bumper repairs - trying to fit prototype bay bumper with mods

trying to fit an prototype bay bumper to my late bay, but without doing any body mods so I can return to stock if desired, so not wanting to cut the deformation panel off.

Held up the eb centre section - fits straight over the deformation panel but bumper mount holes in the wrong place, so I will either weld up the existing holes in the bumper and redrill to line up with the existing mounting holes on the bus, or perhaps fit rivnuts in my deformation panel to line up with the eb mounting points.

Ok, so the bumper does not sit as close to the front panel as on an eb, but it does not stick out any further than a standard late bay (about 47mm).

The issue comes with the side bumper steps - the door does not open as they sit too high up.

So, I have cut the top of the step off and welded it back on about 15mm lower down - just enough to give me enough room for the doors to open.

I have only done one step so far (as I haven't sourced a right hand step yet!) but it's come out OK and looks like it will fit (just need to fabricate a bracket to hold the side steps to the bus and fit some rivnuts to the bottom of the bus side step to attach these).

Welded up as best as I can and given a quick coat of primer, but there are a few little pinholes and divets which really need filling. What is best to use to fill these? I was thinking maybe P40 (think it's P40 anyway - the pink fibreglass matty stuff) as used this in the past and it sets rock hard.

Any other suggestions?

 

bare metal it and then some Isopon or plastic padding..easy on, easy off...pics would be great as I bet there are a few folk who fancy doing this job but never had the bottle...the person who invented rivnuts deserves a knighthood

 

Why not buy an early.

 

a good point well made Sir!

 

I thought the Crossover bumpers are much better looking than Latebay's (We own a 70 but don't tell anybody)

 

IMHO, early bays look better, late bays drive better, so after the best of both worlds!

When I do the other side and fit up, I will take some photos and get them posted on here to see if any other late bay owners would be interested.

 

OK, managed to get the other side bumper step from Busfest, so cut that one down and took some photos along the way..

This is where I made the cut in the step..



Cut the top of the step off..



Welded in back on lower down (don't mind the crap welding!)..



Cleaned up the weld, primered and this is how it compares to an original step..



Done both sides now, just need to fit them to the centre section when I get chance and offer it up to the bus to see where I need to put the rivnuts and sort out some brackets for the side steps. Will take some more photos and post them up as I go along.

 

Ive got a set of EB bumpers, i think they would look nice on mine, only thing that stops me copying you is that they are chrome

 

I'm sure someone would gladly swap them for unchromed ones and a bundle of cash mate!

 

Its the chrome bit i like

 

If you wanted to cut the deformation panel off I would have thought your bumpers would fit lower down and the side steps would not need modifying, although you would have to fabricate some brackets to hold them on.

 

I got the bumpers off Manyprojects and the van hes breaking, the previous owner had fitted them to a late and it looks really nice, i should've paid more attention to how they did it, its the other halfs idea really and she paid for them, i personally dont like the idea of losing the deformation panel, but i think ive lost that argument!
http://thelatebay.com/index.php?threads/1975-t2-unfinished-project.28284/

 

You have to loose the deformation panel and fit an early panel.
Pic's of my chassis Y sections and part of the panel are in the for sale section.
http://thelatebay.com/index.php?threads/1975-t2-rhd-van-front-chassis-y-piece-cuts.29137/
Mine just bolted on to the chassis legs then.
Manyprojects

 

With the deformation panel removed, you should be able to fit the bumper without having to modify the side steps.

 

Just like cross-overs.

 

Had a good day on the bus today..

Trial fitted the complete bumper.

Welded the cut down brackets back onto the side steps in the necessary place..



Put some rivnuts in the inner step on the bottom of the bus to secure the side steps to..



Put some rivnuts in the front deformation panel to bolt the centre section of the bumper on - not rock-solid fixing as the holes that are drilled in the prototype bay bumper are not in the middle of the blade, so as you tighten these bolts it tries to pull the bumper at an angle (if that makes any sense) but strong enough.

Completed job (obviously need to paint them and fit proper bolts, but hopefully you can get the picture..





The bumper does stick out further than an prototype bay should, but no further than a late bay, and in my opinion the bumper looks better (although everyone has their own opinion), but I am pleased with the end results.

 

I like it, prototype bay looks and late bay safety.

 

Yeah I like that Earlies deffo do look better

 

Job done..

Side steps all painted up with new rubbers..



All bolted up on the bus..

 

nice work