1973 Devon

Discussion in 'Restorations' started by Jules65, Feb 16, 2018.

  1. Jules65

    Jules65 Supporter

    Today’s action shot of Ed welding and Tim cleaning up the chassis.

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    First part of a home made chassis jig made.

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  2. Jules65

    Jules65 Supporter

    So the jig parts were made

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    And they were attached to the chassis with the front sections welding to the ‘Y’ section of chassis at the front and the rear ones around the torsion tube after which another piece was welded on to make them fully encapsulate the torsion tube.

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    The larger box section was then offered up and welded into position and cross braces welded into position before the rear section was ‘tacked’ to the torsion tube so that the chassis was braced.

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    Plumbobs were then positioned on the end of the spring plates and extremities of the front beam and the floor marked where they pointed.

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    Then it was squeaky bum time as the chassis was cut

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  3. Jules65

    Jules65 Supporter

    The chassis did not jump and the plumbobs haven’t moved so all appears okay thus far.

    The section of chassis with the bend was saved and the new section cut and bent to suit and small fillets inserted and welded

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    Tomorrow we will continue with the nearside chassis but a visit to the tip with the old metal is necessary

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  4. Jules65

    Jules65 Supporter

    Today has been a good day

    Tuesday wasn’t

    Wednesday was a loss due to it being the current Mrs T’s Birthday.

    Tuesday revealed plate on plate on plate under the torsion beam

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    This meant there was little in the way of good metal to weld to so the replacement section of chassis was run right to the beam and cut to suit. This way we knew the chassis was to something solid.
    However it took a while to trim it to fit and that was when we realised the fabricator (me) had made a boo boo and I had to order a replacement chassis section which had to be trimmed correctly.
    However after a lot of faffing and trial fitting we got to a good fit.

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    The outriggers and jacking point were trial fitted and then a hole for the handbrake tube was created

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    Red oxide was then put on the old chassis section and inside of the replacement section

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    And it was welded into place

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    Just got to tidy the welds up and start on the offside chassis.

    Happy days.


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  5. Jules65

    Jules65 Supporter

    Today was “squeaky bum 2” as we cut the offside chassis.

    Thankfully once again the chassis didn’t flex and The plumbobs are still in the same place.

    So the front section has been removed. Just got to line up the new chassis section to mate with the old chassis that runs under the cab and weld/tack it in before the rear section is cut out.

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    Surprising how you feel you’ve been at something for hours yet have little to show for your efforts and time.


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  6. Jules65

    Jules65 Supporter

    Today the front section of the offside chassis went in. The inner support frame was given a coat red oxide first though.

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    And then the rear section of chassis was cut out and the inner support frame cleaned up. We need to weld some plate to reinforce the support piece but thought the red oxide would protect behind the welds.

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    Also put a section of plate in between the front closing panels so as to clean up where the middle heater vent is located.

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    With luck we will have the rear section of chassis in tomorrow which will mean e can start to weld in all the new top hats, outriggers, jacking points, crossmembers and all the pipes where the handbrake, heater, accelerator and clutch cables run through plus the wiring loom tube.......but at least that will all be nice. Wow shiny metal.

    Then (and only then) can we refit the floor and rear firewall.



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    Last edited: Mar 24, 2018
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  7. Thats quite a repair job, and nicely done, reminds me of when I fitted a half chassis to my Landy, just be careful that the welds do not pull it our of alignment, it's nearly caught me out before.
     
  8. Jules65

    Jules65 Supporter

    We can only hope it stays true.


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  9. Jules65

    Jules65 Supporter

    Today saw the chassis get welded up and if I do say so myself we ain’t done a bad job.
    We have just got to check the welds, and ensure it is welded everywhere it needs to be before we move on to the crossmembers.

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  10. Excellent work
     
  11. Love a bit of heavy chassis work :thumbsup:
     
  12. Bro l have to say that is impressive and you’re right to be chuffed with it.
     
  13. JamesLey

    JamesLey Sponsor

    Looking good.


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    Well done, I feel quite lucky at what I needed to replace. I’m going to look after my floor now more than ever.


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  15. Jules65

    Jules65 Supporter

    The last few days have proved tedious.
    It transpires the most expensive part was manufactured like a turd and when placed in position only one side sat flat as it should.

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    This meant it required taking apart and setting correctly.

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    One side was nice tacks.....the other not so.

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    £108 that piece costs.......

    It was positioned correctly, takes/welded and then painted in red oxide.

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  16. Jules65

    Jules65 Supporter

    Then came the positioning of the crossmembers and the insertion of all 6 guide tubes and wiring loom conduit.

    The insertion of the handbrake tubes also meant the rear outriggers has to be positioned (not welded in)

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    I swear it’s like a huge jigsaw

    The front heater tube was repaired using fibreglass (a replacement wasn’t available and removal of the beam was impractical)

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    Thanks to ‘Razzyh’ we were able to position the heater diverter box and cut the central heater tube to connect the ‘Y’ piece to the heater diverter.

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    So with the front crossmember welded in place, the front top hat welded in and the conduits all positioned we finished the day looking like this.

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  17. Jules65

    Jules65 Supporter

    So it’s 5:15pm on Saturday and some 6-7 weeks since we started.

    2 novice petrol heads have managed to remove a substantial amount of rust and have welded in 3 sections of chassis, inner support sills, inner sills, closing plates, 3 top hats plus all the outriggers and jacking points.........

    .......and it’s all fitted together and actually looks right.

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    We’ve now got to cover it in red oxide and do some snagging. The cargo floor is at the shot blasters and may not be back till Thursday. However there is still work to do on the inner wheel arches......but the welding gas is nearly all gone and no where is open due to the Bank Holidays.


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  18. JamesLey

    JamesLey Sponsor

    Good work guys! Always satisfying getting some fresh metal in.


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  19. Jules65

    Jules65 Supporter

    Thank you. not quite up to your standard with 'Iris' though James.
     
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  20. JamesLey

    JamesLey Sponsor

    Too kind! Glad to be getting onto the tail end of it tbh.


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