Outer leg welded in

Here's the outer dog leg welded in at both ends. I've also given the seams a lick of protective paint. Last night I welded in the inner arch which went in o.k. I was in a bit of a rush and some of the spot welds are not great. They bubbled up and one went through the outer skin. I didn't roll the van over to spot weld which I should have done as well. I'll tidy it up this evening and post a picture.

Dog leg started

Started putting in the dog leg this evening. I've put it in the same way as the other side. Pop rivets and weld to get it square up against the other panel. It looks good. There is a bit of distortion on the panel after I seam welded the outer sill so it needs a very thin skim of filler. That said, I'm very pleased with the way it sits. Need to weld in the front end and then the inner wheel arch will need shaped.

dog leg #2

Finished off the inner sill this evening and ground back the remaining welds that were sitting a bit proud. Then I moved on to the dog leg. I've been bothered with the size of gap on the drivers side door and this led me to think that the front end has popped out a little. There has been a bit of a dodgy repair on the drivers side floor at some point and it's likely that when this was done, the front end popped out. Anyways, there's a shot opposite of the gap before I started work on the door. I then cut out the repair that was made and welded in a piece of metal onto the base of the door pillar. I looped the strainer around this and onto the body roller and got it to take up a bit of tension. This pulled the frame in and allowed me to fiddle with the door to get it hanging right. I'm not 100% happy with it at the moment as there is a bit of tension on the hinges. I'll need to take a look at it and maybe take a bit of the metal off from the hinge to let it close a bit further. Anyway, that's fine tuning. Next step is to tidy up the piece of metal around the floor of the cab. I have a panel to go in. Then I'll start on the outer skin off the dog leg. It's a bit of a job getting it in but I out it up against the van tonight and the shape isn't too bad. As with the other one, it's a little out on the 45 degree slope but I pulled the other one in with a bit of pressure.

inner sill welded in

I've welded in the inner sill this evening and also welded the outer sill along the lower lip of the inner sill. It took a bit of persuading to get the outer sill lower portion square onto the inner sill but I'm very happy with the result. Turning cold again outside but keeping warm with the welding torch!

panel welding done

I've finished welding the panel in this evening. It is looking good. I'm pleased with it, particularly the seams on both ends. They have taken a bit of humouring but I've got a nice straight seam on the panel end and a good straight and flush seam for the dog leg to mount on to. Next jobs for this bit are the inner sill to weld in. I've already cut it and it's ready to be welded up. I need to drill a load of holes along the bottom so that I can weld it onto the outer sill. I'll then leave this bit and move forward to the dog leg. There's quite a bit of tidying up that needs to be done along this side including finishing welding in the rear arch but I want to get the big picture happy before I tidy up on all these little bits and pieces. Then it's finish the cab floor which I have a panel for, tidy up around the front valence where it meets the door pillar (fold the seam over) and then on to the next bit which will see a big change (the load bed and bulk head!). Really making some good progress now and hopefully with a burst over the next few weeks I'll not be far off going back to the sprayers and negotiating a quote. I'm getting ahead of myself again! (Forgot I've the heater tube to weld in and the gear linkage to sort out as well!).

Some more piccies of the outer sill off-side

Bottom inner sill

I folded the seam on the outer sill this evening and got a reasonable tight lip on it. These blocks of wood were made up by my dad to a template I provided. They are made of seriously hard wood. I was a bit over zealous with the panel hammer and the metal started to tear a bit. I put a bit of weld in just to keep it from spreading when I riveted it in. I'm still not sure how you are meant to put the whole thing together but I've ended up with a reasonable result for an amateur! If I was doing it again I'd not cut the spreader cuts so deep. As they started to migrate into the main panel. After riveting the seam, I tack welded the panel onto the top panel. It was a bit tight in places. The panel is a bit wobbly in places which means when you put a bit of weld in the whole panel distorts around the weld. It isn't that bad but it will need filling. I think I will make up a reinforcing brace for the back as well to stop it bending in and out. Next jobs are to finish the welding in of the panel and then tie it into the inner wheel arch. Then drop the inner sill in place, make up the B-post repair (couldn't decide whether to do this with or without the outer sill in place. Opted for the later as I wasn't sure what shape the panel was going to take up). I figure this bit will take me a couple of weeks yet to finish off. The race is on to get the dog leg done before the end of the year! Can it be done? I haven't ever set myself a deadline on this project but with child no. 3 on the way, time is increasingly getting tight. Just as well the crew cab sits 6! That reminds me. I need to also finish the seat belts in the rear.

Inner sill cut and ready to go on

Here's a picture of the work this evening. I had to cut a bit out of the sill and then weld some fresh metal back in at one end before I could get the rest lined up. The sill is a Gerson panel from musclebus. Nice panels to work with. If I do another resto., and Klassicfab survive the world down-turn, I'll use nothing but green panels. Having said that, I've long fancied a Karmann Beetle but Gerson only does split panels. Anyway, I'll probably not weld this panel in for now but fix up the outer sill first. reason being that I can't get at the left hand side of the sill to get a weld in at the seam. I plan on riveting the sandwich of two seams with a support inbetween. I'm going to double check that I can get the inner sill in and out whilst the outer sill is in place.

Inner arch finished

Here's a couple of snaps of the finished inner arch. I've a few pin holes still to weld up but it's largely finished. The next piece of the jigsaw is the inner sill. That shouldn't take too long to drop in but it hasn't been easy getting a straight line on the sill so I'll be taking a few measurements to make sure I get it just right. I also plan on running the sanding belt over the inner arch to take off the gunk and layers of crud then give it a lick of primer to keep the shiney new metal in tip top condition. It's crazy to think that it has already started reacting with the air to form iron oxide. It's a bit cold for throwing paint on though. -6C here last night with flurries of snow. More forecast for tomorrow.

inner wheel arch

Inner wheel arch all but welded in this evening. I've made a bit of a hash of the end so need to go back and make sure that it is welded in properly. Other than that, I'm quite happy. I put the lights off in the garage to make sure I didn't leave any holes. in the butt weld. I need to tidy it up now and then move on to the sill which needs a bit of work. After the sill it's on to the panel and then the dog leg. The last dog leg took ages to get right. I'm anticipating this one will be the same.

Making slow progress

Here's a picture of the work I've done over the past couple of nights. I've managed to get that tricky bit done that was causing me a headache. Now that it's in I've moved my attention to the front inner arch which needs fixing. The top hat section was completely shot and someone had just welded over it hoping it would go away. I've had to cut out the old panel and let in a new top hat section. It has taken me all night to cut out and grind down to a level that is workable. I'm figuring I'll just make up this front section as it's a lot cheaper than buying the piece off the shelf. That said, I'll need to buy some flooring sections I think as I've had to cut a fair bit out to get at this part.

I haven't given up!

Weather rotten and cold so I haven't ventured out into the garage. I need a stove I think to heat the place up! Anyway, here's a video from youtube...

The jigsaw starts here...

I'm not sure how all this will go back together..... I've cut out the old metal to give me a clue but no clue is forthcoming. I'm sure I can make it up but that said, I want to put it in right. There is quite a bit of work in this side yet. The sill needs replaced, the floor repair needs sorted, the top had under the floor ends need replaced and then the inner front wheel arch sorted. End of the year finish for this side is suddenly looking very optimistic...

Panel welded in

I welded in the vertical support panel and started on the outer sill last evening. It's coming on o.k. I'm quite pleased with the line. It's 100 times better than it was. I need to grind back this join and then do a bit of general tidying up before moving forward to the next sill.

jig saw

Final panel cut to fit. It's been a bit of a jigsaw this panel but not taken too long to fit. I've bought a vertical reinforcement panel to put behind this one so I can't do much more with this one until I get that through the post.

Inner Sill welded in

I welded in the inner sill this evening. I'm quite happy with the end result. Next step is to do the vertical support and then measure and cut the Gerson repair panel. I'm finding that I am getting a bit quicker with the work now that I've got a particular way of working.

My favourite Crewie of all time

The piccie speaks for itself!

inner sill

Spent a bit of time bending a new piece for the inner sill and a vertical support piece. The new sill will allow the panel to sill flush this time rather than sitting out at an angle. Next steps. Weld in sill, weld in vertical support, offer up Gerson panel, cut to fit then weld in. There's also a small repair required on the inner wheel arch but that's the last piece of the jigsaw before moving forward.

rear quarter panel

I welded in the first part of the rear quarter panel last night. It went in easily in the end. I've also cut out the botched sill repair. I'm going to make my own repair up for this bit with my new folding tool!

all ready to weld

Here's the panel ready to be welded in. I might have a run at it tonight. Just depends on whether I'm not too tired. The panel is looking not too bad. It has a very small bow in it still but I think I can fix this easily enough by puttins some spacers behind the inner arch. It's shaping up quite nice.

And I thought I had a job on my hands!

back to the side

I've been trying to figure out how best to fix up the side panel for the bus. I'm having to cut out quite a bit of the old metal but it is that high up a repair I need to weld the support strut along the back. That means cutting off the one that is currently on it and welding it onto the back. It's a bit of a jig saw. I took receipt of a Gerson long panel so that should be me with enough panels to finish. That piece of sill will need to come out. A botched repair if ever I've seen one! I had to do the other side sills as well as they were equally as dodgy.

Rear apron

I've been figuring out what to do with the rear apron of the van. There was a dodgy one that came with the bus originally but it had a bend in it to take a second tail pipe and it also looked like it had taken a bit of a knock at one point in it's long life. I've cut up the inards of a bay window apron and folded them to fit. I need to panel beat the split one as it has a few wrinkles in it. It should do the trick...

back to front

I've cleaned up the garage today as it was getting to be a bit of a tip. I also took the panel back to bare metal and that left a lot of filler dust on the floor! I also knocked a few dents out of the panel with the hammer and dollies. It's going to be a bit of a jigsaw once I've finished with it! It would be nice right enough to be offering up a complete panel but it'll have to be bits and pieces for now.

Cutting out the rear quarter panel

I had a bit of a run with the grinder this evening on the van. There was more filler than metal cut out so it will be good to get this panel in. Also took a bit off the bottom to see what the panel was like but typically, I reckon I'll need to replace it also. It's had a botched job already done on it. I got a fold put in the new panel as well. I'm not 100% happy with it as it isn't a tight bend but I'll get the hammer on it and sharpen it up. I'll not be at this for a few days now as I've a busy time at work.

Preparing the louvered panel

I spent a bit of the day today (between listening to the Olympics!) measuring up and cutting out the louvered panel. Rick from Schofields sourced this panel for me from the States. I was trying to get a Gerson panel but he ain't making them yet so I am going to have to make do with these bits. The panel I am replacing has taken a side on at some point and is in pretty bad shape. This one needs a bit of work. I need to bend a lip first at the corner end so that it will sit up against the corner panel. Then cut between the louvre and the fuel tank and weld along hoping that the heat wont contort the louvre which will already be pre-stressed. I'll take it slowly. Also got my Gerson dog leg through the post so all I am needing now is to think about how best to work up the other lower 6 inches between the louvered panel and the dog leg. That and the load bed and then I am there! Sounds quick when I type it but it will take me a bit I'm sure to get there.

Tank stripped and primed

I spent a bit of time today painting the floor under the tank after welding it in yesterday. I also stripped the tank today which took a bit of time. I took it back to bare metal and primed it with red oxide.

Drivers door and fuel tank

I've spent the day tinkering in the garage on the van. Today I drilled out the pins on the door hinges which a bit wobbly. I also put a couple of spacers behind the hinge to bring it out a little. The door gap is still a little bigger than I'd like but I may be able to pull in the door pillar a little yet. I also managed to get the bottom of the fuel tank sorted. I had nothing left over from the original parts as the floor was completely shot. A friend of mine gave me some metal from an old lawnmower and the profiled metal fitted perfectly. Just the right height to allow the rubber gasket to fit.

Before and After

Before

During

After

Dog Leg finally in

Well, here's the dog leg finally welded in. It took me ages to get to this point and I've decided to do the other side as well. Perhaps I wont be ready for Christmas afterall! I've also folded the front valence over the bottom apron and that looks nice and tidy now. I'm going to paint in some seam sealant there as I have done around the dog leg as I imagine it would be easy for eater to work its way up through the fold. Infact, I'm not surprised that these buses tend to go at the same places. The seams are ripe for water ingress.

drilling holes

Drilled holes today ready to weld in the dog leg. I also took the door off again and moved it around a bit to see if I could get a better shape on the angled part of the dog leg. It's as good as I can get it. A skim of filler up against the door will make it 100% flush.

beag air bheag (bit by bit)

I got a few moments this evening to offer up the inner arch. It is as nice to work with as the outer skin. I needed to shorten the front section a bit as it was a few millimetres long but after a bit of bending and mending it is sitting in nicely. Picture dosn't really do it justice. I need to weld it up and also mend a small patch in the bed floor as well. That shouldn't take too much effort. I can shape it up before I put in the inner skin. Another small step. I'm hoping to get this bit finished before I go off on holiday but that might be stretching it a bit. I don't want to rush it.

blueprint

Panels and Interior

My mind wandered today to looking at panels needed to finish the bus. I reckon I might need to do the nearside dog leg after closer inspection. That will also take me into tidying up the nearside inner arch as well. Also need a new rear bulkhead panel and possibly valance and engine lid. I stumbled on this picture of a crew cab today on another DC blog. I've decided the bus will be Dove Blue. The original and best!

Good progress

Life is an awful lot easier with good fitting panels. That's my biggest learning point of this restoration so far. I've offered up and riveted in Gerson's dog leg this morning and it fits very well after a bit of humouring (as my grandfather would say) to get it into place but its day and night compared to the Schofield panel (just needs welded in place now). I may well do the other side while I am at it. Front valence also finished and given a rough coat of paint to protect it from the elements. It came out o.k. in the end. Not my best job and not my worst. I'm learning as I go with this and I've loads of respect for those beautiful restos I see on the SSVC website. Anyway, a light skim of filler will shape it up nicely. I feel I am turning the corner now. It wont be that long before I've finished the bottom half. I need to take a good look at the other side. It has been repaired before but it might need cut out and redone. We'll need to wait and see. I don't want to compromise now that I have got this far.

Gerson's funky green panels

After 6 months wait, Gerson's panels arrived today and they look fantastic. I've offered the dogleg up to the bottom of the door and it is a perfect match. These panels came all the way from Columbia. Isn't that just crazy?! The dog leg in particular is a fantastic fit but the small panels butting onto the bulk head are a real treasure to have. Gerson is the only one making these panels and I'm pretty lucky to get my hands on a set. Spent a bit of time this evening measuring up and straightening out the front lower valance. It is coming in quite nice. It still needs a bit of lining up but we are getting somewhere with it now. I need to shift the panel over a few millimetres and then tightening it up with the panel holds. It is looking quite good but still needs a bit of humouring before it is ready for the welding torch. She's beginning to take shape now. I'm undecided on the nearside dogled. I could attack it too but might try and see if I can straighten it out. There is a bend in it at present but from memory the door profile fitted quite well against the dog leg. Anyways, I've got my work cut out with the valance and the driver side dog leg for the time being!