Looking good Glyn You took me on that last bend you are on the home straight now!!

Thanks guys for all your input and remarks it's been a long time comming.

Been putting all the wiring connections to the engine and lights today, had a few issues but working as they should now, had to make up a few earth wires for the front and rears lights, and re-route a few loose wires to tidy up the look from the new fuse block.

Decided to paint the headlight housing and fit up the new internals only to find we have lost one of the rubber seals, the one that fits between the glass and chrome rim, also been looking for someone who sells stainless steel screws for the headlight adjusters, putting rusty screws on new rims just don't look good.

yay

shinny bits going on

mmmmmmmmmm

Mark

You're doing a cracking job there.

You'll be a proud driver soon when you're able to tell people you've done all the work yourself.

Show us some more pics of the servo install when you get that far, I'd be interested to see where you position it.


Nige

Yep will do a full install on the servo, trying to get it fitted before our trip to Stanford if possible, been rather busy with the doors this week, got the repair panels from Schofields and took some time over making them fit, as you can see they are a little rusty.




The difficult part was trying to get the inner bottom section to close, as they now have 3 raised sections on the return for drain channels, the door wouldn't close at the bottom with them in.







And then finally into painting the inner sides yesterday, along with the upper part of the door in surround.

Had quite a busy week getting all the doors done, paint, flatted and buffed, and today fitted back on the van, had a few issues with some of the old paint reacting with the new stuff so some doors had to be taken back to bare metal.


Decided to invest in a new tube of stopper to try and fill all the minor imperfections in the steel before priming them again, MIPA is a fine filler paste that you apply to low spots and scratches, takes a day to go off but then can be wet sanded to give a smooth finish.


Tried the front bumper back on the van only to find that the bumper side mounts didn't line up, had to cut a section out and weld back in place to make it fit.


Pushed it out of the garage again to allow space to refit the doors and get to the interior once again, looks quite good in the daylight.



Started to put some insulation behind the panels this time, might be warmer and quieter than before, used the silver foam sheet, then loft insulation fibre (itchy stuff) before putting the old panels back in place, these will do for now as we will be renewing the interior later in the year when funds allow.






Just bolted in the rock-n-roll bed seat in it's old position as we are running out of time to get it all done for it's first outing.

Had a mad couple of weeks at work but still had a few hours in the garage to put the cab windows together, but first had to repair the frames at the front, weld a thread onto the quarter light frames as this had snapped off when getting them out.

Finally had all the parts together for the refit, Just kampers do a good kit for the sliding windows so used these, they needed a little trimming to fit.







Used a couple of simple rivets to hold in the catch and frame, along with the new wind deflectors in the quarter light frames should see them all fitted tomorrow.

Great update


not to long to go now





Mark

Finally got the frames in and a weather proof van, the new seals look and feel great, all apart from the one around the top of the frame, the door closed without slamming when they were missing, but now there in it's back to not closing without force.


Also got the bumpers fitted but managed to scratch the paint, it's strange how you can fit things up and they fit with no problem and once it's painted it's a pain to get back on.


Now ready for the MOT or we thought, while adjusting the handbrake cable it snapped, a quick call to GSF and they had one in stock, managed to get it collected while I stripped off the old one only for it to break on the outer alongside the rear torsion bar mount, what a pain that was to get out, the new one was well greased up before fitting and we now have a good working cable.

Took the van for it's MOT and it passed, with just one loose brake pipe to clip up that was an easy fix, while it was in the MOT station we had a supprise that I didn't want to deal with, oil leaking from the engine pulley, that must have been from the accident as the old one was really badly damaged in the crash, looking back at my earlier posts I can see why.

After taking off the pulley I can see a small rutt in the case thats allowing oil to pass through, so looks like another engine rebuild is on the cards if we want to make the show on time.

Finally made it, all back together and packed for Victoria farm, the engine oil leak is managable as the hole has a temporary fix and should last a week or two, while I rebuild another 1776 engine again.
We made it to the show at Stanford Hall and will also be attempting to attend the Apex festival if all goes to plan.

Looks great, congratulations!

On our latest trip the rear wheel locked up, expecting the worst (falied gearbox) as the other rear wheel was driving, we jacked up the rear and tried to get the hub off, backed off the adjuster and still not able to get it off, locked solid.

AA were called and we tried again, brought out his big hammer to tap off the hub, and this is what we found inside.


The brake linings had come away from the steel mountings and wedged against the drum, this locked the rear wheel and caused the problem, the quick fix was to clamp off the rear brake line so we were still mobile, we replaced the shoes later and adjuster everything up to have working brakes again.

Something to remember if it ever happens to you.

Just started to fit up the servo kit we got from Jim VW on here, looking at getting the servo unit mounted under the floor between the seats or to one side nearest the N/S, with all the cables, gear linkage and the front beam sharing the limited space theres not much room, the mount looks solid and should bolt through the floor with no problems, it's just finding the right place to put it, also looks like allmost all the brake lines will have to be redone and a couple of extras made up.

Once we had the van on the car ramps we could see a couple of problems with the planned mounting position, it was going to be difficult to drill through the floor and be able to get the bracket bolted up, it must be something to do with our van being a walkthrough and RHD, but after a little bit of head scratching we decided to add a small amount of square tube to the mount.

This gave us more room to get to the brake pipe outlets and gave us room to get to the bolts, it lowered the servo unit enough to still give clearance so nothing touches, once securely mounted we started to plan the route for the additional brake pipes.

The master cylinder pipes were mocked up and then made by a local motor factor, using the correct fittings supplied in the kit, the vaccum hose was attached and routed through the chassis and along the rail sides.

A couple of options for blanking off the spare master cylinder outlet, make one up from a brake pipe fitting, insert a bolt and weld in place, or fill another brake light switch, this was our option as we had a spare one.

At the enging end we had a manifold bend with a servo outlet pipe already in place, this was from a bay van we had in the past so was an easy fit, we routed the pipe over the gearbox and drilled a hole in the engine bay to route it through, once fitted we started the engine and checked for leaks.

We have yet to test it out and bleed the system but will post up the result soon.