIV Coaches
  • Preparation and presentation of Modification Overhaul Instructions
  • Project planning to integrate the corrosion repairs onto the depot exam cycle
  • Set-up and management of the depot welding bay supported by the introduction of all associated safety measures
  • Structural assessment of vehicle underframes on site
  • On-site and off-site fabrication and on site welding 
  • Management of the welding process to ensure protection of electronics
  • Training and assessment
  • Technical and commercial management of the programme to meet the business needs and safety concession deadlines


“Both impact repair and fleet wide corrosion repair projects were delivered safely, within the budget and in a very timely manner, preventing the need for the rakes to be sent to HM works and providing East Coast with a substantial cost savings.”

John O’Neill, Commercial Manager, East Coast Trains

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