1986 syncro Caravelle twin slider

[silverbullet]

Things are moving forward in Gary's capable hands

Sent from my S60 using Tapatalk

[bluebus1987]

Got off fairly lightly on the oxide front then!

[silverbullet]

Not too bad for an early syncro bus that spent its first 10 years on salty roads around Banbury.
Usual story of front valance, cab steps, B posts, outer sills, sliding door bottoms (both) and a nasty cheap nearside rear wing that had to go. In the event both rear wings have been cut out up to the waistline.
I had already done the rear swingarm mounts and heavy gauge front chassis leg repairs (a typical syncro fail point) then I realized that I needed a professional to take over the lighter gauge panel work!

Sent from my S60 using Tapatalk

[silverbullet]

Nearside is coming together nicely in Gary's skilled hands


Sent from my S60 using Tapatalk

[silverbullet]

Lovely crisp wheel arch now fitted, but an unexpected nearside front repair needed to a rotten and twisted crash reinforcement buttress piece...

Sent from my S60 using Tapatalk

[silverbullet]

Just look at that door shut and the crisp swage lines

Sent from my S60 using Tapatalk

[silverbullet]

The other side is now looking a lot happier too

Sent from my S60 using Tapatalk

[silverbullet]

PS if you were a bit puzzled by the previous sill pics, the syncro has received integral rock-slider sills made from paired 40x40x3 SHS steel tube, along with some other sneaky mods to beef up the shell

Sent from my S60 using Tapatalk

[silverbullet]

Extensive work around the nearside rear corner, where a Klokkers panel had been fitted by a previous owner...
All datum faces and reference points were spoiled or missing as a result, so Gary had to cut back quite hard before the lower C post could be replaced.

Sent from my S60 using Tapatalk

[silverbullet]

Forgot to share: the 2wd filler aperture is gone, LH "C" post now has a lower half again and the corresponding rear wing assembly (not a Klokkers one-piece affair) has been offered up a few times...

Sent from my S60 using Tapatalk

[silverbullet]

More lovely detail work from Gary before the wing goes on, but we're not quite done under here just yet

Sent from my S60 using Tapatalk

[bluebus1987]

Might be a silly question, but how does he weld the top half of the rear vertical seam?

[silverbullet]

I have no idea, but thats why he's the professional restorer and not me!

Sent from my S60 using Tapatalk

[philmcC]

Gary is doing a fantastic job. It all looks terrific.philmcC

[silverbullet]

Might be a silly question, but how does he weld the top half of the rear vertical seam?

Come to think of it, IF I was doing that panel replacement, I'd get it all lined up, tack the vertical seam where I could get access i.e.via the triangular holes in the inner structure, then spring the panel outward just enough to get in and plug weld it up the hidden flange, then bring the panel back in (thereby adding a little tension, no bad thing) before tacking the externally accessible seams.