 |
Photo: John Gascoigne |
When the world sees the
Routemaster bus they think London - iconic looks, great design and legendry
reliability – “the like of which we will never see again.”
Since then every
subsequent bus design is compared – generally unfavourably – a box shape, no
relieving aesthetic features, and a heavier, more fuel-hungry vehicle in
constant need of engineering attention.
But the early days of
the Routemaster were anything but happy ones. Conceived in 1947, seven years
were to elapse before the first prototype even appeared on the streets. A
further two years before it entered service and after three
further years it was withdrawn. Two more (bus) prototypes later joined the
fleet. RM2 managed to stay on the road for about two years, and RM3 about 20
months.
In addition three
other vehicles – fitted with ‘lorry’ bodies – were used to follow regular buses
in service and simulate service operations.
Despite all the trial
running, the first major entry into service in 1959 was disastrous when nearly
80 Routemasters replaced trolleybuses at West Ham and Poplar. On the first day the garages received
over 100 road calls from bus crews in trouble. Subsequently the situation
remained dire, with design defects and poor manufacturing standards often to
blame. Numerous campaigns of modifications were immediately put into place.
A major failure caused
22 of them to be removed from service when a complete steering column fractured
and all the others were found to be at risk of the same thing.
In the first two years
there were 55 campaigns for mechanical alterations, 24 campaigns for electrical
issues and 38 for bodywork.
The District Engineer
at the garages recorded that in the 15 months to August 1961 on 142
Routemasters he changed:
518 brake shoe liners
425 gearbox seals
416 front shock
absorber rubbers
247 alternator belts
185 radiator fans
138 water pumps
126 rear shock
absorbers
101 front shock
absorbers
46 radiators
He records a similar
list for electrical and body work issues.
The heating and
ventilation system was found to be particularly poor and despite efforts over
the years it remained a real weakness of the design.
During those awful
times there were long gaps in service and frequent breakdowns. Passengers were
frequently inconvenienced and the staff increasingly demoralised.
In 1963 – some nine
years after the first prototype entered service and despite hundreds of
thousands of miles of passenger operation – a major rework campaign started. All
of the issues were addressed on over a thousand vehicles and slowly the fleet
began to deliver a reasonable level of reliability.
I have not found any
definitive record of the costs incurred – paid for by fares and taxes alike.
The costs of prototype buses which only clocked up a couple of years’ service
each; the cost of major rework campaigns; and the cost of major losses of
service in terms of revenue. Over
and above this, the countless London Transport engineers and research staff working
full time to resolve the problems.
What is clear is that
despite extensive prototype testing, and early experience in operation, a very
large number of problems in design, manufacture and maintenance did not come to
light till after entry into service.
An expensive and lengthy
process in the end delivered to London a bus which became a design classic. It
was reliable, cheap to run, loved by passengers, staff and engineers alike. Nearly
60 years later it is still in evidence in London.
That process was extraordinarily
slow, and required a huge amount of effort. Imagine if in this modern demanding
world, a bus had taken nine years from design to operational reliability!