Had a bit more free time on saturday so I welded the dash back in.
There aren't many seem welds on the splitties and certainly very few that will be seen except for the two that connect the dash to the Aposts. So i had to get these looking right (ish). A lot of welding and grinding with my dremmel (only thing that would get into tthe tight space) produced these -
Might not look factory but they are ok and solid.
Then I chopped out the small rusty sections of the windcreen edge, to replace them, only to find I hadn't got any sheet steel.-
Thats all till I manage to get my headlight support panel and nose repair.
From the start of the projest I decided that I was going to replace the front wheel tubs as they are quite ropey -
But the more I look at them, the more I am unsure as to just reapir them.
The passenger side (lhd) is beyond repair and will be scrapped but I think the other would be ok with a few repairs.
Is it worth the hassle with Creative Customs units being only £50 each?
Are the fits any good?
Ok, had afew hours to myself again today and as it wasn't raining decided to do a bit on the bus.
Am still waiting for my Hand made headlight support panel to arrive from Gerson in the states, so I though I'd have a break from the front for a while and move back a bit, onto the arches and tubs. -
Passenger side was the first to come out and I was really pleased. The inner chassis and side s of the toolbox were covered in loads of underseal ( or so I thought) however it turned out to be just dust and dirt. A quick blast with the sugar soap and a wipe revealed really good metal. You cab even see original, factory white paint oin some bits of the chassis.
Gonna need the top hat section and both outriggers replacing and I have managed to get a complete bulkhead off Graham. Also got Gerson B post repairs to go in.
Not sure what I'm gonna do about the top of the toolbox though-
The rust patch in the corner of the opening looks to be a nightmare to repair so I may just make a custom panel or try and find another.
Thanks to the weather taking a turn for the better, and grandparents, I packed the little-un off to her nans and did a bit more on the bus today, or whats left of it.
Cleaned up and Kurusted the chassis rails before priming them -
Really is good stuff and you cab see it starting to work almost immediately.
This shot shows the gaping void where the bulkhead should be -
I do have a good bulkhead ready to go in here but its at the shotblasters being cleaned uo this week. The plan is to remove whate left of the front outriggers and top hat section before replaing the bottoms of both A posts and fitting the bulkhead. I reckon this will make a massive difference once its fitted for both strength and motivation.
Also started tidying up the front of the chassis rails and the sides of the toolbox -
Am quite pleased with how well this metal came out.
Then spent quite a long time, turning this -
into this -
Took me ages to painstakingly cut and flapwheel out all the support bars without damaging the outer skin.
Then after about an hours work, I offered it up to the bus to find this -
It seemed to be a completely different size. AAAAAAAAAAAAAAAARGH!!!
Anyway, after worrying for quite some time, I eventually had the idea of measuring the circumference of the panel with a tape measure to find that they are exactly the same. Phew!!
Anyway thats my bit for a few days.
Well I did a bit more today and got to quite a scary point as I hav eremoved both front outriggers completely and theres nothing connecting the B-posts to the chassis. Not too bad but does feel a bit flimsy.
Anyway pics -
New front outrigger welded on-
Front portion of chassis and tool box stripped. -
Was surprised at how good most of the metal was when bare.
Anyway gave it a quick coat of KURUST-
Before blasting loads of red oxide primer on it (no pics yet).
As stated, because I have to fit the outriggers, tidy the B-posts, then fit the bulkhead before I can fit the front top hat section, it will be a bit week for a while.
Got my bulkhead back from the blasters and primered it up ready for fitting -
One of the best second hand panels I have bought.
Needs a bit of work along the seem that is welded to the B post though -
Also had a go at fitting my new passenger side GERSON B post lower half. Was very disappointed with the shape and contours of the panels. Its a two piece affair and didnt match up with the original contours or dimensions at all.
I know they're hand made pieces and better than I could ever do btu its still disappointing when you buy the "best on the market" only to find that it will need chopping into a load of little pieces and modifying.
Anyway plans are to get the front outrigger in place and then tackle the rear wheel tubs.
Have bought a long side panel outer sill repair and am in two minds whether to use it or not or to just take the whole side panel off and put a new one one.
Mine is ok but am just worried about distorting it when I weld the new outer sill on.
A bit more progress today thanks to the sun making an appearance -
Front chassis and outrigger finished -
Then I set to repairing one of the rear wheel tubs so that I can think about getting an inner sill in.-
Spent quite a bit of time lining it all up and trimming to fit but I am happy with where it fits now. Those little clamps from FROST are a very good idea and held the metal in place firmly but were a bugger to fit one handed. Th elittle bar kept falling out.
Anyway I fully welded it in -
I'm happy with it so far. I was having a nightmare with my MIG today. Couldnt get a decent sound or penetration until my smart arse dad came round and turned the feed up two notches (big respect dad).
As you can see from the last picture, when I ground down the continous line of tacks there are some pin holes left to be welded up but I ran out of time so just blasted a coat of primer on to protect the fresh metal. (bloody lack of garage).
Am considering putting a bit of copper behind the holes to prevent the weld dropping through when I come to repair it.
