Offered up the doors today and at first it all seamed ok -

Doggy Doors by Duke of Boots1966, on Flickr

....but then some issues started to raise their heads. I am sure this should close further....

Doggy Doors by Duke of Boots1966, on Flickr

this seems ok

Doggy Doors by Duke of Boots1966, on Flickr

ah rats, a good inch at the bottom which makes me think the door bottom is warped which given the crap welding and repairs that are down there is a distinct possibility.

Doggy Doors by Duke of Boots1966, on Flickr

and the off-side is not much better.

Double door trouble by Duke of Boots1966, on Flickr

Double door trouble by Duke of Boots1966, on Flickr

Double door trouble by Duke of Boots1966, on Flickr

Looked online but CandC have stopped doing the bottom section frame repair and their correct fit replacement door is for 55-60 so has the wrong handle pressing. hmmmmmm

Nothing a bit of filler can't sort out.....

All straight and level by Duke of Boots1966, on Flickr

Cut the dash out of the bus today and got to the heater tubes. Hmmm some work required.

Dash it by Duke of Boots1966, on Flickr

Dash it by Duke of Boots1966, on Flickr

Dash it by Duke of Boots1966, on Flickr

Dash it by Duke of Boots1966, on Flickr

Dash it by Duke of Boots1966, on Flickr

Dash it by Duke of Boots1966, on Flickr

Started tackling the dash repairs today. could be a long job.

Dash 2 by Duke of Boots1966, on Flickr

Not much to weld to so out it comes

Dash 2 by Duke of Boots1966, on Flickr

Dash 2 by Duke of Boots1966, on Flickr

Hole gone

Fast 3 by Duke of Boots1966, on Flickr

There is something not quite right with my parcel shelf, answers on a postcard.........

Mishmash by Duke of Boots1966, on Flickr

I resigned myself to resurrecting my worm ridden air box but purists should look away now!

Cheese by Duke of Boots1966, on Flickr

Purists look away now! by Duke of Boots1966, on Flickr

Purists look away now! by Duke of Boots1966, on Flickr

Purists look away now! by Duke of Boots1966, on Flickr

Loving the previous parcel shelf ‘repair’ - the pressings in the plate nearly match the originals

The left hand side is fat lip pressing and the right hand side is thin lip pressing so it can be used on all years of bus

Spent the day repairing the sidewall of my cab air box today. Tough finding any sort of metal to weld to and add the mig on such a low amperage it felt like soldering

Before -

Less ventilation more metal by Duke of Boots1966, on Flickr

After -

More metal by Duke of Boots1966, on Flickr

More metal by Duke of Boots1966, on Flickr

Got the steering box and associated U/J's in today and fabricated the morning brackets.

Left and right stuff by Duke of Boots1966, on Flickr

Left and right stuff by Duke of Boots1966, on Flickr

Looking back towards the Porsche 964 steering rack

Left and right stuff by Duke of Boots1966, on Flickr

Steering box on the right bidding behind its mounting bracket

Left and right stuff by Duke of Boots1966, on Flickr

If you ever have to fit a top bearing then the order is

bearing, split washer, spring and not like this!

Left and right stuff by Duke of Boots1966, on Flickr

The chassis having its final prep before heading of for shot blasting and weld through primer. Hopefully the last time it is upside down.

On its head by Duke of Boots1966, on Flickr

Today was all about fixing the cab door locking mechanism with a clothes peg.....

Original looking system with return spring for the latch intact -

Doors and Stuff by Duke of Boots1966, on Flickr

The clothes pegs who may provide the answer -

Doors and Stuff by Duke of Boots1966, on Flickr

The cut down clothes peg spring -

Doors and Stuff by Duke of Boots1966, on Flickr

and in situ plus a repair to the retaining rivet -

Doors and Stuff by Duke of Boots1966, on Flickr

Cargo door fixing day. Trying to make 2 good doors out of 4.

Off with the old -

Doors and Stuff by Duke of Boots1966, on Flickr


On with the new skin -

Doors and Stuff by Duke of Boots1966, on Flickr

And a repair to the bottom frame -

Doors and Stuff by Duke of Boots1966, on Flickr

Not so 'perfect fit' repair panels (again!) -

Doors and Stuff by Duke of Boots1966, on Flickr

Cut out the original window aperture -

Doors and Stuff by Duke of Boots1966, on Flickr

Pulling out a bashed in bump stop with a metal bar, 2 nuts and a bolt -

Doors and Stuff by Duke of Boots1966, on Flickr

Doors and Stuff by Duke of Boots1966, on Flickr

Doors and Stuff by Duke of Boots1966, on Flickr

Donor window tacked in place -

Doors and Stuff by Duke of Boots1966, on Flickr

Doors and Stuff by Duke of Boots1966, on Flickr

The chassis waiting for its primer having been shot blasted

Chassis at spray shop by Duke of Boots1966, on Flickr

So I was mildly surprised to find that the correct fit A pillar does not have the door stop fitted into it so there is no other option than to cut a new post and retro fit the old piece. Given that when they came from the factory the door stay was weld into the A frame and sandwiched between the 2 parts then it would have made sense to do this with repro parts but rant over.

Sooooooooooo.....

Cutting a new post

Perfect (ish) fit by Duke of Boots1966, on Flickr

Fitting the old door stay

Perfect (ish) fit by Duke of Boots1966, on Flickr

Perfect (ish) fit by Duke of Boots1966, on Flickr

Cutting the inside of the A frame and welding in the reinforcing leg. Originally it was sandwiched between the 2 parts that make up the A frame but I bent the leg so it would pop out the cut i made and could be butt welded.

Perfect (ish) fit by Duke of Boots1966, on Flickr

and making good -

Perfect (ish) fit by Duke of Boots1966, on Flickr

Perfect (ish) fit by Duke of Boots1966, on Flickr

And fitting the door to check alignment (doors don't come with the door stay hole either

Perfect (ish) fit by Duke of Boots1966, on Flickr

Perfect (ish) fit by Duke of Boots1966, on Flickr

Perfect (ish) fit by Duke of Boots1966, on Flickr

Perfect (ish) fit by Duke of Boots1966, on Flickr

Perfect (ish) fit by Duke of Boots1966, on Flickr