The GASWAGON (act III)

[lloydy]

All i can say is wow! attention to detail on stuff that won't even be seen is fantastic
like this

and this

Awesome!

[Plasticman]

how else would you do it though? just donk a great patch in there? this way we both know its right
mm

[lloydy]

Well, i didn't even know all that was behind there! Really nice to see it being done like that

[Plasticman]

well,wiring

tugged it all out and made the final cut

so i have now fed the awkward lot through to the cab

now where do you want the ecu and stuff fitting, at this stage it can be anywhere in here but i would like your advice as you know what will work best for you
this is back in the eng bay, i have rebound it with sefl amalg tape, its good enough for my subsea use so reckon it will work when you get the van in deeeeeep water

and

oh and the new hoses we ordered are spot on

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[lloydy]

Yep, hoses look good, nice and tidy in that corner now
Hhmm, ecu and relays... First thought is on the floor, between that fuse box and the cables coming up through the floor. Maybe with a little protective cover? How does that sound? I'm Open to suggestions

[Plasticman]

ok, i will mock it up there and see if it suits you then make it permanent
mm

[lloydy]

I think it will be the most effective use of space as it will just mean the floor raises up a inch or so. I am happy to make a false floor out of ply or something when the bed goes back in

[Plasticman]

Well,flat on the floor it is and i will make a removable cover for it..then you play with the devils material as i hate wood
so we remove the remnant of the nsr wing
here i have done a line down the extent of the centre(fridge panel) and lined the area that is the rear wing, spots drilled out

and

here its drilled out and i have releived it from the outside and the whole lot is now free and moving away from the C post,note the lip at top left,this is used especially when the wing is on a slider side, and they are all like it even if not in use, so it adds to the hassle of removal as it is also welded at the rear and a pig to get to

i have cut the strip to aid removal , here is the lower part behaving


leaving us with a slightly rusty lip

prying out

to get at this sod with the lip

and

ending up with

note that the holes through the centrepanel will be used to spot through this and the new arch ,it will wensure fixing tight to the outside of the seam, this will become clearer as it progresses

now the inner stiffeners, not had the pleasure of removing these before, be interesting to know which models they were fitted to etc

and why only 3 of the 5 apertures utilized them ?
anyway they are off

gives needed access to weld the outer wing to the inner arch

first time this has been looked through ,again it will assist me when im fitting the wing

remnants coming off, i dont bother drilling these, just snick either side with the cutting disc then use a pair of wood butchers nail pullers to grip either side of the spot ,fold the metal up and a quick twist and its off

just confirming vertical fit of the new wing to centre panel prior to popping a fastener in the top

same at the rear, though im holding it in place but same idea

so now its placed i have held it in place along the top

and am happy to mark the inner lip to affix the arch and such knowing its positioned right. there is the usual issue of the new panel being a touch too long but i will shorten it a bit as usual.
ran a disc over the lower center panel as im also marking out for the new lower part i will be making, loads of filler in it to hide the crap in the bottom and to cut a seam into it

rear of lower sill sits nice against the new part of the C post so happy with that as well,also the curved part of the sill sits nice to the bit i made too

mm

[ninja.turtle007]

Wow, this is flying along!

Great work.

[lloydy]

Stiffeners were on all the 16" vans. I don't think the 16" dokas/sikas got them..

[Plasticman]

Well, use full to know that.
well had the munchies and could only find this

with the disgusting strawberry cup, they were squeezed as i had the jar open in the car at night and the only way to avoid soft ones was to squeeze them, but desperation called and they are all gone
just to go back to a previous picky ,

note the swage, .. im lining up with the upper as this then works better in all other areas, but i cant think of any other way to do it,....yet
spotted these 2 bits in


out with the blaster this aft

and

amongst other areas
secret is to coat it within minutes

and

nsf arch now squared up blasted and coated

other side

we go back to the cooler , im working this rear corner together, no problems but thought i would show a couple more of it, im just working the best simplest way to mount it
underside of unit

fan mount plate

i have tried to remove the fan with cooler in situ and its easy enough so that stumbling block is out the way
fan mountings

closer

which brings us nearer to the fitting area
this was the main bad bit of this side inner arch, cut it out

and here we have the usual issue



good what you find,better look ?

and on the other side

close up

and so i lay the cooler in there and mark out and cut a rough hole andddddddddd


not pretty

so .having had a think about it, ive decided to cut the rest of the area with a cross in it of out the way back to a clean chassis leg, pretty much what i do most times as there is nearly always rot here,
so i think i will make a new base/platform incorporating a mount for the cooler that will also allow it to be withdrawn into the engine bay,
it will be sealed to the cooler and provide brackets for the under body duct and the mudflap, it will also needs a very simple but effective method of being held down, in this case i do not want and nuts.bolts.threads etc protruding trough the flooring as this will give grief min time to come,
so thats what im up to
mm

[lloydy]

Where is that bit where your pulling back the underseal like wallpaper? can't quite work it out. Have to say, don't think i'll ever tire of looking at that intercooler
Odd with the swage line.. pattern parts

[Plasticman]

well its the rear of the nsr wheel arch and your cooler is going to fit on the other side of it
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[300CE]

Great stuff Mike, it's like that rust plays a game of hide and seek, sneakily concealed behind that underseal! Bet you can't wait to get the old girl back Lloydy.

[Plasticman]

Well a strange package arrived

im expecting a couple of big ones but anyway
like pass the parcel this

ahh, the quality of this inner one

and inside we have a hens tooth

right back to reality
as ii said earlier im going to start from scratch in here as its easier, so first i make a plate and secure it so it cannot move, this aspect is very important,also note i have taped up the inlet ducts etc, never trust "objects" to keep out, also very very important when doing anything near heater ducts

because this is the other end and there is only a few mm's to play with

so this bit fits up to it and and now im happy i can proceed to hack the rubbish off

rubbish out, this is why i was so careful to locate this new plate in a replicable way, as i can use it to assist the correct positioning of the rest of the corner.

im busy making the fixtures for the cooler and its much easier with the new base plate on the bench, i will take a template of this so it will be an easy mod for subsequent coolers, even though the whole plate may not be required, its better to have and discard then to be found wanting..
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