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.