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Restoring the stained-glass windows
The much-loved stained-glass windows created by local artist Chloe Buck in 1991 are being carefully restored as part of the replacement carriage project by a local leaded and stained glass specialist Brocksdown Glass.
Each panel is also being extended to fit the new, deeper window openings, designed to give visitors broader views from the carriages.
Two restored panels have already been fitted into the new carriages, with the remaining panels due to be installed later this year.
A painstaking restoration process
Before the old carriages were removed from the tracks, all 24 stained-glass panels were carefully taken out. Each one is made up of around 100 individual pieces of glass and more than 200 solder joints.
For each original panel, a full-size tracing, known as a cartoon, is created. Every piece of glass is numbered to match the tracing, which is then used as the guide for rebuilding the panel.
The panel is then carefully dismantled and the old lead is removed. Each piece of glass is hand washed to remove dirt, old cement and sealant before being numbered again.
Using the cartoon as a guide, the panel is rebuilt with new lead strip, known as came. New border glass is cut to fit the revised dimensions, and any damaged glass is replaced.
Once assembled, the panel is held securely in place with horseshoe nails. The lead joints are cleaned, tallow flux is applied, and the joints are soldered on both sides so the panel can be safely moved.
Leaded light cement is then brushed over both sides of the panel to strengthen and weatherproof it. The panel is left for a couple of days so the cement can harden.
Finally, the panel is washed, dried and carefully cleaned. A patina is applied to darken the solder joints, and the exposed lead is treated with grate polish for protection.
Once complete, the panel is taken to a glazing specialist, where it is fitted into a sealed unit for added safety and long-term protection.
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