SR Class 4Sub

The SR Class 4Sub, also designated as British Rail Class 405, was a series of four-car electric multiple units (EMUs) designed and built for suburban passenger services on the Southern Railway's electrified network in southern England.^[1] Introduced in 1941 following a 1939 design initiative under Chief Mechanical Engineer Oliver Bulleid, these units featured a close-coupled configuration with driving motor-trailer-trailer-driving motor (DM-T-T-DM) formations, wide bodies with curved sides for six-abreast seating, and slam doors for each seating bay.^[2] Early examples retained compartment-style interiors from re-formed pre-war three-car units, while later builds adopted open-saloon layouts with central corridors and all-steel construction starting in 1946.^[1] Construction occurred primarily at Eastleigh Works between 1941 and 1951, encompassing over 200 units and approximately 955 cars across multiple batches, including augmented conversions from older LSWR-derived stock (1942–1949) and entirely new builds numbered in ranges such as 4101–4130 and 4621–4754.^[2] Equipped with English Electric electrical gear for 660 V DC third-rail operation, the 4Subs delivered around 1,000–1,100 horsepower and a top speed of 75 mph, enabling efficient peak-hour services, seaside excursions, and compatibility with other Southern EMU classes like the 2-BIL and 4-LAV.^[3] Notable design elements included the Bulleid profile for aerodynamic efficiency and, in some early units, a dedicated "ladies only" compartment reflecting period social norms.^[4] These units entered widespread service on routes radiating from London Victoria and London Bridge, such as to Orpington, Sevenoaks, and coastal destinations, forming the backbone of the Southern's suburban fleet through the post-war era under British Railways ownership from 1948.^[1] Withdrawals commenced in the early 1970s as newer classes like the 4-VEPs and 4-CIGs replaced them, with pre-1939 augmented units cleared by 1962 and the final operational 4Sub running on 6 September 1983; surviving motor coaches were repurposed for departmental roles, including de-icing trains, until the mid-1980s.^[3] The class's legacy endures in preserved examples, such as unit 4Sub 4732, the only surviving complete unit, preserved and under restoration at the 1:1 collection in Margate, Kent, as of 2025, highlighting mid-20th-century British electric traction advancements.^[5]

Development and History

Origins and 3-Car Precursors

The London and South Western Railway (LSWR) initiated the electrification of its suburban lines out of Waterloo station in 1915, primarily to counter competition from expanding tram and Underground services, beginning with routes to Wimbledon, Kingston, and the Hounslow Loop using a 600 V DC third-rail supply system. This early electrification effort culminated in the construction of 84 three-car electric multiple units, numbered E1 to E84, between 1914 and 1917, which were converted from existing steam-hauled compartment stock dating back to around 1913.^[6] These units featured a non-corridor design with mixed first- and third-class accommodation in compartment layout, torpedo-shaped "bull-nosed" ends (earning them the nickname "Nutcrackers"), and power bogies positioned under the luggage compartments of the two motor coaches flanking a central trailer.^[7] Each three-car unit was equipped with four English Electric DK.315 traction motors—one per axle—delivering 275 hp each for a total output of 1,100 hp, controlled via British Westinghouse (later Metropolitan-Vickers) electromagnetic gear with gear-driven motors and Westinghouse air brakes.^[6] Technical challenges included the rigid compartment stock's limited adaptability to electric operation, awkward shunting requirements due to the short formation length, and initial compatibility issues with the third-rail pickup, though the system proved viable for peak-hour suburban services often paired with two-car trailer sets to form longer trains.^[8] Upon the formation of the Southern Railway (SR) in 1923 through the amalgamation of the LSWR and other companies, these 84 units were inherited as the core of the suburban fleet, with only minor modifications—such as cab improvements and underframe reinforcements—undertaken until the onset of World War II.^[7] By the 1930s, the aging converted units had accumulated substantial mileage from intensive daily operations, exceeding hundreds of thousands of miles per set, which contributed to growing reliability issues including motor failures, brake wear, and structural fatigue in the wooden bodies.^[8] In response, the SR launched a comprehensive ten-year suburban fleet modernization program in 1939, aimed at enhancing capacity and efficiency across its electrified network, but wartime material shortages initially restricted new construction, leading to plans focused on augmenting existing three-car sets by adding a fourth vehicle to create four-car formations.^[6] This augmentation approach laid the groundwork for the evolution toward dedicated 4-Sub units in the postwar period.^[8]

Construction and Variants of 4-Sub Units

The first prototype 4-Sub unit, numbered 4101, was delivered from Eastleigh Works in September 1941 as part of the Southern Railway's effort to expand suburban electric services with four-car formations.^[2] Production was severely limited by World War II, resulting in only a small initial batch before a complete halt until 1946, when resources became available under British Railways (Southern Region).^[3] In total, approximately 239 four-car 4-Sub units overall, including new-build and reformed sets from earlier three-car stock between 1941 and 1951, yielding around 955 cars numbered in ranges such as 4101–4299 and 4601–4754 (with numbering gaps due to reallocations and wartime disruptions).^[2] All units were assembled at Eastleigh Works, with underframes fabricated at Lancing Carriage Works for those on the standard 62-foot Southern Railway design.^[2] Early wartime units, such as the 1941–1943 batch numbered 4101–4128, followed Oliver Bulleid's distinctive design featuring curved bodysides, domed cab fronts, and compartment-style interiors with separate first- and third-class sections to maximize seating within material constraints.^[3] Postwar production from 1946 onward introduced slab-fronted variants with revised fluorescent lighting, improved ventilation, and more open-plan seating layouts to accommodate higher passenger volumes; the largest batch comprised 134 units numbered 4621–4754, built 1949–1951, with all-steel bodies and semi-saloon trailers for enhanced capacity.^[9] Construction utilized steel underframes for durability, timber body frames for structural support, and canvas-covered roofs to conserve metals during shortages, though wartime rationing led to variations in wood quality and occasional use of reclaimed components, affecting long-term maintenance.^[3] These material limitations influenced design simplicity, prioritizing rapid assembly over luxury finishes in both new-build and reformed units.^[10]

Design and Technical Specifications

Unit Formation and Dimensions

The SR Class 4Sub units consisted of a standard four-car formation designed for suburban passenger services, comprising two Driving Motor Brake Second Open (DMBSO) vehicles at each end, a Trailer Second (TS) vehicle, and a Trailer Second Open (TSO) vehicle, with all cars connected for multiple unit control to allow operation as a single unit.^[2] This configuration enabled efficient close-coupling and shared power distribution across the train, optimizing for high-capacity commuter routes on the Southern Railway network. The design emphasized reliability and ease of maintenance, with the DMBSO cars housing driving cabs, brake equipment, and passenger accommodation, while the trailers provided additional seating without motive power. Physical dimensions of the 4Sub units were standardized to fit the Southern Railway's infrastructure and loading gauge, with DMBSO cars measuring 62 ft 6 in (19.05 m) in length, and TS and TSO cars slightly shorter at 62 ft (18.90 m); overall unit length was approximately 257 ft 5 in.^[2] Width across all cars was 9 ft (2.74 m), and height reached 12 ft 9 in (3.89 m) including the roof. Trailer bogies had a 9 ft 0 in (2.74 m) wheelbase, while motor bogies had an approximately 8 ft 9 in (2.67 m) wheelbase, contributing to stable running on suburban tracks. Early units utilized rigid bogies for both powered and trailing axles, while later variants adopted swing bolster bogies to enhance ride quality and reduce wear on high-speed services. Weight distribution varied slightly by batch, with DMBSO cars ranging from 39 to 43 long tons and trailers from 28 to 30 long tons, resulting in a total unit weight of around 134 to 144 long tons.^[2] Interior layouts prioritized high passenger capacity for peak-hour demands, accommodating 368 to 386 seats in a mix of compartment and saloon arrangements depending on the variant, with six-abreast seating in open sections for efficient space use. Each DMBSO included a guard's compartment measuring 7 ft 5½ in wide for operational staff, and one DMBSO per unit featured a lavatory for passenger convenience. These features reflected the units' focus on suburban functionality, balancing comfort with the need to transport large numbers of commuters without intermediate stops.^[2]

Electrical and Mechanical Systems

The SR Class 4Sub units drew power from a 660 V DC third-rail electrification system, with current collected via sliding contact shoes mounted on the underframes of the two motor brake second vehicles.^[9] Propulsion was provided by four English Electric type 339 series-wound DC traction motors, each rated at 275 hp (205 kW), mounted on the inner axles of the two powered bogies for a combined output of 1,100 hp (820 kW) in pre-war and early post-war builds.^[11] These motors employed series-parallel control via electro-pneumatic contactors, with resistance grids mounted on the underframe to manage acceleration and prevent overload during startup.^[1] Post-1948 units incorporated the lighter English Electric EE507 self-ventilated traction motors, rated at 250 hp (186 kW) each for a total of 1,000 hp (746 kW), paired with revised gearing to sustain the design maximum speed of 75 mph (121 km/h).^[9] Braking was handled by Westinghouse straight air systems on the motor vehicles, using compressed air to apply blocks to the powered axles, supplemented by hand-operated screw brakes on the unpowered trailer vehicles for shunting and emergency parking.^[1] Multiple-unit formations relied on 660 V jumper cables for traction control intercommunication, alongside separate jumpers for distributing power to heating elements and lighting circuits across coupled units.^[11] Auxiliary equipment included underframe-mounted air compressors to maintain brake reservoir pressure, electric blower fans driven by General Electric Company (GEC) series motors for compartment ventilation, and interior lighting supplied through series-parallel switched bulb arrays powered from the traction supply.^[1] Passenger heating was generated by axle-driven dynamos under the trailer floors, converting mechanical rotation into DC electricity for resistance heaters, with battery banks ensuring standby operation during power interruptions.^[2] Reliability challenges emerged in the 1950s, particularly with postwar EE507-equipped units prone to tyre flats from sliding under heavy braking, attributed to unrevised brake rigging that delayed air application; minor modifications, such as adjusted resistors in control circuits, were implemented to mitigate overload-related motor issues during peak-hour demands.^[1]

Operational Use

Principal Routes and Services

The SR Class 4Sub units were primarily deployed on inner-suburban commuter routes radiating from central London terminals on the Southern Region network, serving the dense populations of south and south-east London from the 1940s onward. Core services included the busy London Victoria to Orpington line, where the prototype unit 4101 entered traffic in 1941, with later extensions to Sevenoaks via the same corridor. Additional principal workings encompassed Victoria to Sutton via Crystal Palace and the South London line, London Bridge to East Croydon via Sydenham, and limited operations from Waterloo to Shepperton on the South Western suburban network. These routes formed the backbone of the electrified suburban system, emphasizing short-haul, high-frequency passenger movements.^[2][3][12] Integration with other electric multiple units was a key feature of 4Sub operations, enabling flexible train formations to meet peak demands. Units frequently ran in multiple with compatible classes such as 2-BIL, 2-HAL, and 4-LAV stock, allowing consists of up to 12 cars on congested lines like the Victoria-Orpington shuttle. This interoperability enhanced capacity on shared suburban tracks, including those through Wimbledon, Raynes Park, Thornton Heath, and New Cross Gate, where 4Subs displaced older compartment stock to improve passenger flow.^[2][3][12] After nationalization in 1948, British Railways Southern Region expanded the 4Sub fleet with further builds through 1951, incorporating them into diagrammed services across the Central Division and Kent lines. Typical workings included semi-fast and stopping patterns on the aforementioned routes, supporting the post-war economic recovery by facilitating daily commutes for clerical, industrial, and service workers in the growing London suburbs. The units' role in these high-density flows underscored their importance to the region's transport infrastructure, handling substantial passenger volumes on the largest electrified network of the era.^[2][3][4]

Performance, Modifications, and Incidents

The SR Class 4Sub units demonstrated reliable performance in suburban operations, powered by four English Electric traction motors delivering a total of 1,100 hp, enabling a maximum speed of 75 mph suitable for dense inner-city routes.^[11][13] Their design emphasized frequent stops and high acceleration for commuter demands, though specific rates were not documented beyond general compatibility with Southern Railway's third-rail electrification system. Reliability remained strong through the 1940s and early 1950s despite wartime wear, but post-war maintenance backlogs and component aging led to increased failures, particularly in braking and traction systems.^[1] Modifications during service focused on enhancing capacity and efficiency to meet growing passenger volumes. Early units featured traditional compartment layouts with a total seating capacity of approximately 456 passengers, including first-class accommodations, but later batches from 1948 onward reduced compartments to prioritize standing room, with units such as 4111–4130 accommodating 420 seats in more spacious configurations.^[2] Some units received lighter EE507 motors (185 hp each) in place of the standard EE339 types, altering gear noise and performance characteristics, while livery updates transitioned from Southern Railway malachite green to British Railways blue and grey with yellow warning panels by the late 1960s.^[2] These changes, along with periodic overhauls, extended operational life but could not fully offset the obsolescence of slam-door designs. Incidents involving 4Sub units were relatively infrequent given their high mileage, though collisions highlighted vulnerabilities in dense traffic areas. On 24 July 1949, unit 4114 collided with a light locomotive near London Bridge, damaging motor coach 10968 and requiring repairs.^[2] Unit 4120 sustained cab damage to motor coach 10980 in a collision near Gipsy Hill on 18 December 1961, leading to a replacement cab during overhaul.^[2] A more severe event occurred on 31 December 1968 at Norwood Junction, where unit 4103 collided with 4 EPB unit 5115, resulting in motor coach 10946 being written off.^[2] Crew feedback often noted the units' stiff suspension, which provided stable handling but could feel harsh on sharp curves during peak services.^[1]

Withdrawal and Disposal

Passenger Service Withdrawal

The withdrawal of SR Class 4-Sub units from passenger service occurred in two main phases, reflecting their advancing age and the Southern Region's fleet modernization efforts. The early phase, spanning 1972 to 1975, saw over 100 units—primarily those with compartment stock and older designs—removed from service due to severe corrosion in steel underframes and body panels, as well as frequent motor failures in the aging English Electric EE339 traction motors.^[3] These issues were exacerbated at depots like Stewarts Lane, where stripping and initial scrapping took place, and the process was accelerated by the introduction of newer 4-EPB (Class 415) units, which allowed for upgrades to the 750 V DC third-rail system from the original 660 V configuration.^[1] By mid-1975, approximately half the fleet had been taken out of passenger use, with many vehicles stored briefly at Selhurst depot in the mid-1970s before disposal.^[9] In the later phase from 1976 to 1983, the remaining post-war all-steel units were relegated to less intensive fringe routes, such as East Croydon to London Victoria and the Sheerness branch, where their lower performance was more tolerable.^[3] High maintenance costs, driven by the need for frequent repairs to corroded structures and obsolete electrical systems, combined with non-compliance with emerging safety standards—particularly concerns over passenger security and vandalism in compartment layouts—hastened their demise.^[1] The introduction of Class 455 and 456 units in the early 1980s provided the final impetus for replacement, as these modern slam-door EMUs offered improved reliability and adherence to updated safety requirements on suburban services.^[14] The last regular passenger operations occurred on 6 September 1983, with units 4279 and 4754.^[1] Following withdrawal, most units were disposed of through cutting at Derby Works or Vickers Barrow, though a small number received departmental conversions for non-revenue duties.^[3]

Departmental and Non-Revenue Use

Earlier conversions in the 1950s–1960s included de-icing units like DS347–DS350 (withdrawn by 1962). Following the withdrawal of most SR Class 4Sub units from passenger service in the early 1980s, several were repurposed for departmental roles within British Rail's Southern Region, primarily for maintenance and infrastructure support tasks. These conversions extended the operational life of withdrawn vehicles, providing cost-effective solutions for non-revenue duties before eventual disposal.^[15] A significant number of 4Sub driving trailers and motor coaches were converted into de-icing and sandite applicator units at Selhurst carriage sheds between 1977 and 1981, with eleven such formations created (numbered 002, 004–013). These units initially equipped with water cannons for winter de-icing were adapted from 1979 onward to apply sandite—a gel-like abrasive compound—to rails for improved traction during autumn leaf-fall seasons, particularly on lines in Kent and Surrey. Examples include ADS70098, withdrawn in November 1981 after de-icing/sandite duties, and ADS70050, which operated until February 1993.^[15][16] Additional conversions saw 4Sub vehicles allocated to route learning, where they facilitated driver training on electrified networks. Several 4Sub vehicles were converted for route learning, serving into the late 1990s. Other units found use in track recording to monitor rail conditions and as staff accommodation or instruction vehicles at depots like Norwood Junction; for instance, trailer DS40 (ex-8564) was employed for training until February 1975. Mobile stores units, such as 024 formed from 4Sub outer cars, supported depot logistics from 1972. In total, these departmental roles involved around 15 vehicles, drawn from redundant 4Sub stock.^[15][16] Departmental operations continued across the Southern Region until 1986, with units like the sandite applicators active on winter and autumn workings to combat railhead adhesion issues. Most 4Sub-derived departmental stock was withdrawn by the late 1980s, with some lasting into the 1990s; examples include ADS70050 withdrawn in February 1993 and scrapped later that year, after which they were scrapped at facilities including C.F. Booth's yard in Rotherham (e.g., ADB977362 in 1994) and Eastleigh Works (e.g., DS40). This phase of utility demonstrated the adaptability of the 4Sub design, prolonging the service of otherwise obsolete units by several years and supporting infrastructure maintenance economically.^[15]

Preservation and Legacy

Preserved Units

The only complete preserved SR Class 4-Sub unit is No. 4732, constructed in 1951 at British Rail's Eastleigh Carriage Works as part of the final batch of these suburban electric multiple units.^[5] This unit, comprising driving motor brake second open cars Nos. 12795 and 12796 (both built 1951), trailer composite open No. 10239 (built 1946), and trailer second open No. 12354 (built 1948), represents the last intact example of the class and holds significant historical value for illustrating the evolution of Southern Railway suburban electrification post-World War II.^[17] Withdrawn from revenue service in 1982 and retained by British Rail for charter duties until 1998, alongside the rest of the class which ended revenue operations in 1983, it was acquired for preservation in 1998 by a group of railway enthusiasts at scrap value (£5,785); it is now owned by the Heritage Electric Trains Trust (HETT).^[5] Following withdrawal, No. 4732 was initially stored at Lovers Walk Depot in Brighton, later moving to Long Marston in 1995 and the Electric Railway Museum near Coventry until its closure in 2017, after which it relocated to secure storage at Locomotive Storage Ltd in Margate.^[18] An individual preserved vehicle from the class is driving motor brake second No. 8143, a 1925-built Metropolitan Cammell example originally formed in Southern Railway 3-Sub unit No. 1293 (later augmented to 4-Sub No. 4308 under British Rail).^[17] Acquired for the national collection, it has been on static display at the National Railway Museum in York since 2003, showcasing early SR electric suburban design features such as its original compartment layout and English Electric traction equipment.^[4] Beyond these, surviving relics are limited, with bogies and assorted components from withdrawn 4-Sub unit No. 4217 understood to be held at the Kent & East Sussex Railway, while minor parts such as electrical fittings and interior panels reside in private collections among railway enthusiasts.^[5]

Restoration Efforts and Current Status

The restoration of the sole surviving SR Class 4Sub unit, No. 4732, is led by the Heritage Electric Trains Trust (HETT) in collaboration with the 4-Sub Association, a volunteer organization formed in 2017 to support its preservation following the closure of the Electric Railway Museum in Coventry.^[19] The unit, comprising cars 12795 (DMBT), 12354 (TS), 10239 (T), and 12796 (DMBS), has been stored at the One:One Collection in Margate since June 2018, where it arrived for long-term safekeeping at the former Hornby factory site.^[18] Efforts focus on a phased cosmetic restoration to display standard, with plans to eventually return the unit to operational condition to demonstrate 1940s-era Southern Railway electric multiple unit technology.^[5] Restoration work commenced in earnest in October 2025, when the first car, Driving Motor Brake Second Open 12796, was transported from Margate to Barrow Hill Roundhouse for overhaul by Ramparts Railway Contracting, including bodywork repairs, underframe cleaning, bogie maintenance, and a full repaint.^[20] This phase, estimated at £60,000, is funded through public donations, the HETT's 750 Supply Scheme (a membership program supporting third-rail heritage projects), and online auctions of railway memorabilia; by late 2025, sufficient funds had been raised to initiate the work, building on earlier appeals targeting £50,000 for initial cosmetic efforts.^[21] The remaining three cars remain undercover at Margate, partially dismantled for assessment, and are available for public viewings during special events at the One:One Collection, such as model railway exhibitions.^[22] Key challenges include sourcing obsolete components from the original English Electric traction equipment, which is no longer in production, and ensuring compliance with contemporary third-rail safety regulations for 750 V DC operation, such as updated insulation and earthing to meet modern heritage railway standards.^[23] These volunteer-driven efforts, reliant on enthusiast expertise and crowdfunding, have faced delays from the unit's prolonged storage and the need for specialized facilities, but progress in 2025 marks a significant step forward.^[20] As of November 2025, unit 4732 is in active restoration, with car 12796 undergoing overhaul and the others in static storage pending sequential treatment; no immediate plans exist for full reassembly beyond cosmetic completion in the near term.^[24] Future ambitions include mainline test runs once operational, alongside an educational role highlighting early post-war EMU design and Southern Railway suburban electrification.^[25]