The VOLTSWAGON

[Plasticman]

im on me f******* hols
mm

[Wychall]

Don't remember seeing the application in triplicate posted up here asking if you could take a break? Most inconsiderate!

[lloydy]

slacker!

[jamesandtheopenroad]

Holidays are for wimps.

[acw]

considering the volumes of information MM has posted on the site i feel he is due a holiday, short one mind you.

Andy

[ELVIS]

New pics please slacker!!

Quality metal porn as ever chap

[Plasticman]

Hmm, well ive unloaded and sorted after hols.and made a 15' steel flue for the ratburn so back to the van in the morning be glad of the rest...............
mm

[Plasticman]

Well, what was going to be the start of nice stuff got delayed as i had to extricate the cables down through the A post,not so easy on a dehler...nothing is.
you wanted picks of your dash ??


you will notice a vent missing
i need to get to the back of the dash assembly to find the cables that run down the A post, but being a dehler it aint so easy, dash is NOT coming out so we have a peek

this is through the vertical fwd vent as in pick above

i have removed the ductings etc and can just get a skinny hand in
here you should just be able to see the wires above the rear duct

i can grab these to pull through with a steel wire attatched to the other end
the cables for the rear screen wash etc run along the top of the gutter and down the A post and then behind the x member to the footwell. finally the wire from the door switch to courtesy light itself.

t'other end


so i now have 3 steel wires running to the correct place and no risk of them melting when i weld up this mess
no0w i had to get distracted by this plum crumble steeped in havana club


very tasty with thick custard made with added cream
now ih happy and know the wiring side will be safe ,i start by removing the front bit of gutter, i need to keep this part intact as much as possible to act as a pattern for the new item, i have cut through the top of the A post seam, this is now neede really as the gutter is not welded here but it does help freeing the bond

next comes drilling out the spots, no need to mess about with spot bits, just crack on with say a 3/16 then a 5/16 ish


and its off

here you can see the cut i made, i will simply reweld it to the gutter support area.

now to peel away the remnants


and this is the old bit laid back in place, it confirms that all is as it should be and so i can make this item before cutting too much more away. this way i will be able to use the new bit of gutter as a guide to remaking the adjoining parts,

and so this takes us to this stage

its basically made up of 6 external parts, we have 1 + 4 so need to make up the other 4,
number 4 is the part the gutter sits on and weld to, this runs down the length of the van and is in good enough order.
n 2 is the corner cap that ties the whole area together and it fits inside the A post and is factory brazed here, a 30mm hole will be made in the new part to accept the grommet for the cables.
then the new gutter is offered up and held in place.
next n5 is cut away and remade to match up to the gutter.
then n 3 is made and this sits on 5 and the roof in turn fits on this..
mm

[ZsZ]

I like that aftermarket AC console. Had some flyer about it somewhere.

[Plasticman]

well, im gratefull i didnt need to remove it all for access, the lower ac part is bolted to the main dash so that has to be removed as a unit
anyhows back to making bits.
started as needs by forming the front gutter section

nearer

cutting a tiny bit more out now that the gutter fits ok

infact off and out with the lot is the best solution

first trial fit of this part

lip added to rear and nearly there

happy it all lines up ok , hole made with Q max for grommet

err ??!! bit of thin air to fill here

welded up ,

so trial thge gutter back on and then start to make/add the next 2 missing parts. i have welded this piece to the inside of the A post, reason being its stronger and a lot easier, also if i was to braze this part I would then be forced to braze all the subsequent parts in the area, so i will weld and sacve the brazing for the final part and blend it into the aperature so it forms a good profile for the screen rubber to fit against
mm

[Cruz]

Looking at the roof pictures has got me thinking what could be lurking under my leisuredrive roof.......

[Plasticman]

hehe.van conv' roofs are no so bad to do as they westie/dehler style front ends, when you decide you need a full set of gutters you know where to get them
mm

[Cruz]

I know the anwer Mike but I'll ask it anyway in the vain hope that I am wrong but in order to weld the rear tall arches (arch up to slider rail) does all the interior need removing?

[pionte]

looking at these pictures scares the bejesus out of me.... my gutters are looking bad and I I try not to look at them.... give me a oily engine in pieces anyday of the week

[Plasticman]

sod your oily greasy muck and all those nasty mech parts......
but with regards to roofs, if they are gone then they will have to be done at some time, that or plan on the scrapping of your van

well you can remove the wing with the van intact as you know, and i think you answered your own question leaving aside the fire risk, how would you get to the rear of the seams to weld them, ok some folks end up glueing them on, if theyre happy with that then fine ,ive also seen so called dubworks type places and creative types places etc where they actually weld the seam on the outside and then grind and fill, i suppose ignorance is bliss.
anyhows if were talking like your own then fridge side is the one where it all has to come out that side as the join is awkward as you know, t'other side is only a bit of seating and such,
mm