1975 devon revamp - scampervan

Looks like its been keeping you busy

 

small update, engine is now with me at work, and stripped and cleaned. main journal shells are worn but crank is still untouched so will be all good for some new shells. pistons have slight scoring to the thrust sides but barrels look ok. i also recieved a pair of solex 40mm carbs for the engine also with fuel lines, linkage and inlets.

im looking to rebuild the engine using std sized shells, solex 40 carbs (rebuilt once i can find a rebuild kit), 1641cc barrels and pistons and maybe a cam of some sort as i accidently knocked mine off my work bench and it chipped a couple of the teeth on the gear

and as for bodywork, i have recieved what i hope is the last panel for the front end (apart from the drivers arch which is still on back order) and hope to get this fitted asap.

i decided to buy the panel from vwheritage that joins the cab floor to the inner valance as this will help me align the inner valance also. hopefully with this panel i can now finish the repairs to the a pillars, replace this panel, weld on the inner valance then get the main front panel fitted ;D

but im sure it wont be as easy as that!!

 

the engine pics so far

the shelfs of camper bits next to my box at work



the main shells. brass anyone??



doh! dont knock a camshaft onto the floor



one pritty knacked flywheel, reface or replace?





old barrels



engine casing after a quick clean. needs a good wiring brushing before i can paint it though



and inside





and my new carbs, solex h40/44eis in need of a clean up and new filters

 

Reface the flywheel.

 

just a small update as normal. been spending a couple hours up the workshop the last 2 nights to get abit more done as wont get a chance this weekend.

last nite i removed what was left of the panel that joints the front of the cab floor to the inner valance





then once fully removed i trial fitted the new panel. as you can see that new brazilian panel is alot taller than the old panel so some modification will be required for the washer bottle to be refitted. i also need to redrill the holes for the wiring loom on the other side of the panel





i havent yet welded the panel on as i want to get the chassis rail ends repaired, cleaned and painted to protect them as now is the time to get into all the spaces that i otherwise couldnt.

tonight i made a start on the chassis rails repair. the only one that needs attention is the n/s outter chassis rail.
ideally i dont want to have to cut off and replace this chassis leg so for now i am going to try and repair it and see how it goes

this is how it started off, the main rotten part



when looking down the inside of the chassis rail i spotted some light so marked up all the rotten parts ready for cutting





and set about removing the rot. as per usual with a camper, the pieces removed always become bigger than first antisipated





i also needed to remove part of the inner face of the chassis rail also. there is still more that needs to be cut out but my last cutting disc was getting too small to reach into the rail now



the biggest part removed, ready to be copied in 2mm steel



the new lighter, rust hole "free" rail



i decided not to do anymore to the larger of the holes this evening as it needs more work before i fabricate the repair so i made a start on the smaller repair patch.

i used the old piece that was removed as a template for the new piece and checked it for fitment



then tac welded it into place



and while the welder was out i finished welding the lower a pillar repairs and the small patch





once the chassis rails are completed then its time to get cracking and get the front end on

;D

 

i would of got more done i think but my brother needed a hand with his latest project, the renault 11 in the back ground which he has just fitted a clio 16v engine into and bolted on a supercharger 8)

 

Nice work.

 

keep up the good work.

I thought you would have had that front on before me ;D

....you still going to fit the early valance??

 

diddy - i was hoping to have it on by now, but with it removed it easier to get to all chassis rails, and the parts of the cab floor that need repairing still. there only small patches required but much easier with the front off.
i plan to keep the early front end but not sure if im going to use the lower panel that i have, or buy the one thats used when fitting the early bumper to a late bay, as its not too expensive. as long as the front is on before winter then i will be happy lol.

update, spent another couple hrs up there this eve with the missus and made a repair panel for the big hole in the passenger chassis rail. back up the workshop tomorrow eve so will get photos then

 

You aint mucking about with that are ya dude shes going to be cracking when shes done

Id say source a new flywheel and use that one as a door stop dude

 

good looking work there mate

 

i havent been able to get down the workshop as much as ive wanted to but finally got another couple hrs in this eve, but doesnt feel like i got much done.

welded up the inner side of the rail



then after alot of bending, cutting, straightening, more bending, more cutting and more bending i finally got the outter repair panel into a shape i was happy with and got it tacked into place



then coated everything in zinc primer for now

 

Good work. 8)

 

some work carried out this weekend.
yet more welding to the chassis rail but im happy to say ive finally got the patch completely welded and ground

sat -





then i ran out of welding wire and typically it was 1minute after the local diy store closed so give it all a coat of zinc primer



so i cracked on removing the rest of the underseal in the arch area





then noticed the corrosion to the cab floor which was covered by black paint, just like the other bodgey parts







sun -

with 5kg of welding wire and finally some proper welding gas (no more disposable bottles) i could finish off the welding





then attacked the next hole, in the "tunnel" for the front beam



and whilst i was doing this, my missus was busy on the drivers side removing all the underseal from inside the arch and then decided to remove the arch itself



with the underseal removed we uncovered a small hole in the outter chassis rail but nothing as bad as the passenger side some previous repair patches to the rear of the arch area. i think i am going to cut this out as the bottom of the B pillar was filler and when removed it didnt look pritty inside. i think i might be needing to cut the bottom 6" off the sides and replace the sills

 

Great work As you have gone this far I think it would be worth changing the sills as well. It will be worth it in the end.

Keep up the good work & enthusiasm.

 

progress has become rather slow im sorry to say due to me managing to injur my back during a gym session.
i have though made some progress.

i have collected my engine casing and crank etc from the engineers. the case has already been line bored and is .5 over and the crank mains had already been reground to .25 under. i have had the crank shaft mains reground again to .5 under and the mains have been polished. i also had the con-rods line bored due to them been oval so the big ends are now .25 over.

now i just need to order the new parts then the rebuild can start to a 1641cc.

yesterday my latest package arrived from justkampers -
- n/s cab floor repair
- o/s cab floor repair
- n/s + o/s seatbelt mounts
- n/s inner and outter 'b' post repair panels
- o/s inner and outter 'b' post repair panels

i plan to get cab floor sorted next and then get the front panel on. ive started too many bits and not finished them so its time i finished the first part i started.

but seeing as i cant get to the camper atm all i managed to get done is polish the hub caps for the std wheels, which ideally need re-chroming

 

few pics from today

centre caps (need re-chroming or im tempted to leave abit ratty)









new rocker covers and clips



the latest shipment of panels









im hoping the cab floor repair sections will help remove most of the corrosion to the cab floor and only small patches might b needed towards the centre of the floor

 

good to here your back on it

always nice to get new bits ready to fit ;D

I think re chroming will be expensive compared to buying a new set .......but the chrome on the new set wont last anyway :

..........and DEFINATLY start repairing the bits you've chopped off before you start anything else ;D

 

Great job. How's your wallet feeling?