Major the Westies rebuild project

Discussion in 'Restorations' started by MorkC68, Sep 26, 2016.

  1. aka Operation Velma.

    Our old westy, Major has been sat for a couple of years and hasn't seen much use. We know he does need some work doing, inside and out, so, the time is right to make a start!
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    He needs a new left hand battery tray as the PO back in the US fitted an oil cooler and hacked a hole in the middle of the tray :(
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    There is corrosion near the engine hatch which has bubbled through, left hand side:
    [​IMG]

    The sliding door has rusted through at the bottom:
    [​IMG]

    The front panel needs replacing; its had a new section in the past which was poorly fitted plus the top of the panel is bubbling away:
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    The left hand cab door skin has cracked & needs attention:
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    The roof needs repainting:
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    The interior needs new upholstery, most of it is past its best:
    [​IMG]

    All of the side window seals need renewing; under the sliding door track cover looks pretty good:
    [​IMG]
     
    Last edited: Jul 5, 2017
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  2. The sliding door has been removed for repair. The rollers at the bottom have seized, the spring loaded tabs are seized and the spring broken on the fixed part. The door lock needs tripping and cleaning/lubricating!
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    Pics to follow later :)
     
    Last edited: Jul 5, 2017
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  3. Flakey

    Flakey Sponsor

    Good luck Mark I'm sure you'll do a cracking job :thumbsup:
     
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  4. good ta here your not sittin round suppin next yar :thumbsup:
     
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  5. Thanks Dunc, hopefully learned some lessons from Gusbus!
     
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  6. Should keep you busy for a while!
     
  7. Not six years worth I hope :D
     
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  8. Terrordales

    Terrordales Nightshift Mod

    Wonder if you'll be finished before @dog ? ;)
     
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  9. Nothing to bad there Marc but best to catch it early



    Sent from my iPhone using Tapatalk
     
  10. I'm hoping the chassis is as good!
     
  11. Good luck. Looking forward to see how things progress. It's reminded me put some photos on about Baldricks resto.
     
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  12. cheers Jon :)
     
  13. Doesn't look too bad but as others have said, good to catch it early. Watching with interest as i'm sure mine will need something similar in a few yrs time.

    Are you doing the work yourself?
     
  14. Looking forward to seeing major back.out on tour :thumbsup:
    Dosent look that bad.
     
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  15. As much as we can, yeah, it helps now that we have the unit at work, both buses fit in. It gives us the space to roll the body on its side and do the underside much better than we did Gusbus.

    I figure that the lessons we learned over the past years will help us do a better job!
     
  16. This past couple of weeks has seen us working on the sliding door, see how bad the rust bubbles are:
    [​IMG]

    They look to be limited to an area about six inches long, whats hidden away though, we didn't know. Overall, on the inside the bulk of the door skin is fine, on the inside the Fortafix has gone hard and broke away. The inner lower section showed some signs of corrosion:
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    Last edited: Jul 5, 2017
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  17. Taking it very gingerly, I Dremelled the outer skin away, approx. 6" along and 1.5" up from the bottom to reveal how bad the inner skin was behind the outer skin:
    [​IMG]
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    Overall we ended up going 8" along as this revealed the end of the rotten section into good solid steel, I am pleased to say
    [​IMG]

    We had bought the Klokkerholm inner repair section but ended up cutting repair pieces away from it and fabricating them into the existing door section
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    We checked out the curvature in relation to the correct profile, a quick tweak and we're happy its as it should be!
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    Next week we need to turn the door over, dress the welds from the other side and fill in any pin holes.
     
    Last edited: Jul 5, 2017
  18. Good luck Mark, I'll be watching with interest, and hoping to see Major at a techenders weekend before toooo long ;)
     
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  19. Crack on Mark - watching with interest :thumbsup:

    :hattip:
     
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  20. Is it finished ?
     

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