I resorted to my preferred material for the lorry structure, namely 1.5mm aluminium sheet. Very easy to work, bend and cut. The model lorry has three main components, a chassis, a cab and a loading platform which, after cutting out and forming, are bolted together. Front and rear wings and separate parts as are the seats, and the engine cover, which sits inside the cab. Some bought-in components were needed and these comprised road wheels, steering wheel, radiator and headlights.

Method

1. Establish the main dimensions for the vehicle, using the known sizes of a prototype. Scale the drawing until it looks right. (Much reference was made to photographs at this stage and the key figure used was the body width which is 7ft 6in, or 53mm. The coal lorry is a short wheelbase vehicle and 11ft or 77mm seems about right.)

2. Draw out the cutting and folding lines on to the aluminium sheet. The cab section is shown in the accompanying photograph. Allow tabs to enable bolted joints on assembly.

3. Cut the window openings first by drilling pilot holes and trimming the window to size using needle files. Do this before cutting round the outline.

4. Using tin snips, carefully cut the outline, tidying up the cuts by filing.

5. Fold the cab to shape using a vice and pliers, forming a rectangular box. The roof profile is slightly curved. The tabs at the back and front of the cab are folded through 90 degrees and fit behind the cab sides. After folding, secure the structure using M2 countersunk setscrews and nuts.

6. Where the screw head needed concealing, use a dab of P38 filler and sand down. Heads can be left exposed where they formed a feature, notably the cab door handles. P38 filler was also used to fill the joints at the corners, obtaining a smooth finish by sanding.

7. Mark out the chassis and loading platform. Cut out using tin snips. These are straightforward shapes cut from flat sheet and folded. The chassis incorporates a slot through which fits the tab at the rear of the cab.

8. Mark out and cut the front and rear wings, cab seats and engine cover. The wings are small rectangles, curved to shape by forming round a piece of wooden dowel.

9. Carry out a trial assembly of cab and chassis. The two items are secured with M2 setscrews and nuts, enabling removal for subsequent processes. Fit the front wings by gluing into position under the cab sides. Mark out the axle positions on the chassis, locating the front axle position concentrically with the front wings. Dismantle the two components.

10. Drill the chassis to take the axles. Care is needed drilling the chassis for the axles as the holes on each side have to be lined up and the front axle location centrally placed to suit the front wings.

11. Fit cab seats into cab and the engine cover onto the chassis. Fit the steering wheel. Next paint the inside of the cab and once the paint is dry, cut the cab glazing to shape and glue into position. Canopy Glue is recommended as this leaves no visible residue.

12. Cut up the coffee stirrers and glue to the loading platform to represent wood boarding.

13. Assemble lorry chassis, cab and body. Fit the rear wings by gluing into position, concentric with the wheels. For added realism, a fuel tank can be added. This is made from a short piece of 10mm dowel.

14. Fit the two axles and wheels, glue on radiator and headlights.

15. Paint. Chose a suitable colour for the cab. Black for chassis. Varnish the floorboards on the loading platform.

16. Make up a cab top sign to suit.

17. Dress the vehicle by adding coalmen to taste, weighing scales and full and empty coal sacks. The sacks can be scratch made using ‘J’ cloths soaked in PVA glue and filled with real coal (dust) to a technique found on the internet.