Star Of The Moment - Electrostar First Sample Breaks Cover

[Warbonnet]

Recently, we received the first sample of our highly anticipated Electrostar project — a model we’re developing in conjunction with our friends at Rails of Sheffield.

This early, unpowered sample has been sent for us to inspect the fidelity of the moulds and to begin our feedback process, allowing us to accelerate the model into the decoration stages.

Well, we were certainly taken aback when we saw it. We know self-praise is no praise, but wow — it’s a bit of a stunner!

As with any early sample, there are a few areas that will need some fettling before moving forward. The kinematic couplings, for example, will require a little refinement.

Our development team will also be revisiting the roof access and fixings, as they’re not entirely satisfied with the magnetic fittings and roof removal — particularly on the PTSOL. These areas will be adjusted to ensure a more secure and reliable fit.

Another element under review is the mechanism that enables the fitting of destination screens. The concept works, but it needs further evaluation to see how it impacts other areas of the design before it’s finalised.

On a more positive note, the underframes are looking excellent, with plenty of fine detail and an accurate shape — especially around the cab. The overall weight, centre of gravity, and balance are spot on, and the integration of the mechanics — including the motor and pantograph — has turned out very nicely indeed.

We expect a fully powered version to arrive shortly, allowing us to begin performance evaluation and electronics testing. This next phase will bring a whole new level of interactivity and fidelity not yet seen on any UK-outline multiple unit to date.

If everything goes according to plan, we hope to show you decorated samples around Easter 2026, and at this stage, our delivery date remains unchanged.

All in all, it’s a very encouraging first step for the Electrostar — a few tweaks still to make, but plenty to be happy with as the project moves closer to production.

Look out for videos taking a closer look and offering more in-depth insights from both Rails of Sheffield and ourselves next week!

Fancy one? Place your pre-order (with your reservation fee) through Rails or directly via the link below.

Pre-Order Your Electrostar Direct Here!

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[Mol_PMB]

You might want to take another look at the bodyside near the intermediate ends, where you have a bold raised bead line running vertically. 

The end module (last 800mm or so of each end of the carbody) was bolted on with 6 big bolts (2 M36 and 4 M30 if I remember correctly from my time in U shop). This left a gap between the end and the bodyside, which was filled with black Sikaflex sealant from a big air-powered sealant gun. The gap was filled flush, not to a raised profile.

Also, the end module included the part below floor level. So that joint continued down across the solebar. 

This photo on Flickr (not mine) shows what the end joint should look like:

Not like this:

 

More recent builds may have a slightly different treatment in this area, but it's still not a raised bead line, and again the joint continues below the solebar. Again, a photo on Flickr, not mine.

 

The raised bead between the doors also looks wrong to me. The doors were designed to seat very flush, there isn't a raised portion where they join:

 

Cheers

Mol

[BosKonay]

8 hours ago, Mol_PMB said:

You might want to take another look at the bodyside near the intermediate ends, where you have a bold raised bead line running vertically. 

The end module (last 800mm or so of each end of the carbody) was bolted on with 6 big bolts (2 M36 and 4 M30 if I remember correctly from my time in U shop). This left a gap between the end and the bodyside, which was filled with black Sikaflex sealant from a big air-powered sealant gun. The gap was filled flush, not to a raised profile.

Also, the end module included the part below floor level. So that joint continued down across the solebar. 

This photo on Flickr (not mine) shows what the end joint should look like:

Not like this:

 

More recent builds may have a slightly different treatment in this area, but it's still not a raised bead line, and again the joint continues below the solebar. Again, a photo on Flickr, not mine.

 

The raised bead between the doors also looks wrong to me. The doors were designed to seat very flush, there isn't a raised portion where they join:

 

Cheers

Mol

The sample is a 375/6, so a South Eastern example, which do exhibit the mastic sealer joins.
 

[Mol_PMB]

It was 375/6s that were being built when I had my spell on the production line. They did indeed have the mastic sealer joins.

After a fair amount of searching on Flickr I have found an example with the broad raised join, basically as per the sample model:

 

This is not how the trains were when built, or for much of their lives.The picture above shows a raised rubber strip which must be a later modification.

Originally the joint was a thin line, and the specification for applying the Sikaflex was that it should be flush. The whole design vision of these trains was to be flush-sided and sleek. The inmates of the Playpen* would have spat out their crayons in horror at a vertical rib on the sides! Here's another photo from Flickr which is a 375/8 and shows the original design which was also used on the 375/6 and the other early Electrostars:

When I looked at the sample model, this joint was the one thing that really jumped out at me as being 'wrong'. Now I appreciate that this version represents a train in its current condition rather than original state.

Perhaps the tooling will allow for a more subtle joint line on the original liveries and other classes? 

 

As built, the door seals were also flush, and most more recent photos I've seen also show a flush door seal. It's possible that there have been modifications since, with pressure-sensitive door edges that may be a bit raised like on the model. 

This distinction won't stand out so much because the door seals are all black, and the visible width of the seal hasn't changed.

 

 

* Playpen - the glass box in the corner of J shop, where the Industrial Design team were based. 

 

[BosKonay]

The EP is a single variant from a tooling suite that has 17 different builds allowed for. Once reach decorated stage we will have each version in this run to share including a range of differences in joins, placement and even glazing.