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During the following year’s Autumn Steam Gala, 68501 suffered more damage when one of the sand pipes was caught on a rail joint at Kidderminster. This was drawn to the Guard's attention by a passenger pointing out that 'The exhaust pipe has fallen off!'.<ref>SVR News 102</ref> Further repairs were required in 1996 when 68501 sustained a broken window and cabin-end damage during a misguided attempt to move an out-of-gauge load.<ref>SVR News 119</ref>
The first major overhaul since 1980 was undertaken at Bewdley, beginning in early 2006. The underframe was cleaned and painted, and new step boards constructed. A replacement sand pipe for the one broken off in 1991 was also fitted while the roof canvas fitted in that year was also replaced. A number of planks were replaced in the body and cabin door, while the two side doors were also removed and replacements made. The floor planks were replaced using spare keruing Keruing planks left over from earlier jobs. The stove was repaired, with a new cast fire brick lining and new stovepipe fitted. The guard's seat was re-upholstered and the wagon repainted in the same livery as before. The overhaul was completed in March 2007.<ref>SVR News 155, 163</ref>
Over winter/spring 2011, 68501 received a complete overhaul of the handbrake gear, with new pins being machined and a number of components re-bushed.<ref>SVR News 175</ref>
