Rusty (T&F)/Behind the Scenes

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This is a behind the scenes subpage for Rusty (T&F). This subpage contains all behind the scenes material relating to said article.

Background Information

In 1994, Rusty was introduced in the fourth series of Thomas the Tank Engine & Friends. The series placed a great focus on the narrow gauge characters, with a number of stories from the original books televised. In The Railway Series, Rusty was painted black. However in the television series, Rusty is painted orange (presumably to match his name).

After being absent with the other narrow gauge engines for the eighth series, Rusty returned in the following series. Previously, Rusty was portrayed as a friendly diesel and dedicated worker. However, as the series progressed, Rusty's character gradually became altered under the influence of HiT Entertainment. He had an occasional habit of being impatient, careless and prone to procrastination.

When the show transitioned into full CGI in 2009, the narrow gauge engines were absent for three years. Rusty later returned in the 2012 special, Blue Mountain Mystery, along with Skarloey, Rheneas, Sir Handel and Peter Sam. In the CGI series, he has been seen frequently working at the Blue Mountain Quarry.

Gender

A New York Times article about the introduction of Rusty (26 February 1995)

While Rusty was originally portrayed as male in The Railway Series, according to a New York Times article from 1995, Britt Allcroft intended to make Rusty gender-neutral in Thomas the Tank Engine & Friends due to the lack of female characters.

In the series itself, Rusty was more portrayed as gender non-specific rather than gender neutral. The episodes Trucks, Home at Last and Rock 'n' Roll removed or changed any instance of Rusty being referred to in gender-specific pronouns, as the original stories refer to him as male. For example, Duncan's line "Send him packing! Send him packing!" is changed to him saying "Send Rusty packing! Send Rusty packing!"

On Rusty's 1999 Thomas Wooden Railway card and in the Thomas and Friends Writers' Bible from March 2003, Rusty was referred to as female.

When the narrow gauge engines were reintroduced in the ninth series, Rusty was depicted as male, like how he was in The Railway Series, and Rusty remained as male for the rest of series. While this was the case in the UK narrations, in the original US narrations of Tuneful Toots and Duncan and the Old Mine, Rusty was incorrectly referred to as female. This problem most likely came from the Writers' Bible, and the lines were renarrated for US DVD releases, now identifying Rusty as male.

Rusty is also depicted as female in the German dub of the fifth series episode Duncan Gets Spooked, the first Polish dub, and the Korean dub of the sixteenth series.

Voice

Since his return in 2012, Rusty has been voiced by Matt Wilkinson in both the British English and American English dubs of the series. Matt Wilkinson gives Rusty a West Country accent.

Behind the Scenes

O gauge model (Small scale)

Rusty's small model was custom built from brass by model maker, Peter Eves to run on O gauge track to the Gauge 1 Scale Standard during production of the fourth series. It was painted using glossy car body paint and lined with yellow Letraline pin-striping tape. The number and nameplates were custom printed stickers.

Rusty's wheels were sourced from unspoked SM32 "Quarry Hunslet" wheels made by Slater's Plastikard. These wheels were used on an O gauge locomotive chassis. The buffers were sourced from Slater's Plastikard as well, with most engines using the square based short sprung buffers.

The model had a motor to power it mounted inside the chassis as well as an eye mechanism. There was no room to fit a battery and receiver needed for the R/C eyes. Wires connecting to the battery, servo and receiver were usually hidden off camera or carried in trucks behind the engine. The eye mechanism used servos mounted in the cab; the servos were hidden by blacking out the cab doors and windows. Metal rods went from the servos in the cab to a bracket in the smoke box behind the face-plate, one for up and down movement and one for left and right movement. This limited the range of movement of the eyes as well as being cumbersome and jamming often. Rusty is nearly twice the size of his basis. This was so his eye mechanism and motor could be accommodated.

A view of the Rusty model's undercarriage (plunger pickups are visible)

In the fourth series episodes, Rusty to the Rescue and Thomas and Stepney, Rusty was seen with a headlamp above his radiator. This was powered by a hidden battery pack.

Rusty with a lamp

The small scale Rusty model was predominantly used in the fourth series. It was used in the fifth series for in between shots where he would interact with the gauge 1 scaled characters and sets. It then appeared via stock footage in the seventh series episode, Trusty Rusty. The small scale model made its last appearance briefly in the 2005 special, Calling All Engines!, in Thomas' dream sequence where he was seen with Lady's gauge 1 model.

Filming Duncan Gets Spooked

Rusty's small scale model in Calling All Engines!

Reference Sheets

Series 4

Fourth series ruler reference of Rusty's small scale model

Faces

Eight different facial expressions were made for Rusty, although only seven were used on-screen and one of which, his horrified face was left unused. The faces were first sculpted in clay and from that resin casts were made using a silicone mould.

Reference Sheets

Series 4 - 1994 (Alongside Smudger's faces. Note: Rusty's unused horrified face is in the middle left. The little diesel's happy face is not pictured.)

Series 6 - 2001/2002

Usage and Evolution

Rusty's faces

Rusty's smiling face that only appeared in both the fourth and fifth series (1994-1998)

Rusty's cross face that only appeared in both the fourth and fifth series (1994-1998)

Rusty's sad face that only appeared in both the fourth and fifth series (1994-1998)

Rusty's shocked face that appeared in both the fourth and fifth series (1994-1998)

Rusty's happy face that appeared in both the fourth and fifth series... (1994-1998)

...and last appeared in Calling All Engines! (2005)

Rusty's suspicious face that only appeared in both the fourth and fifth series (1994-1998)

Rusty's laughing face that only appeared in the fourth series (1994)

Present Day

After production of the model series ended in 2008, most of Rusty's faces (except his happy face) were put into storage, with them being listed as "TF01651".

Seven of Rusty's small scale faces taken after the model series ended (circa 2010-early 2011)

Rusty's happy face is currently owned by Twitter and Instagram user ThomasTankMerch. In 2021 for the Halloween Clearwater Event, Rusty's horrified face and a prototype face would be exhibited and worn on a fan-made replica. A prototype face for Rusty is currently owned by Twitter user SeansModels. It would be exhibited at the History of Thomas Event and the first Awdry Extravaganza Event. A failed production made cast of Rusty's happy face would be sold by The Movie Reliquary in 2023. The rest of Rusty's faces are currently still in storage alongside his horrified face (when it is not being used at events).

Rusty's unused fourth series horrified face used on a replica made by Twitter user RailwaySkarloey alongside a prototype face at the Halloween Clearwater Event (1994, 2021)

A prototype face as owned by Twitter user SeansModels

The prototype face at the History of Thomas Event...

...and at the Awdry Extravaganza in 2021

A failed production made face cast as prior to being sold by The Movie Reliquary

Fonts

The following fonts were used on Rusty's small scale model:

• Dallas Print Shop Sans Reg (name)
• Clarendon Medium (number)

Present Day

After production of the model series wrapped in 2008, most of the models and sets would be put into storage, with some being put on display at Drayton Manor Theme Park. All other models would be logged and referenced from 2010 until early 2011 by HiT Entertainment. From this HiT would decide on which models were to enter storage once again, which would be given to crew members and which would be disposed off. Due to the larger models being more frequently used at the time, Rusty's small scale model would be disposed off by the company in favour of the large scale model, which would stay under HiT and later Mattel's ownership.

As of April 2020, Rusty's small scale model, along with his nameboard (the nameboard being supplied by TomsProps) and happy face is now owned and preserved by Twitter and Instagram user ThomasTankMerch. In late 2021, Rusty's small scale model was put on display at the Edison train show alongside other props from ThomasTankMerch's collection.

(Courtesy of EdsTrainz)

Rusty's model with his nameboard

Rusty at Edison in 2021

Rusty in ThomasTankMerch's model collection

Two sets of spare unused lettering sheets for Rusty's small-scale model in both white and red, are currently owned by Twitter user TomsProps.

A replica of Rusty's small-scale model (made by Twitter user SkarloeyRailwayAdventure) is also currently displayed at Drayton Manor.

O gauge model (Large scale)

For ease of filming and reliability, the fifth series introduced larger-scale versions of the narrow gauge engines and from the sixth to twelfth series, these models were used almost exclusively. The larger-scale models were built to a larger scale than the gauge 1 engines and ran on O gauge track. They were close to 16mm scale, but slightly larger.

The model was made from brass. The wheels and chassis were custom machined (CNC). The model was track powered, so pickup contacts were attached to the metal wheels, which ran into the motor to power it. The electricity ran from the track to the wheels/pickup contacts and went into the motor to power him. Sometime during production of the eighth series, Rusty received a new chassis.

During production of the eighth series, Rusty and the other large scale narrow gauge models were all fitted with a new chassis, as the original chassis' became too run down to use. The wheels would be reused and a new chassis block and motor would be built. For Rusty specifically, new buffer beams and a running board would also be built.

The new chassis, buffer beams and running board under construction during production of the eighth series

The eye mechanism had two servos, one for up and down movement and one for left and right movement. The up/down servo was attached to the body. The left/right servo had a rod attached to the arm, which connected to a bracket. The eye balls were coupled to the bracket and locked in by the face-plate, so whenever the servos were powered, the eye balls would move however the crew members desired.

Rusty's O gauge model (large scale)

2004 promo (Note: His bufferbeam is unpainted and his coupling hook is missing)

Filming Duncan Gets Spooked in the fifth series

Filming Rusty and the Boulder in the fifth series

A side view of Rusty

The large scale model's last appearance in Push Me, Pull You in the twelfth series

Faces

Eleven different facial expressions were made for Rusty and used on-screen. The faces were first sculpted in clay and from that resin casts were made using a silicone mould. Most notably, he received a much larger face than his previous small scale model counterpart.

Reference Sheets

Series 6 - 2001/2002

Series 12 - 2008 (Page one)

Series 12 - 2008 (Page two)

Usage and Evolution

Rusty's faces

Rusty's joyful face that appeared between the fifth series and The Great Discovery, excluding the eighth series, Jack and the Sodor Construction Company, Thomas and the Magic Railroad and Calling All Engines! (1998, 2002-2003, 2005-2008)

Rusty's content face that appeared between the fifth and tenth series, excluding the eighth series, Jack and the Sodor Construction Company, Thomas and the Magic Railroad and Calling All Engines! (1998, 2002-2003, 2005-2006)

Rusty's sad face that appeared between the fifth and eleventh series, excluding the eighth series, Jack and the Sodor Construction Company, Thomas and the Magic Railroad and Calling All Engines! (1998, 2002-2003, 2005-2007)

Rusty's shocked face that appeared between the fifth and eleventh series, excluding the eighth series, Jack and the Sodor Construction Company, Thomas and the Magic Railroad and Calling All Engines! (1998, 2002-2003, 2005-2007)

Rusty's horrified face that appeared between the fifth and ninth series, excluding the sixth and eighth series, Jack and the Sodor Construction Company, Thomas and the Magic Railroad and Calling All Engines! (1998, 2003, 2005)

Rusty's cross face that appeared between the fifth and tenth series, excluding the eighth series, Jack and the Sodor Construction Company, Thomas and the Magic Railroad and Calling All Engines! (1998, 2002-2003, 2005-2006)

Rusty's unused sixth series wincing/sleeping face that only appeared in a deleted scene from the ninth series episode, The Magic Lamp (2002, 2005)

Rusty's happy face that appeared between the sixth series and The Great Discovery, excluding the eighth series, Jack and the Sodor Construction Company and Calling All Engines!... (2002-2003, 2005-2008)

...but did appear in his promotional image from the eighth series (2004)

Rusty's suspicious face that only appeared in the seventh series episodes, The Refreshment Lady's Tea Shop and Trusty Rusty (2003)

Rusty's angry face that only appeared in the seventh series episode, The Runaway Elephant (2003)

Rusty's unused seventh series smiling face that only appeared in The Great Discovery (2003, 2008)

Present Day

Rusty's large scale happy face would be put on display at the Awdry Extravaganza in 2021.

Rusty's happy face on display at the Awdry Extravaganza in 2021

CGI Face

The twelfth series marked the beginning of the show's transition into CGI and the characters' faces were animated through CGI with the aid of motion capture animation. The physical models' moulded faces were replaced by white targets with triangles to fix a computer-animated face in post-production. In addition, Rusty's face decreased in size to its original fourth series size.

Rusty with a CGI face

Fonts

The following fonts were used on Rusty's large scale model:

• Publica Sans Round Extra Bold (name and number)

Model Changes

Rusty's model has had many modifications and changes from its small scale counterpart throughout the television series. These include:

• Series 5:
  • His face became larger.
  • His grey buffers became silver.
  • Part of his radiator cap became black.
• Series 6:
  • His paint was given a matte finish.
  • His silver buffers became black.
• Series 9:
  • He received a two-toned horn which was heard in Tuneful Toots only and was played by a 'c' note first, followed by an 'f' note. However in the rest of the same series, his horn sound changed, but this time, it was a different note and was played by a 'c' note and it was the same as Brum's from the television show of the same name.
  • He gains a tail lamp.
• Series 12:
  • His face went back to its fourth series size.

Present Day

Rusty's large-scale model is now currently on display at the Hara Model Railway Museum in Japan. It was previously on display at Nitrogen Studios in Canada.

Rusty's model at Nitrogen Studios

Rusty's model at Hara Railway Museum

A side view of the model whilst on display

Close-up model

A larger-scale model of Rusty was built in the fourth series. It was required for scenes where he had to interact with the close-up scale figures.

The model was made in pieces so it was able to be dismantled and reassembled when needed. In addition, most of the close-up scale models were usually not built as complete models, on top of the fact the faces would most often never need to be seen in this scale.

Unlike both his O gauge models, Rusty's front and back cutout windows had glass. These were removed in the fifth series.

It appeared in the fourth, fifth and sixth series.

The model under construction beside Rusty's small scale model

Rusty's driver and cab

Series 11 ruler reference (2007)

In the fourth series episode Trucks, Rusty's engine was missing.

In the fifth series episode Rusty and the Boulder, Rusty's close-up model was reused for Rheneas as a model of this scale did not exist for Rheneas. This was achieved by a close-up shot of Rusty's circular cab porthole which resembled one of Rheneas'.

Present Day

Rusty's close-up model is currently in Mattel's storage unit in Southampton, England. In 2023, it was put on display at the Awdry Extravaganza 3 at the Talyllyn Railway in Wales.

Rusty's close-up model at Awdry Extravaganza 3 in 2023

CGI model

In 2009, the series introduced Computer-Generated Imagery (CGI) as a replacement for the show's long-standing live-action models. Rusty was recreated from scratch in CGI by Nitrogen Studios in 2010 for production of the 2012 special Blue Mountain Mystery. His model was "hand-sculpted" in Maya, a 3D animation and modelling software.

Photographs of Rusty's large scale model were used for referencing. According to Greg Tiernan, every detail of the original television series models for each character is carefully reproduced in the CGI model. The models are subjected to many rounds of review before they are submitted to HiT Entertainment for final input and approval.

In addition, Nitrogen Studios went to the Talyllyn Railway and took photographs of Rusty's basis, Midlander to use for referencing purposes. Unlike his basis, Rusty is nearly twice the size of Midlander in the television series and was never fitted with a different shaped radiator. So when Rusty returned in CGI, he was the same larger size and retained Midlander's original designed radiator for continuity reasons.

Rusty has had modifications throughout the CGI era. These include:

• Blue Mountain Mystery:
  • His face went back to its fifth series size.
  • Air vents and starter outlets were added on his sides.
  • Rivet detailing was added on his cab.
  • He gained a more accurate chassis to his basis.
  • He regained his two-toned horn from Tuneful Toots, but more altered with an additional upgraded sound.

The following pantone colours are used on Rusty's CGI model:

• ■ PMS 159 (orange)
• ■ PMS 1807 (red)
• ■ PMS (black)
• ■ PMS 116 (yellow)
• ■ PMS 871 C (gold)
• ■ PMS 877 C (silver)

CGI model

Head-on CGI promo

Final render

Fonts

The following fonts were used on Rusty's CGI model.

• Publica Sans Round Extra Bold (name and number)

Reference Sheets

Rusty's 2012-2020 CGI model orthographics sheet

Voice Actors

• Matt Wilkinson (UK/US; Blue Mountain Mystery - twenty-fourth series)
• Hideo Ishikawa (Japan; fourth - seventh series)
• Tokuyoshi Kawashima (Japan; ninth - twenty-fourth series)
• Arash Marandi (Germany; Blue Mountain Mystery - sixteenth series)
• Achim Buch (Germany; seventeenth series onwards)
• Stan Limburg (The Netherlands)
• Scott Maurstad (Norway; Blue Mountain Mystery only)
• Christian Greger Strøm (Norway; sixteenth - seventeenth series)
• Abraham Vega (Latin America; Blue Mountain Mystery - eighteenth series)
• Gabriel Juárez (Latin America; twenty-fourth series only)
• Krzysztof Szczerbiński (Poland; Blue Mountain Mystery - seventeenth series)
• Grzegorz Kwiecień (Poland; eighteenth series onwards)
• Carlos Moreno (Spain; Blue Mountain Mystery onwards)
• Alexander Kotov (Russia; sixteenth series onwards, excluding the seventeenth series)
• Denis Bespaliy (Russia; seventeenth series only)
• Taisto Oksanen (Finland; Blue Mountain Mystery onwards)
• Haris Grigoropoulos (Greece)
• Ole Møller (Denmark)