The Trukkvagon is coming

[Plasticman]

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[Plasticman]

Well a very nice Cali

not really a lot wrong but there are oine or two issues that need doing once only really, it starts with a fairly full interior strip out, well it didnt start that way , firstly there is this small matter

and there is a certain ammount of work required to get the horseshoe off as there is no way were going to paint up to a seal like that

then there was this little matter

and to get to the back of it is err a bit of work . i have tried to log the order the interior came out in with the hope it might help anyone not fammiliar with it, so a brew and I will be back to it
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[Plasticman]

well this needs to come out

pair of screws into the side through the cubby(shelf and tabler leg removed

and on the other side

and upper

front behind drivers seat

then gas to disconnect (turned off at tank) and sink drain and water feed to tap

side grill off and hand in to ease the fridge flu pipe away (I had removed the external vent first)
then slide fwd lifting over the gas outlet

then disconnect the wiring which is on plugs so saves some time ,
and away with the kitchen block

at this point I could see nasties so it was out with the next unit and water tank

wiring disconnected and i have removed the external hook up box

have to leave this bit for now while i have a search for the pickies
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[Plasticman]

cant find them so will move onto the roof horseshoe spoiler,
these have to come off both sides

leaving this

just so we can get to this bit of headlining both sides

this also shows the cover strip and the row of screw securing the headlining to the metal rail behind

then you get this and there are the 2 bolts at either side that screw up through the roof into the spoiler

externally there are 4 x 6mm bolts sticking bthrough with finnishing caps on them , these are bolts that are held in place with tape on the underside..
then it lifts off.
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[Plasticman]

Well I will picky up the refit of the other internal units and removal would be the opposite.
so what was found behind that minor ish bit of rust



when i say its more than it looks I really do mean it,


as found

sop now its down to chopping all the carp out, i figure if the rot and rust is removed then no need to blast,,,,

but the rear is another matter

no point even going near ity with a grinder or blaster as its gone right through so,,if in doubt, cut it out

make and fit a bit to let in and gas it along


makes it sort of right now
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[Plasticman]

Well sill going on

cant tell from these picks but there had been an attempt to maybe jack the van up under the sill towards the rear of it as it was stoved in a touch but since straightened.
all is happy with it

next I made a lower panal and have clamped this in place


theres a few tricks involved to allign it and the panal is made in a way that is wrong untill fitted so to speak, i alsoi made about 5 spares some with extention lips on the lower sections to aid repair all in 1.2 mm steel.

camped on

T'other side

I have left the repair panal a touch shy so that when I make and fit the closure plate it will fit up to the repair panal and not over the top of it, much neater this way and will heaven forbid allow easier removal in the future if its bumped or w.h.y


spotted behind , there are a good few more now and the fasteners have been removed and the holes welded from the inside


bit more jiggery needed and then the internal closures done, i will template these up and make some spares so i can supply the lower fridge panal and the sill closures to enable you to replicate the original as near as is practical . well thats if you want to
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[Mickyfin]

Always love watching your work Mike, you really have a good skill when it comes to metalwork, and fabrication, its fab watching piece by piece coming together. Also with good photos to boot, it also serves as reference to others.

Is this bus yours, or another?

[trucker]

Is this bus yours, or another metalmickey customers, like kev's?

I'm the lucky one! Really excited

[Mickyfin]

Cool.! I bet you are, its in safe hands

[xriss]

some creamy looking metal work going on there as ever

[Plasticman]

be better with a nice expresso
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[xriss]

ja ja ........die Crema ist wunderbar

[Plasticman]

Well as things go its been an ok day , took a while to sort the closer as i needed to make a template so i can remake lhd & rhd to order then make this one which is cut down to suit what im doing here. so this is the first part that fit in

the template is the full length to the rear of the seat box with a 90' fold and the curved part around the B post has a small upstand, the centre is raised and these items are handed.
this is with the rear part laid in, this isnt handed


this is how they sit with each other


part welded in

tacked in place

all secured together, if it was as they usually are then this panal would have continued to the seatbox but as its perfect then there is no point disturbing good original metal/sealer/joins

So now we move onto the next innocent looking seam

the inner arch stood a good poke about not that long ago but now its my pleasure to get into it properly and hack off/out the factory sealant

now weve all heard the expession gullwing as in gullwing doors well heres the original 'gullwing'

when i sliced through it it nipped the disc as the rust had swollen and was forcing the wing upwards.
so now we can see this

gonna be a nice interesting one to sort, in the picky but one above you can see the reinforcing plate for the jp , I have made and sent a few of these out , mine are a bit longer for several reasons anyhow as i cut it open tomoz i will show how and what its doing
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change of topic but no jam for breakfast toast so picked this in the dark and will make it now

[Plasticman]

yopu know in picassa i have rotated the two picks and in pee bucket i have them rotated yet they are wrong here , anyone know why or how i should do this
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[evilnoodle]

Who cares if the pics are upside down or back to front, or whatever...your work is awesome!

Nice rhubarb too