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“ it was a momentous moment “ The crowds had come from miles...well my neighbour Simon had popped over. The moment had come to reunite the lower cab with the chassis!! You could feel th

Evening everyone    Well....the time had come to see if everything fitted 🤔 and..........it did!! , well almost......sort of.....kind of.....a few alterations later and a certain amount

It’s been a busy few days, I’ve used every scrap of spare time in a big push to finish the back panel 🎉😬 22 separate pieces of sheet steel folded, joggled, curved and welded in....I must need my

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Good job,

When your in the middle of it all and the pile of rusted cut offs  is large than whats left it can be a bit overwhelming  but full marks to you for persevering,  the result is worth all the effort.

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7 hours ago, earlymb said:

Btw, did you consider spraying on metal for some of the repairs? And using metal filler instead of bondo?

 Bonda is the make of red oxide paint with zinc, it’s been recommended by another forum member and I am very pleased with the coverage, the filler is standard car body filler as it’s economical rather than a metal repair filler , as for spray on metal that’s something I’ve come across before, is it something that can be done in a domestic garage environment?

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8 hours ago, Pete Ashby said:

When your in the middle of it all and the pile of rusted cut offs  is large than whats left it can be a bit overwhelming 

The pile is only getting bigger🤨 I will hopefully be starting the roof next week so best order another sheet of steel 😁

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20 minutes ago, 67burwood said:

 Bonda is the make of red oxide paint with zinc, it’s been recommended by another forum member and I am very pleased with the coverage, the filler is standard car body filler as it’s economical rather than a metal repair filler , as for spray on metal that’s something I’ve come across before, is it something that can be done in a domestic garage environment?

The metal repair filler has the advantage of not soaking up moisture and bonds better to the metal than normal body filler, but it is more expensive indeed.

As for the metal spraying, I don't think that is something you can do yourself as it seems to require quite special tools... But there are a few vids on youtube about the process.

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27 minutes ago, earlymb said:

As for the metal spraying, I don't think that is something you can do yourself as it seems to require quite special tools... But there are a few vids on youtube about the process.

Thanks for the info, I’ll have a look on YouTube to check it out.

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Just a quick update 

Gave the garage a good clear out ready for the next step 🙄 didn’t want to be tripping over any rusty off cuts. 
 

The roof section is obviously worse than I thought, loads of filler and old repairs.

 

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Believe it or not the top looks better than the underside 😩

 

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Same problem as before, all the rusted out areas have been previously repaired so I have no original patterns to follow, hopefully the previous restorer repaired like for like. 
 

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Wish me luck!! 🤨

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So.........here we go again 🤨🤔😭😬

I swear I spend more time just staring at it trying to work out were to start and how I am going to do it !! 
But... I now have a plan and it’s full steam ahead. 

Stripped the remains of the gutters and upper door shuts ( not a single cutting disc needed ! Result )

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Started at the rear with 3 sections of repair panels 

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Next up was the corners, slightly tricker to do so I’ve skipped a few pictures 

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Worked my way down the side, again a lot of fettling needed to accommodate the shape and gradual curve. 
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Turned it over just to check everything was going to plan.

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Now.....what idiot thought this was a good idea!! 🙄

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But it worked, I needed to make sure the new corners lined up with the rebuilt back section. Good job I checked!! the previous old repairs had a different line to the new one’s. 
 

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New curve formed and we’re away, it’s all very professional, honest😬

 

It was all going to well......then disaster.....I was not a happy bunny....

I decided to join up the spot welds on the 3 rear sections of repair panels, I welded inch at a time, moved from one section to another and had a damp rag to keep it cool....but....all the effort put in to keeping it lined up went out the window 😡 it’s no longer straight!! 

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it’s now clamped up in a bid to straighten it, I am not holding my breath and a selection of hammers are on standby.

 

 

 

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There is no way that you could have done that without distortion but you now have good metal to beat into submission. This is one of those jobs that will suddenly come right and you will wonder what you were scared of (100 man hours later). Just keep going !

David

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10 hours ago, rog8811 said:

You may end up having to use a bit of heat for stress relief but going by what you have done so far I don't doubt you will sort it.

Had a go at heating it up but as I only have my plumbers torch it didn’t really work, the area is just to big to equally heat up at the same time, if anything I think I made it worse 🙄 

 

David’s suggestion of beating it into submission is most likely the route I will take, failing that I will just tell everyone it ran over a land mine!!

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I agree, now there is new metal there it at least gives you something to work with.

A bit of careful panel beating and the result could be ideal. From experience though its just something that may take bloody ages .

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I feel your pain but I don't think that you would ever have had total success at keeping it straight, no matter what you did. Distortion due to heat is always a problem and I have tried most things but in the end you have to live with it. I assume that the roof bolts on to the rear panel, so if your holes are drilled with reference to either the inner or outer edge rather than in a straight line, will it not straighten itself to an extent when bolted in place?

keep smiling,

 

Jon

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12 minutes ago, johann morris said:

I assume that the roof bolts on to the rear panel, so if your holes are drilled with reference to either the inner or outer edge rather than in a straight line, will it not straighten itself to an extent when bolted in place?

Well..... I am not actually sure what the original construction was as it had previously been patched up/repaired many many times!!
I decided that I was going to build it as separate sections, ie back panel, roof section and windscreen just to make it easier to manoeuvre on my own, it was previously all held together with braised welding and fresh air.
I still have an ace up my sleeve to hopefully save the day, I have to fit gutter around the outside edge, this will also double up as the internal frame that will bolt to the back section, it should  ( if I don’t cock it up ) form a straight line so visually it should look ok......( .if you close your eyes a bit and don’t look up )  😬

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You always knew this bit would be a challenge (being polite here) But so far it looks seriously impressive.  As for the heat distortion, you think the curved bits are going to be the most difficult to get the shape right, but in reality it is keeping the straight bits straight that is the real problem.

As mentioned earlier top marks for the bottle and determination to tackle it, it'll look good when it's done  

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