Sills both sides starts Monday 11th

[Plasticman]

well , fuel tank was vactanned, then u/coat and now shiny glossed. colour co-ordinated

rear floor repair welded in

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coated

when dry tomoz i will seam seal it all

then start sticking a few bits back together inside
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[Ian Hulley]

well , fuel tank was vactanned, then u/coat and now shiny glossed. colour co-ordinated

Steady now ! This isn't ya common or garden show pony tha nose

Ian

[Plasticman]

well its a weekend so light duties , taping up for sealing

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this way keeps it neat , when dry will repaint it then treat the nooks etc
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[Plasticman]

well sealed

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when dry these were recoated with grey the dried and a heavy coat of gloss brushed on

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safe anchorages now

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providing it dries overnight then insides back tomoz, i have underside to finish sealing and another small welding job to do on it then we go testing
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[Plasticman]

Well sealed of the underside joins, this shows the underside of where i repaired the rear panal , the sheetwork was butt welded so no crevice for future trouble

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rear springs and shocks back on (and yes they were Tight)
didnt bother taping these up as they have more stuff to go over

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loose fitted the exp tanks and drilled mounting holes, when i fit these i will fill the recesses with sealant then a layer of clingfilm then fit the tanks

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one of the sill to inner sill joins sealed

then the underside of repairs done with dynax UB and the inside of the sill doused with dynax S50 this man ky stuff that drips out and onto you

tank and stuff back in then off to test
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[Plasticman]

Well, ahhhaynes said there are two M8 screws holding the tank on , cant find them or is it a case of "did you manage to sort the small hole under the rubber mat....................hole
must be this little one

hmm

knew I'd forgotten something
lets have a look

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just a little bit more

well

no point trying to patch it,and then theres the issue of all the burnable hoses and cable and such and the H/brake anchor is iffy etc so will have a think
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[Plasticman]

Well folded a new section up,

have added the recess to accept the brake cable and its rubber boot

i have sat it through the hole and brazed underneath, ive again pre heated it and its flowed nicely through so no chance of it rusting away here

trial fit inc handbrake lever

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now the original flooring had the usual swaged pressings, thias is often done to give strength and to prevent drumming, also usefull if using very thin steel as was the case OE, if it was seen as in doka load bed etc then it would be replicated no problems but here its very well supported and if you n ote the OE at 0.8mm and my part at 1.6mm then im happy doin g it my way

old and new

so weld ity up first thing
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[Plasticman]

Well ded

prior to this I welded 2 new strips of 25mm wide steel to top of x members to bring these up to correct height and also give a nice surface to weld to
at the front edge it meets just as the OE

sealed

and coated

will gloss it in the morning
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[Plasticman]

well gloss it is
hmm picky not through yet, ok
mounted the fuel tank and ran new fuel grade hose on the tank breather outlets to plaggy fuel pipe and new ends to the exp tanks. grommets all cleaned and refitted with luuube..
here you can just make out the tank spigot sat in the steel ring

secured with an SS m8 csk setscrew chose this as it sits fairly flush under the rubber matting and being ss shouldnt seize.

blick

with seats and belts etc back in , handbrake lever feels nice and solid, may have to view the osr hub as its not 100%
but
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[Plasticman]

well, hummed and hah'd and thought about it and well nope

be wrong to leave it in precoat

so dragged a good mate down after tea and

first bit of 2pack being drifted on

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loads on

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[Plasticman]

Well finished a few bits off,
first before


now with seals and grommets in

door ready to rehang

after a few trials to readjust this

and yep it dropped off ,well nearly as i sort of caught it.
there is just so much wear and slop in the linkage,and as im out of late ones i had to do a temp repair

shaft was well worn away soi built up with braze and a quick file top take most of the slop out, also packed it with a washer under so it functions a bit more like , the kick out spring is not happy but its sortable later
ive also ran another thin bead of steel along the top edge to help compensate for the wear in the runner wheel etc and this has enough room to accommodate a new assembly should it be acquired

its abit tight to shut with the old seals bvut shut it does

and Steve should prefer this view


so onto tea

tester coming in early for me in the morning so we get it done and away by lunch..ish
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[nige73]

My God you've got some balls tackling that I thought mine was bad but its mint compared to yours before the work.Superb job and an inspiration to everybody,well done.

[kevtherev]

Nige this is not Mikes van, this van belongs to Ian Hulley, Mike does this as his hobby

[nige73]

I spotted some other posts So I guessed this one of many labour of loves!!.

[Plasticman]

thats good face saving they are all labours of love, and not all get done and money has nowt to do with it
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