Rebuilding the Left Bolster

In the last episode, I removed the two bolsters - the wooden blocks between body and frame - and noted a difference in height, as well as a difference in construction and bolt pattern - between the two.

Today's post concerns making the two bolsters match, at least in height and appearance.

The actual difference in height is 1/2", and the upper surfaces of the bolsters, which mate to the bottom of the carriage body, are slightly concave, to match the curvature of the body.

My best plan (not my original plan) was to add a piece of wood to the upper surface of the left bolster.  I found the perfect piece of straight grained, 1/2 x 1 1/2" red oak at Home Depot.  Here you see the slight concavity of the bolster, and the new piece of wood that must match the curve.  I was getting all geared up for a small wood bending project...

...when I discovered that the new wood was flexible enough to conform to the curve with slight pressure.

New board is trimmed, surfaces clean and roughened, coated with epoxy glue and clamped.

Twenty four hours later, a knowledgeable friend suggests the bolster may have been originally shortened to accommodate a sagging right hand spring.  A possibility I hadn't considered!  Oh dear.  Well, too late now, and I doubt I'd have been able to cope with the visual discrepancy anyway.  And besides, that still doesn't explain the two-part construction and different bolt pattern.

Anyway, the left hand bolster (which has been heat stripped of old paint and crud) is now 1/2"taller...

...the new wood is drilled and the altered bolster is checked for fit against the upturned body.  A little sanding is required to match the curvature of the body, but the modified bolster bolts up perfectly to the body.

Now to finesse. The extra length of new wood must be trimmed to match the right hand bolster...

...curvature at the end is roughed out...

...a wee bit of carving in the corners...

...and we have a matched pair!

A thin smear of fairing compound will fill blemishes in the joint.  Once that is sanded back, the bolster will be ready for a coat of grain filler, followed by a coat of clear wood sealer, then set aside until I am ready to fire up a paint gun.  Of course the other bolster will be cleaned up and prepped for paint as well.

I am SO glad I did this before painting the body!  So much risk of incurring "reassembly rash" with new bolt holes and such!