Billy/Behind the Scenes

Television Series
Billy is a fictional character created by Sharon Miller.

In 2007, Billy was introduced in the eleventh series of Thomas & Friends. His only appearance was in the episode, Don't be Silly, Billy. He was going to appear in the thirteenth series episode, Splish Splash Splosh but was cut and replaced by Charlie.

Gauge 1 model
Production orthographics were drawn up for Billy's gauge 1 model on July 13th 2006. Billy's model was based on a Manning Wardle 0-6-0ST. Charlie shares the same basis. It was built to approximately 1/32 scale and designed to run on the gauge 1 track. The model's body was made from brass.

Six different facial expressions were sculpted for Billy, although only five were used on-screen and one of which a shocked face was left unused. The faces were first sculpted in clay and from that resin casts were made using a silicone mould. Some of Billy's screen used and production made faces are now owned by Twitter users IsaacM6991 and TomsProps. His content and unused shocked face were previously owned by a private collector.

While only one body was made, two complete chassis' were constructed from scratch (CNC). The chasses had two motors, both powered by electricity from the track via the pickups on the metal wheels. The main motor powered the wheels, while the second motor (located at the back) powered an inside piston for the smoke mechanism. One of the two chassis is now owned by Twitter user TomsProps.

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 member desired.

Fonts
The following fonts were used on Billy's Gauge 1 model:
 * Arial Bold

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 in 2009 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 to be disposed off. Due to only having one gauge 1 scale model made, Billy's model would stay under HiT and later Mattel's ownership.

Billy's full model with the other chassis is currently in Mattel's storage unit in Southampton England.

Close-up model
A close-up shot of Billy's cab and firebox was required for scenes in Don't be Silly, Billy, where he had to interact with close-up scale figures. For this, Thomas' cab interior was recycled.

CGI model
The eleventh series episode, Don't be Silly, Billy, was planned to be recreated for CGI testing in 2009, therefore, a CGI model of Billy would have to be created. In addition, Billy was supposed to appear in the thirteenth series, however, he was dropped in favour of a new character, Charlie. Interestingly, Charlie and Billy share the same basis.

Voice Actors

 * Yukito Soma