Woody my 72/73 bay window resto project .......an epic tale of rust.......

Discussion in 'Restorations' started by Diddymen, Aug 11, 2011.

  1. Diddymen

    Diddymen Moderator

    April 27th 2010

    Well I got a bit done at the weekend, not as much as I'd hope though.

    I had chopped about the front jacking point and rewelded it through the week, welded together the rear jacking point and drilled all three outriggers for plug welding, then gave them a coat of paint inside on Friday....so then had to wait for it to dry...

    Saturday I welded them all on to the bus..

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    I then started to drill the chassis for the fixings fot the centre belly pan and started fettling the outer belly pan. I know this might be a bit controversial for some but I thought the belly pans had given some protection to the underside so I'm going to refit them.....but I'm going to bolt them on so I can take them off now and again to check underneath. Sooo I needed to weld some captive nuts on to the inner sill....pilot holes drilled

    Sunday...

    Finnished drilling the holes in the inner sill - gone for 6mm bolts here as 8mm nuts were a little bit too big IMO. Welded in captive nuts and painted inside inner sill....

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    A bit hard to see in that pic I know..

    Then finished fitting the fixings for the centre belly pan (8mm)

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    I can't get the welder in to weld in captive nuts so I have used these..

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    I know them as rivnuts but they have probably got other names. They look like small top hats with a thread in the center. They fix in place a bit like pop rivits do ie the back mushrooms out when you use the tool and it tightens against where you are fixing to.

    Lastly gave it all a good a paint along with the middle sill inner face (which I cant get to once welded in) Now out of paint so I've ordered some more....and some of their rust converter (rust buster FE 123 - any one used it is it any good??) as I've not been completly happy with the Jellonite I've been using.

    I've drilled some holes on the bottom of the middle sill this evening ready for plug welding, I've noticed it wont slot in now I've fitted the jacking points Doh! Think it will require persuading with a hammer. I've also noticed that the bottom lip seems too big as it overlaps the inner sill by about 10mm, any one know if I will have to chop it down (after the outer goes on)??

    Going to take Friday off and make a long weekend of it and hopefully get a bit more done....although the kids and Mrs Diddymen will probably want to go out for a day somewhere as a family... I think there might be a classic car show on some where I'm sure they will want to come around an auto jumble to look for rusty treasure!!!.....well they do want to go out for the day don't they??...and I wont be under the bus....I'm sure I can sell it to them (I seem to remember the fell for it too) ;D
     
    Last edited: Oct 2, 2017
  2. Diddymen

    Diddymen Moderator

    At the bar Yoda is still drinking........

    the band is playing an irritating tune in the background...

    Family Guy - Cantina Band (full song).wmv

    Alien to Princess Diddymen at the bar: He doesnt like you, and I dont like you either

    Princess Diddymen: I'm Sorry

    Alien: You'll be dead

    Ob Wab: (Jedi mind trick) This young ones not worth bothering with..

    Alien pulls out a blaster

    Ob Wan pulls out his light sabre and chops off aliens arm

    Princess Diddymen to Ob Wan: A light sabre, thats impressive

    Ob Wan: Yes, its 12 inces but I dont use it as a rule Ah that looks like the Pilot we need to take us to Alderaan ....his name is Hand solo
     
    Last edited: Oct 2, 2017
  3. Diddymen

    Diddymen Moderator

    from May 14th 2010

    I've not posted any updates for a while (yea, its been at least 10 mins) so heres what I've done

    Firstly got the middle sill welded on, took a while, had to plug up some holes in the floor first then, as usual it isn't an easy perfect fit so all in all I probably spent the best part of the day on it probably shouldn't have kept stopping for tea breaks.
    so from this......

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    to this......

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    And now thats in I can use it as a datum to start putting bits back on ....starting with the inner B post

    from this

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    to this

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    After I'd got the B post in I started on some patches for the seat bulkhead

    Here it is with a bit more cut out..

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    then spent most of Saturday before last making some repair bits to go in

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    They are a bit crude with a few hammer marks but I was only using a vise a hammer and a chisel - and a grinder for cutting. It took me ages to make the bit with the recess, I could have used a flat bit of metal straight across but I wanted it to retain its original appearance with all the pressings in the panel. It is a bit anal of me I know

    Here they are held in place with a magnet as I couldnt get any clamps in

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    and then welded in

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    and with a coat of etch primer inside

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    It still needs a bit of fettling as there was some slight distortion which needs hammering back followed by some fine filler but I'll leave that until I'm nearly ready for paint.
    on the Monday I made a panel for the outside.....again it took most of the day to make but I was really quite pleased with this one

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    I decided to cut as little as possible from the original panel so only used a small bit of the repair panel I had made

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    I could then graft in a new outer B post and weld it up

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    I then Got a little bit done last week end. Spent all Friday afternoon after work trying to make a c Post repair panel

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    I had expected to find a simple ish box section (as shown in green) after I had done some cutting. Instead it had a lip out to the side (arrowed) which threw me a bit...

    hear is attempt No 2 at making the section with the lip

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    That was as far as I got, it was one of those days when nothing seems to go right.

    I went in to work for most of Saturday and for the rest of Saturday was wiring up the sister in laws house - well putting in a few extra sockets.

    I decided to have another go at the C post on Sunday, third time lucky......

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    The one on the right was the bit with the "lip" I made it from 3 separate bits and welded them together.

    I then tacked them both in place and ground them down to shape

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    Lastly closed it all up with another strip of metal

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    Not much for a weekends worth of work really but Im much happier with the repair even if it is a bit rough and ready.

    just got to patch up the corner of the side panel and the outer sill can go back on!!
     
  4. Diddymen

    Diddymen Moderator

    Ob Wan to Hand Solo: We need a fast ship to get us to Alderaan

    Hand Solo: You never heard of the millennium Falcon? its the ship that made the kesstle run in less than 12 par secs

    OB Wan: Oh

    Hand Solo: start the ship Chewie, we'll meet you in docking bay 94

    Princess Diddymen: we better get Yoda

    C3PO: He wont be happy sir, he's just paid for a lap dance

    Mrs Diddymen: Turn that computer off I told you about this last night

    Diddymen: just up dateing the resto thread for the late bay'ers dear, they want to hear more of the starwars story

    Mrs Diddymen: TURN IT OFF

    To be continued...................
     
    Last edited: Oct 2, 2017
  5. Diddymen

    Diddymen Moderator

    Update from last weekend - Aug 11

    got a bit more welding done - dont mean to muck up the time line of the repost so I'll keep it short!!

    I keep on getting the list of welding jobs down to 10 items, each time I tick a couple off I recount and there is still 10 bits left to weld ???

    So last bits of welding still to do are:-

    2 plug welds to end of off side sill
    petrol sender hatch to make and weld in
    2 plug welds to rear of front arch to B post
    Battery mount for leisure battery
    front valance (if they ever get them in stock again :mad: ) and in fill bits
    front clip
    lower front outer clip/section
    add a few more plug welds to driver seat belt mount
    weld up screw holes inside bus (only the ones which will be seen)
    rear seat belt mount captive nut & plate - I'll wait till I've got the R&R seat to get it welded in the right place

    (and thats 11 items ??? )

    and thats it

    unknowns:-

    under poptop
    under sliding door and tailgate window rubbers
    2 off side side windows under the rubbers
    beam
    chassis under beam

    hopefully thats the lot ;D
     
    Last edited: Oct 2, 2017
  6. Diddymen

    Diddymen Moderator

    ...........Oh yea, and remove the raised bit on the front panel where the badge goes :D
     
  7. Diddymen

    Diddymen Moderator

    quick pic from this weekends work (Aug 2011) just to muck up the time line even further.

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    you can read more of that on......shall we say, page 20??? ......I'll meet you there :D
     
    Last edited: Oct 2, 2017
  8. I admire your perserverance ;D

    Keep at it when its done and back on the road you wil have a great sense of achievement.
     
    Last edited by a moderator: Oct 2, 2017
  9. i missed this thread. i went to remove my arch the other nite and wanted to check your thread before hand and it was gone :(

    keep it up, and im sure you'll get your front end on before me!
     
    Last edited by a moderator: Oct 2, 2017
  10. Diddymen

    Diddymen Moderator

    Thanks Jimmy for the kind words :D , it does mean a lot to know that all that time I spent taking photos comes in handy for others to use as reference :D

    Thanks Pickles .....it has been a long haul :D
     
    Last edited: Oct 2, 2017
  11. Diddymen

    Diddymen Moderator

    Right are we ready for some more reposts????

    May 17th 2010

    No still not finished yet, it is stil very much a work in progress. I've had it since Sep 09 but at the rate Im going it probably won't be on the road until Sep 2011 :( (that was a reply to a question I was asked - was it nearly finished........thought I'd leave that reply in so you can see the irony of it ;D )

    Never the less I got my first outer panel on this week end.......o.k. so its only the outer sill.

    Spent Friday making up a small patch for the side panel

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    Went in nicely.....but then I made a small dent in it trying to bend the lower lip into place....oh well a bit of filler will sort it.

    Saturday I spent a bit of time fiddling and fitting another patch for the bulkhead panel, I also reinstated the oval hole in the original B post. I'm not sure what it was for, it had a rubber bung in it, but it was an original hole so I thought I'd put it back - at least I can use it to waxoyl the box sections, just the fiddly curved sections and the lower outer bit that covers the top hat still to go

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    ....and from outside

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    Then painted it all. Sunday I fitted the outer sill....at last!!!! I spent a bit of time getting it fitted, it's not perfect but I'm more than happy with it

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    Lastly I cut out a patch for the lower rear wheel arch and clamped loosly in place....hopefully get this welded in next weekend

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    Roll on next week end ;D
     
    Last edited: Oct 2, 2017
  12. Diddymen

    Diddymen Moderator

    Looking back, it does look a little "rough" on that seat bulk head/b post repair I might go back over it and see if I can tidy it up a bit

    In hind sight I should have replaced the whole of the rear arch rather than replacing that small lower section .....as I ended up replacing a section further back as well (probably be on page 12 ish when I get there?)
     
  13. Diddymen

    Diddymen Moderator

    The Gang leave the bar and make their way to the docking station when they are stoppen by some storm troopers...........

    trooper: how long have you had these droids?

    Princess Diddymen: about 3 or 4 seasons

    trooper: let me see your identification

    Ob Wan: you dont need to see our identifications

    trooper: we dont need to see their identifications

    Yoda is sick in the back of the speeder

    trooper: move along

    Yoda: your posting is improving with content it is (Yoda passes out)

    They make their way to the docking bay

    time for an intermission

    Pearl and Dean 1970s

    ice creams and ciggaretts are available from the usher
     
  14. Diddymen

    Diddymen Moderator

    Done a little bit last weekend,

    finaly closed up the gap at the rear of the sill - The front of the rear wheel arch. Was hoping to use my new interclamps..... but realised I wouldnt be able to as I wouldn't be able to retrieve the backing bits :(

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    Not brilliant pictures but hopefully you can see it has all lined up pretty straight :D In hind sight I should have welded this bit in first and then the outer sill.

    there is a line of filler just above the new bit on the rear wheel arch about 1-2mm thick, not sure why its there as there doesnt appear to be any damage showing inside........perhapse I shouldnt have cut the whole panal up for this small repair ::) any way I'll find out when I'll grind it back for painting.
    Started a bit more on the front wheel arch area.

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    this is the bit I was concerned about as I wasn't really sure how it should go as there was nothing to copy - hopefully it's ok as I'm not chopping it out again ;) .........

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    Then got the bottom section which covers the top hat welded in

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    Fingers crossed I might get a bit more done tomorrow.

    I've still got the curved, bulgey bit to fill in.....I'm not looking forward to it. I've already tried bashing a bit of metal around with a hammer and it didn't come out well!!! think I may have to make a few little bits and make a patch work repair of it.

    Then I've got to do some repairs under the seat runners and then I can get the arch back in :D . although offering it up it seems to have shrunk a few millimeters ??? every thing else seems to have gone back in the right place.... ??? not sure what to do about it yet....think I'll get the other bits done first then figure out what to do.

    I've started wondering what I should do next ??? - rear corners, front, cab floor....or sliding door sill and sliding door. I suppose I should do the stuff under the bus so I'm not lying in mud again next winter but I'd really like to do some bits which will be seen....so my wife can see some progress (she wont go under the bus to admire my progress!!)

    Any one bought new sliding door sills?? do they come with the runners and are they a good fit?? recommendations greatly recieved :)

    On a different note, I've just had to replace the speedo cable on my MGB, whilst under it I noticed how rusty it was and that I should be doing some work to it. I seem to remember coating it with the sticky hammerite underseal with added waxoyl a few years ago.......theres hardly anything left of it now :eek: thats another job before winter then ::)
    Laters all
     
    Last edited: Oct 2, 2017
  15. Diddymen

    Diddymen Moderator

    from June 02 2010

    Think the sliding door sill might have to wait a few weeks. Mrs Diddymen wants me to fit some doors to our built in cupboard :( it will take me ages :( it took me long enough to build the cupboard :( .........5yrs ago ::)
    still, if I dont make them she will buy some sliding doors.....for £900! :eek:
    Better do as she says :(

    anyway...........here is a bit more from this week ends work
    it took long enough but finally I got the "bulge" patched up I tried to make it from one bit but your skills are way out of my legue zed (in response to some pics posted by zed)

    I ended up making it from several little bits

    so from this.....

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    to this......

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    Im being a bit lazy and not grinding the welds on the outside smooth....I'm worried I'll thin the metal too much with over enthusiastic grinding ::) it will need a bit of finishing on the inside though...........even though I will probably have a panel over it eventually ::)

    Next there was a patch under the rear of the seat runner to do as there were a few small holes as you can see with various things stuck in them!!

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    Then new bit welded in, I will finish it off when I get the seat belt mount repair welded in

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    I'm going to join the seat belt mount panel to this bit where they meet under the seat runner so I can get a really good welded join......which I wont have to grind back ;)

    I roughly held up the wheel arch and it will need a bit of work. I may have made too big a cut when I chopped it out as there is a 2-3mm gap between the other bit of the arch....or it might have been fitted in that position because of the patches underneath it - now there gone it sits back further making the gap ???

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    Still.....it's now ready to go back on :D

    Just got to get rid of the old underseal on the existing arch bit and clean up the bit I chopped out.

    Started stripping off the under seal this is what I found

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    :D :D

    looks nice, unfortunaltly I started striping it off with a chemical which softened it up...and the paint under it - hence the scratches, it made it sticky again.....and difficult to remove. I then realised it was so brittle I didn't need the chemicals it just scrapped off easily :D I like the look so I will be doing the arches in body colour eventually but once I've sorted out the rust patches it will be keyed up and painted black with the epoxy mastic.
    unfortunatly the outer area next to the wheel arch is worse and will require some serious rust removal and treatment :( suppose I should be used to it by now - at least it wont need welding.

    until next time..........
     
  16. Diddymen

    Diddymen Moderator

    Got a bit more done than I expected to do this week end

    First gave a good coating of paint over the back of the wheel arch where I had done all the work, then cleaned up the old welds on the bit of the wheel arch I'd chopped off.

    Once clamped in place I decided to make a new rear flange as the old one was bent and it would have been messy to try to re bend it and repair it.

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    I welded it on and then made a coller for the inside of the wheel arch. I tacked the coller to the removed bit of wheel arch and offered it up, had to bend it a little and chop some off before I could get it to bridge the gap.........forgot to take any photos of this bit :-[

    Once I clamped the wheel arch in place I tacked welded a few spots to the B post outer, then some on the inside against the B post and then tacked the two halves back together. It was a bit tricky to line up and clamp in place, but the result was spot on using a straight edge against all the surfaces :D

    I then plug welded through some 6mm holes I had made in the wheel arch flanges when it was off the bus to further fix it to the B post area. Next was a few stitch welds across the two halves, a few more stitch welds to the inside of the arch to B post and then closed the welds across the halves
    Ta Daaaaa!!

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    I ground all the welds back and filled a few pin holes, I also had to do another seam across the joins to compleatly fill it, then ground back again

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    I have to amit the under side was tricky, I couldn't be sure how well the inside of the outer lip was welded as I just couldnt see let along barely getting my welder in. So I had to do this bit by touch (so to speak) I put loads of weld in there and couldnt get a grinder in to grind back to check for holes I've had to make sure I've given it a very good coating of mastic and hope it does the job.

    gave a coating of primer just to see what it would look like

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    I then cleaned back the rusty top edge of the wheel arch, gave it a coat of rust killer and a coat of galvo spray (which I don't like using as nothing paints over this particular stuff easily)

    I then cut the seat belt repair to size and fitted in

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    Going to go back and put a few more plug welds through the seat belt repair to wheel arch

    again with this the underside isnt pretty as I couldn't get to it very well to grind down the welds. There was also a bit of distortion as I was welding up, where the new patch meets under the seat runner part of the new panel was not sitting flush with the bit it was welded to forming a lip. Unfortunatly I couldnt hammer it back into place due to all the weld around it :mad: in the end I ran several seams of weld over the join. I plug welded the rear lip from the cargo side as it was eaisier to grind back the welds.

    .......any way here it is with a light coating of primer so I could see if the welds were all flat

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    There was a bit of distortion to the deformation panel behing the drivers seat from welding in earlier patches. I decided to see if I could straighten it by applying a little heat then cooling it quickly to shrink it........... ::) ........That panel doesnt take much heat at all before it distorts :eek: . just a light blow over from my blow torch saw the distortion move around the panel :eek:

    .....this kind of reminded me of Father Ted....the one where he got a brand new car to give away as a prize........it got a small dent somehow, so Ted tries to gently knock it out with a hammer......then gently knock out the slight dent he just made......then gently knock out the next small dent he made.....then camera cuts to some time later and the whole car is covered in small dents :lol:

    Any way I soon put the blowtorch away after beating the metal back to its previous state of distortion :p luckily when I welded the seat belt repair through this panel the heat seems to have pulled some of the distortion out.......which was lucky.

    Then I gave the wheel arch a good coating of epoxy mastic........I'm coating every thing in this as I probably won't get round to spraying till next year so I need to give every thing some good protection untill then....I know I'll have to either remove it or sand it back before I paint though.

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    Then a tidy up and back in with the seat just to see what it was all like before I started ;D

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    A look at the drivers cab floor it looks in pretty good condition with only a few small patches which I may take off and re do at some point. (which I do in the end)

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    And I've still got to make some brackets to fit the belly pans....but that might have to wait as there is DIY on the horizon :(

    Laters
     
  17. Diddymen

    Diddymen Moderator

    16th June 2010..........

    Not much done this weekend,

    finished stripping most of the crap from inside the front arch and gave it a good clean before giving it a good coating, found the serial number on the front beam.

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    The arch was coated in that sticky underseal which had gone brittle and was easily scrapped off........except for the rusty bits...it stuck like s**t to a blanket....didn't stop the rust underneath though. From these bits it was a real bugger to shift using various chemicals, white spirit and a lot of elbow grease. I hate the stuff, hides all kinds of problems and is difficult to clean up to repair the area :mad: ....rant over. found a small hole which is being hidden by the patch repair inside the cab but I will do some work to the cab floor at a later date.

    That little lot took a whole day to do :(

    Next I made a few angled brackets to hold the belly pan on, welded them to front and rear outriggers/jacking points

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    I then loosley bolted the belly pan on to hold it in place so I could drill through the belly pans and into these brackets. Once the pilot holes were drilled I took the belly pans off to drill out the holes in the brackets to 6mm. Next I used a 6mm bolt to hold a nut in place whilst I welded it to the bracket, bolt removed and cleaned thread with a 6mm tap.
    Belly pan has been on and off countless times to get it to fit right, trim a bit here, drill a hole there....etc

    Finaly a test fit with a few bolts holding it in (I did have all the bolts in but removed most of them before remembering to take photos)

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    Took it off again as I've got to seam seal every thing underneath. I'll then give the bits it will bolt against (chassis, sill etc) a coat of POR15, I'm then going to give the belly pan a coat of POR15 - I've got all the correct POR15 products now so will apply it to the letter of the instructions.

    I'm thinking of using rubber or fibre washers between belly pan and body as I'm hoping then it wont trap moisture against metal work as it will "breath" a bit better....it might just let more moisture in though so I've not made a final decision yet

    Thats all I've got done so far :( may get a chance to paint the belly pan this week end......but the wood for the bedroom cupboard doors are coming tomorrow so I know what Mrs Diddymen will have planned for me :( .....although I think we are supposed to be going to London Saturday for a day trip :( - is it Fathers day Sunday??? might use that as an excuse to get some me time....working on the bus of course!

    Anyway, here is a pic of the passanger side arch which I'm going to have to chop off to repair that side.....I'm wondering ...can I do it carfully like the other side and then repair it whilst it's off the bus (no, I replace the whole thing in the end ....wasnt too difficult either)

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    Laters all
     
    Last edited: Oct 2, 2017
  18. Diddymen

    Diddymen Moderator

    think the bellypans had really helped protect most of the load floor area, the problem areas were where the belly pan was welded on to the sills and chassis which trapped moisture causing all the rot. It's a common problem that we're all familiar with.

    I like the idea of belly pans for underside protection and possibly help aero dynamics......if that is possible ;D

    Don't know if they will really help much which structural strength as some belive

    I think the epoxy mastic will give a good stand alone protection for the underside if belly pans not fitted

    Thinking about it, the washers may also stop some vibration which may cause the belly pans to rub against the paint work, as I said it "may" also help to prevent moisture getting trapped so not having the same problems as I had before. As I've cut and fiddled around to get it fitted there is also a small gap between the pans and outriggers, I could seam seal these to stop moisture getting through but it will probably get through anyway and sealing might just trap moisture in??? I'm also thinking of putting some sound deadening rubber matt on the top side just to stop reverberation.

    In my case it may also be "as it was fitted when I got it, it will go back on to keep it original....... ish"
     
  19. Diddymen

    Diddymen Moderator

    21st June 2010....

    In between going to London and DIY I managed to do a bit this week end......not as much as I'd have liked :(

    Mainly painting more of the underside, Gave a coat of POR15 to the area which will be hidden by the belly pan...

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    Looks nice and shiney. Then gave the pelly pan a coat of POR15 after cleaning thoroughly with marine clean then coating with Metal ready and rinsing inbetween processes.....

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    Very shiney..........shame about all the dead flies which have got stuck to it ::) .....yes after all that prep you'd think I would have painted it in side (or in the van)......I've painted it with rust preventative POR15 and will give it a top coat with POR15 chassis black. I'll have to get rid of the flies by sanding them off with some scotchbright first.....then I should re-clean with Marine clean.....

    I'm going to do a bit of a trial with the underside protection, So far the area which will go under the belly pan has had a coat of POR15 then a coat of epoxy mastic then another coat of POR15, the side belly pans will be coated only in rust preventative POR15 and POR15 chassis black. The center of the bus under the center belly pan will only be getting epoxy mastic, and the front pan......well I've not decided yet...... but hopefully this mini trial should give me an Idea of which will be the best underside protection.

    And thats as far as I got..........................until I decided to take this afternoon off ::) well it is the solstice!!!

    So this afternoon I removed the remanents of the belly pan from the chassis on the near side...you can see a few spot welds remaining..but surprisingly it's in pretty good condition :D

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    Theres a bit of pittting but nothing too serious which will need welding.........but I expect it to need some work behind the rear jacking point Which I've started hacking at.

    I cleaned the area up with a wire brush attachment on my grinder and drill and it looks pretty good

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    I will be cleaning this with marine clean, then rinsing, then applying metal ready then I will give it a coat of POR15 in other words "as per instructions" - TO THE LETTER!!

    Lastly I decided to chop off the rear NS arch bottom just to see what the sills are like ::)

    [​IMG]

    Well after poking about I made a hole through it where the C post should be......I was expecting as much :lol: ;)

    Laters
     
  20. Diddymen

    Diddymen Moderator

    All safely aboard the Millennium Falcom they make their way to Alderaan.

    They drop out of hyperspce into an asteroid field......

    Hand Solo: thats an imperial fighter

    Princess Diddymen: If they identify us we're in big trouble..... he's heading towards that small moon

    Ob Wan: Thats no moon, thats a space station.....

    Yoda (now sobered up slightly): into a corner you have backed your self, to rescue Leia was the story line aboard the Death Star, Mucked up the starwars references now you have.....continue you cant

    Princess Diddymen: I'll give it my best shot, just you see

    R2D2: woooo beep whistle

    Every one: I knew he'd say that.....

    C3PO: we could go to the forest moon of Endor to visit the Ewoks ......I know technically this doesnt happen until return of the Jedi.....but as we've mucked up the plot already.......and I've got a cousin who lives there

    Diddymen Narator: now what will our intrepped heros do - do they continue to the Death star and play out a poorly concieved attempt to get the plot back on track........do they go to forrest moon of Endor? ........should Diddymen stop these starwars references???.......... Will diddymen stop typing before he gets told off again by Mrs Diddymen........will any one tune in to find out what happens......

    tune in next time to find out............
     

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