Train Exteriors & Interiors
Trans Alpine & Trans Coastal Trains
FDL was involved in the construction of the new Trans Alpine and Trans Coastal train carriages built at Hillside, which were manufactured entirely in New Zealand rather than being refurbished from older imported rolling stock.
FDL produced a wide range of fibreglass components for the carriage fit-out, including window surrounds, display consoles, toilet cubicles, exit doors and HVAC ducts. Around 14 carriages were completed as part of the programme and went into service on scenic rail routes around the country.
FDL also supplied Wellington-based design company Merje DDM with fibreglass seat backs for the scenic train carriages.
The project demonstrated the depth of local manufacturing capability involved in delivering a major New Zealand rail programme, with FDL contributing specialist composite components across both functional and interior applications.
In 2013 we won 2nd at the design awards.
Britomart Trains
FDL was involved in the design and manufacture of fibreglass components for the refurbishment of Auckland’s ADL/ADC passenger trains following the opening of the Britomart Transport Centre.
The project initially focused on updating the interiors, but the exterior design was also revised to include new fibreglass nose cones and bright yellow cowcatchers, giving the trains a more modern and distinctive appearance.
Safety was a key consideration throughout the project. Fire-retardant resin was used in the fibreglass components, while additional steel reinforcement was incorporated into the front of the trains to provide driver protection. Bright blue and yellow finishes, together with ditch lights, also improved visibility at crossings.
FDL manufactured the exterior nose cones and cowcatchers, along with a wide range of interior fibreglass components including walls, ceilings, seat backs and seat bases.
One of the main technical challenges was accommodating variations in the dimensions of the existing carriages. Internal measurements could differ by several centimetres, so the moulded wall and ceiling components had to incorporate sufficient tolerance to fit consistently while still achieving a clean finished appearance.
FDL worked closely with the designers to adapt specifications and refine the moulded components to suit the original train structures.
