All photos: Joel Fairhurst
You've likely heard of the PBS television series "This Old House" where through the course of the season (18 weeks) the crew shows restoration methods for making a run-down house into a very nice place to live.
This series was done in the same manner, but in this case, we followed the progress of the rebuilding of MBTA bus 8887. This bus was seriously damaged in a collision (fortunately there were no serious injuries), and was at one point rumored to be the first RTS in the MBTA to be retired. However, that rumor was premature. RTS 8887 was moved into the Everett Shops on April 17, 1996 to receive the work necessary to restore it to its original condition.
The bus went to the capable hands of Joel Fairhurst, an MBTA Sheet Metal Mechanic (Local 17) who has had quite a bit of experience in repairing damaged buses for the MBTA. The work on 8887 will probably be the single largest bus rebuilding project that the MBTA has done in-house, but Joel and the capable crew at the Everett Shops were up to the task.
Two factors that may have helped give 8887 a second "lease-on-life". First, the 8800-series buses are currently being rehabilitated as a fleet. While the work being performed on the other buses in the series was not as extensive as 8887, the other components for the bus were in stock and ready. The second factor that may have helped was the RTS's construction; unlike older buses, the RTS is made up of several modules. The damaged modules were removed from the bus, and new modules were installed and welded into place to create a "seamless" repair job.
If much of this seems confusing at the moment, don't worry! We've followed this process in a step-by-step manner!
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<--- The final update!
All photos: Joel Fairhurst
On April 17, 1996, bus 8887 was brought into the Everett shops. An evaluation of the bus was made to determine the best way to proceed.
Photo: Joel Fairhurst
By April 24th, work was underway at cutting off the "nose" of the bus. Also, components and fixtures on the inside of the bus were removed.
Both Photos: Joel Fairhurst
By April 29th, 8887 was up on the lift with most of the floor removed. Damage to the frame-member next to what was the front step is (barely) visible in the photo on the right. The engine, transmission, and other components that would have to be removed and repaired (as part of the normal overhaul program) have also been removed by this time.
Photo: Scott Moore
The replacement modules are on the property and in storage at Everett. The "nose" module is in the wooden frame-work, while the passenger module is standing (in the shade) behind it.
Both photos: Scott Moore
This is the status of 8887 as of May 2nd, 1996. Arrows on both images point to where the damaged modules will ultimately be cut away from the bus. The entire module will be removed and replaced with the new ones shown above.
Both photos: Scott Moore
A close-up (left) of the aforementioned frame-member that will need repair. The plate that is welded on is merely a temporary repair. Each module is designed to be integrated with the frame - meaning the frame and the modules (when in place) bear weight equally. Without the temporary repair, the remnants of the front-end of the bus (right - marked with arrows) would not be supported while work progressed.
Photo: Scott Moore
An interior shot of 8887 on May 2nd.
Photo: Scott Moore
MBTA 8887 as it appeared on the morning of May 21, 1996. The bus has been lowered back down to the ground, and sections of the damaged modules have been cut away.
Both photos: Scott Moore
Joel uses a circular saw to cut away the module section behind the front door.
Photo: Scott Moore
Again, Joel is using a circular saw, but this time he's cutting the driver's side corner-post.
Photo: Scott Moore
Using a torch, Joel begins to cut the roof into small, manageable sections. This process will continue until the bulk of the damaged modules have been cut away.
Photo:
Scott Moore
With the bulk of the first two modules cut into managable pieces, work now progresses on making the fine cuts to prepare the bus for the new modules.
Photo:
Scott Moore
RTS 8887 now only has six of its eight modules.
Photos:
Scott Moore
Joel continues to make the finish cuts, separating the last edge of the #2 module from the #3 module.
Photos:
Scott Moore
The frame and module sections that will be retained are ground down, and free of rust, in preparation for welding on the new #1 and #2 modules. The image on the left shows the section that recieved the "temporary" repair earlier. The new modules will be welded to this "stub" end, and to the "tubular" sections in the other photos. Additionally, the #1 module will have to be welded to the front of the frame and the drivers platform.
Photo:
Scott Moore
The new #2 module lays on the shop floor. Cut lines are already drawn on it so it will match up with what is still on the bus.
Photos:
Scott Moore
Now with the original #2 module completely removed, Joel does the finishing touches in preparation for the new #2 module.
Photo:
Scott Moore
Joel cuts the new module along the lines drawn previously. The cuts have to be precise, and match what still exists on 8887, or the module will not fit properly.
Photos:
Scott Moore
After the new #2 module was readied, a crew of about a half-dozen men was assembled. The crew picked up the new module and sat it in place on the rest of 8887. Joel then used a series of clamps to hold the module in place until it could be welded.
Photos:
Scott Moore
A week later, the clamps had been removed, and the #2 module was welded to the #3 module and the rest of the frame. The welds shown here are only temporary until the body is completely together. This will allow for any necessary adjustments after the nose (#1 module) is installed.
Photo:
Scott Moore
The #1 module has undergone the same cutting treatment as the #2 module did. It is ready for installation.
Photo:
Scott Moore
With the #1 module in place, 8887 begins to take on a "finished" appearance, though much work on the bus is still necessary before it will be ready for service.
Photos:
Scott Moore
Work on the interior has commenced, and piping and insulation have been installed inside the #2 module. The #1 module at this time is still being held on to the bus by clamps.
Photos:
Scott Moore
By the end of June, the nose has been welded to the rest of the #2 module, and the bus is (for the most part) in one piece. Most of the welds are still "temporary", and more welding will be necessary before the job is complete. Since we last saw Joel, he had cut new holes in the nose to allow the installation of additional access panels, one below the left-side driver's sash, and one below the right-hand windshield (windshield washer filler). The vent door (beneath the driver's side windshield), a feature on the 8000s, 8800s, and 8900s, has been added as well.
Photo:
Scott Moore
Work on the interior of the bus continues to progress, but more slowly. As Joel's sheet metal work comes to a close, carpenters will be called over to install the new sub-flooring.
Photo:
Scott Moore
The new bus driver's platform begins to take shape.
Photo:
Scott Moore
Our next visit in the middle of July shows that the carpenter has arrived, and the new sub-flooring for the bus has been installed. The driver's platform has also begun to shape up nicely.
Photo:
Scott Moore
The new sub-flooring has been installed. New rubber flooring will be installed along the entire length of the bus as part of the rehab program. The old rubber flooring has yet to be removed. Also, the inside of the nose module has been painted dark grey. Most of this metal will remain exposed when the bus is complete.
Photo:
Scott Moore
Some additional welding has taken place in this image, but the most notable change here is the wiring harness hanging out of the windshield. The electricians are now in the process of stringing wire throughout the body of the bus.
Photos:
Scott Moore
In August of 1996, the last pieces of Joel's work were coming to a close. The new flooring has been installed by the carpenters (left). The bumper and glass has been attached to the front of the bus (center). And the only easily visible evidence that any additional work has taken place is in the right-front wheel well (right). The extra bead of welding there is the back side of the weld which was (ever so) carefully matched up when the modules were being installed.
All Photos: Vinton
Wong
In late October and early November, after Joel's work was completed, 8887 joined its sister units in the production line of the 1989 overhaul program. The interior of the bus (left) is being rehabilitated including the installation of new light ballasts (hanging) and the new speakers for the ADA mandated PA system. The drivers area (center left) is also seeing a similar level of work as 8887's sister units, except that the work in Joel's area was purposely stopped short of where the rehabilitation work was to begin as there's no sense in doing the job twice! The two photos on the right show the exterior of the bus as it was in the overhaul program. Note that 8887 was the only "unpainted" bus in the program. The sheets on the windshield are the checklists for work to be completed.
Photo:
Vinton
Wong
In late January/early February, the bus was released from the overhaul program. A fresh coat of paint tops off the job. Windshield wipers and some last checks of the bus will take place before it is returned to service.
Photo:
Scott Moore
RTS 8887 in its completed form on February 22, 1997, just two days before the bus was returned to the Fellsway Garage, and just over ten months after work on the bus commenced. Looking at 8887 now, you would have a very difficult time telling that this bus was the same bus as the one shown at the beginning of this photo essay!
Congratulations to all of the men and women at the Everett Shops, who gave their time and attention to seeing that this bus be returned to service, and for a job well done!
A special thanks to Joel Fairhurst, and everyone at the Everett Shops for allowing us to document this event. A special thanks also must go to Vinton Wong, who was able to fill in for me and get photos when I was unable to get back to Everett. And also a thanks must go to Jonathan Belcher who kept tabs on the bus and its progress; and took many long walks with me to photograph the bus and find pieces of the long torn-down elevated structure to Everett (yes, this is an inside joke!).