A restoration for Iris

Discussion in 'Restorations' started by JamesLey, Jul 6, 2015.

  1. Lazy Andy

    Lazy Andy Supporter

    You could go viral with a gritty resto series on YouTube
     
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  2. JamesLey

    JamesLey Sponsor

    Tales of a crappy old bus. Think I need a more distinctive hat for it to work though.


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  3. Lazy Andy

    Lazy Andy Supporter

    Taboo hat.... you could finish each episode by finding an indiscriminate piece of metal and saying "I have a use for you..." switch to credits and advert for Patreon. :)
     
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  4. JamesLey

    JamesLey Sponsor

    Starting the N/S cab door. This looks like fun!
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  5. Been there. :mad:
     
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  6. JamesLey

    JamesLey Sponsor

    Out in the sun at the weekend. Made a start on this cab door. Inner frame needs the pitted metal cut out and replaced. Now I know why most peeps replace doors with imported ones!
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  7. JamesLey

    JamesLey Sponsor

    A bit further this week with the cab doors. The inner frame is pretty thick metal (2mm) however on the N/S it had started to rust through in places so I cut out a huge chunk of it and replaced it with some fresh steel. The O/S frame wasn’t too bad (some pitting in places) so just got a clean up and rust converter applied:
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    The inside of the doors has a style line which the door cards sit inside, on both sides these were sculpted out of filler! I’ll need to make some repair pieces for this as the panel I’ve got from schofields doesn’t have this. You can see in the below where I’ve chipped away at the filler.
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    I’ve zinc primed these areas, and will get some epoxy in there on Friday. Then I should be able to get the panels from schofields in over the weekend and make a start on fabricating some further repair panels for the rest.
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    I’ve just bought a nice 3 in 1 sheet metal machine which will help in making up the curved corner section and some U channels. Quite enjoying repairing these!
     
  8. MorkC68

    MorkC68 Administrator

    They look better already! those sections from Schofields are pretty good, we used one on our door. Just got to hope the right hand one is ok!
     
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  9. JamesLey

    JamesLey Sponsor

    Good productive day down the workshop today.

    Schofields lower door repair welded in. They’re slightly too deep but I’m having to recreate the style line on the inside anyway so i’ve cut the lower edge and need to re-weld it to sit further in.
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    Made good use of my new sheet metal machine to make repair panels for each of the door braces. So much quicker and accurate than an angle grinder and a vice.
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    Next up I need to make the funky corner panel up. Luckily I have my new roller so it shouldn’t be too bad.
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  10. Nice work ,:thumbsup:

    they do look like one of the tricky parts to fabricate..
    Have you got a pic or link of the new roller.. .?
     
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  11. Looking good James, as you probably saw I did the corner (Lottie Restro) in 2 sections, one for the channel sections and separate bit for the sloping curved area of the jamb, trickey work but rewarding when it all lines up.
     
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  12. JamesLey

    JamesLey Sponsor

    Here's the beauty.
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  13. JamesLey

    JamesLey Sponsor

    Cheers mate. Yeap they look like good fun!


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  14. JamesLey

    JamesLey Sponsor

    Cheers @paradox ! [​IMG]


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  15. JamesLey

    JamesLey Sponsor

    @martinvention how good a condition were your original corners? Mine look to have had some welding there in the past so not the best reference point. Your repairs looked great so I'm tempted to use your template as a guide. My dodgy corner seems to swoop from the seal channel into the corner curve, the inside bit of the u channel doesn't have a defined edge it just seems to swoop up if you get my drift. Yours has a definite corner where the u channels meet whereas mine just seems to curve round more (or that could just be welds piled up and ground down by the looks of it). Any pointers appreciated.
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  16. Hi James, there are 3 definite sides to the seal channel as in the photo below and on the outside curve from the jamb there was also a definite corner to form the sides of the inner channel wall. Mine were pretty rusty and I hope I have recreated them OK. But if you have access to a good original door it would be better to use that as a reference. Best wishes Martin Cab Door Corner.png
     
  17. JamesLey

    JamesLey Sponsor

    Thanks mate. Just what I needed. I've got 2 days off now so hopefully I'll get most of the inner part of this door done.


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  18. JamesLey

    JamesLey Sponsor

    A good test of my fabrication skills and a chance to use my new sheet metal machine recreating the corner section of the cab doors.

    I made it in two parts. The section that forms the seal channel starts life as a sheet of steel:[​IMG]

    After a bit of folding the piece turns into this:
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    Trimmed down and a curve cut into it for the second repair panel to attach to I then tacked it to the door (I trial fitted the door skin to make sure the repair fits correctly):
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    The second repair is formed by rolling a sheet of metal into a curve with a slight lip on it to follow the style lines of the door:[​IMG]

    And then trimming it down to fit:
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    I’ve painted the inside of the repairs and will get it all welded in tomorrow. It’s a lot of work to get this to fit right but hopefully worth it (I screwed up my first attempt as it wasn’t a right angle, and then my second attempt was the wrong way round but I can at least use that on the other door).

    Thanks for the pointers @martinvention!
     
  19. Impressive..:hattip:
     
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  20. Loving your work!

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