Mk 5 Minibus Project

[Big_Andy]

Well, I've decided to start my own project with the family minibus, and record it here for you all, and to remind me of the jobs I need to do.. It's currently residing in my mate's garden about a mile away, and family has been getting in the way of me working on her until today. First some details from Etis.

Primary Features
Build Date: 09.05.1997
Vehicle Line: Transit 95
Cab Style: Bus (M2)
Series: 130
Engine: Diesel 2.5 (76PS)
Transmission: 5-Speed Manual Transmission - MT75
Drive: RHD RWD
Axle Ratio: 4.63
Emission: 95 EEC Light Duty Truck
Territory: (+)"IRL"
Paint: Diamond White 73
Interior Fabric: Windrush G-C

So, my plans? Well, firstly to replace the broken engine from 20 months ago, get van through MOT and back driving. Then a few changes to improve the van for it's purpose: carrying the family around and taking us to re-enactments with all our gear.

1/ Increased soundproofing.
2/ Board out rear half of van (seats already removed)
3/ TBA

Forgot to take the digital camera over today, so will up some pics when I get them.

[Big_Andy]

So, got over to do a little bit on the van tonight, though I had to take the 3 y.o. daughter along with me, so work was a little limited. But at least I took the camera over to take a few pics for all you voyeurs on here.






and how she currently looks at the front


Tonight I got the steering pump, alternator, fuel filter and gear lever removed and the engine mount top nuts loosened. I'm hoping to get down on Friday to remove the starter motor, prop bolts and the gearbox cross-member. I'll rent an engine hoist and trolley jack soon (money tightness at the moment) to get old engine out, then it's clean, de-rust, and paint engine bay, add extra sound proofing, then install the new engine/gearbox with new clutch. Once I've got the engine running,I'll have to free the brakes up and give her the once over in preparation for gaining an MOT. So, a bit to go yet on top of everything else that happens in my life.

I am debating changing the colour of the bus to blue (or possibly black) but it would be a hand paint job, as I can't afford to pay to get it sprayed. Am I right in thinking that Nadjenka has hand painted hers with Rustoleum? If so, andshe reads this post, how much have you used so far, and how did you apply it? I was told years ago that I could spray my rally car using regular house gloss by thinning it 50/50 with thinners and then heating it to thin out further before using standard spray equipment. Anybody heard of this?

Anyway,lots of thoughts for the future months. I'll just be glad to get her running again. Will post more as I get things done.

[not-a-jappa]

You guys amaze me.

We tend to market ourselves as ingenuity personified, worldbeaters armed only with No8 fencing wire and a length of baler twine.
The first priority for anyone getting into "projects" tho is a bloody great shed filled with lots of stuff to contemplate, a powerful stereo, and a fridge for the beers.

Looking at the photos it looks like most of you jokers are doing it, and doing it well, in the backyard or the driveway with no shelter and even less gear

You got a choice I reckon, keep it up, yer keeping the spirit of Henry Ford alive or emigrate, and we'll see what you can do with a proper shed and an acre or two for the spares.

[Nadjenka]

Oh, you need to tell us what kind of seed have you planted in that garden to grow such a clean transit from it Very nice

As for the Rustoleum - I'm still playing with it. Initially I bought the standard Rustoleum Combi Color to be painted with roller and brush. It does cover really nicely, although you can absolutely tell it wasn't pro job (but I would definitely put that down as lack of skill on my account ). I found it great for complete color change. Few things I learnt - it really IS important to prepare the surface/panels properly. The paint needs to be thinned, and it gets thicker even in the tray - so keep thinning reasonably, otherwise it leaves "orange skin". If thinned correctly - you will see the paint smoothing itself in front of your eyes when you're painting I spent about 2.5L to paint the whole van with one coat (including roof), but in my opinion - one coat isn't enough. There is a "top coat" version of Combicolor too, but I haven't tried it, so can't tell what is the difference.

My second Rustoleum test was done with spray cans. It's called Rustoleum Hard Hat and I wanted to try it because I wanted to see what difference does it make when you spray the paint, rather than roll. And I have to say - the result is very different and looks surprisingly good BUT - this way of doing it DOES require much more elbow grease! I will make you detailed picture of the part of my bonnet where Andyg showed me how to flatten it to perfection and then used some polishing compounds and vax - it does look pro. But when I was trying to do rest of the bonnet, my arms almost fell off I used 6 cans to do one coat all around the van (thin one tho) excluding the roof. I recon I'd need further 6-8 cans to finish the job with two (on some places three) coats. Plus side of this method is that the paint IS dry after only 15-20 minutes, ready to be flattened and receive second coat. It's more expensive though... And - any rust would have to be treated and primed with rust primer first. This primer is definitely the end of primer tests for me, I absolutely love the way it covers and literally sinks into the metal, rather than creating just a coat of paint on top of the panel. I will have to see after couple of years if it really does the job, but so far - I'm impressed. It doesn't compare with primers I had from Halfrauds .

I have yet to try Rustoleum with air compressor and spray gun to see the difference there bear in mind - this is the very first time I'm doing anything like this, so can't tell if I'm doing it right. I will have to try the "proper way" with the air compressor, but if I'm unable to do that, out of the two options above I will go with the aerosol paint when my other van is due for a respray. And if my arms won't fall off after that, I'll just buy a pipe, can of spinach and

[matthew2riches]

Oh, you need to tell us what kind of seed have you planted in that garden to grow such a clean transit from it Very nice

As for the Rustoleum - I'm still playing with it. Initially I bought the standard Rustoleum Combi Color to be painted with roller and brush. It does cover really nicely, although you can absolutely tell it wasn't pro job (but I would definitely put that down as lack of skill on my account ). I found it great for complete color change. Few things I learnt - it really IS important to prepare the surface/panels properly. The paint needs to be thinned, and it gets thicker even in the tray - so keep thinning reasonably, otherwise it leaves "orange skin". If thinned correctly - you will see the paint smoothing itself in front of your eyes when you're painting I spent about 2.5L to paint the whole van with one coat (including roof), but in my opinion - one coat isn't enough. There is a "top coat" version of Combicolor too, but I haven't tried it, so can't tell what is the difference.

My second Rustoleum test was done with spray cans. It's called Rustoleum Hard Hat and I wanted to try it because I wanted to see what difference does it make when you spray the paint, rather than roll. And I have to say - the result is very different and looks surprisingly good BUT - this way of doing it DOES require much more elbow grease! I will make you detailed picture of the part of my bonnet where Andyg showed me how to flatten it to perfection and then used some polishing compounds and vax - it does look pro. But when I was trying to do rest of the bonnet, my arms almost fell off I used 6 cans to do one coat all around the van (thin one tho) excluding the roof. I recon I'd need further 6-8 cans to finish the job with two (on some places three) coats. Plus side of this method is that the paint IS dry after only 15-20 minutes, ready to be flattened and receive second coat. It's more expensive though... And - any rust would have to be treated and primed with rust primer first. This primer is definitely the end of primer tests for me, I absolutely love the way it covers and literally sinks into the metal, rather than creating just a coat of paint on top of the panel. I will have to see after couple of years if it really does the job, but so far - I'm impressed. It doesn't compare with primers I had from Halfrauds .

I have yet to try Rustoleum with air compressor and spray gun to see the difference there bear in mind - this is the very first time I'm doing anything like this, so can't tell if I'm doing it right. I will have to try the "proper way" with the air compressor, but if I'm unable to do that, out of the two options above I will go with the aerosol paint when my other van is due for a respray. And if my arms won't fall off after that, I'll just buy a pipe, can of spinach and

Nad!!! I'm interested about this new van of yours You must make a post with pics of it immediately

[Big_Andy]

Well, don't know what to say or do now. Feeling really low after just 4 hours sleep and getting a phone call from my mate at 7:45 this morning to say that the rear doors and bonnet have been stolen overnight. After the break in a fortnight ago, and now this, I really don't know what to do. We don't have a lot of money, and are going over to Northern Ireland soon so I've just had to lay money out on flights. What next? I keep going, replace the doors and bonnet and get the engine in and they steal the van while I get it ready for an MOT or while I'm saving for the tax and insurance deposit? I'm so gutted at the moment, I just feel like throwing in the towel and just sell it for scrap/parts. Could just be the tiredness and news affecting my depression, but I know I can't do anything for a couple of weeks or so.

[madbri]

barstards i hate them! only you can no what to do 4 the best jesus i feel 4 you. u never no might b some1 0n here got the bits you need cheep/free lets hope so. if i had any doors/bonnet ud have them chin up and dont let it ruin ure holiday

[matthew2riches]

Stolen the back doors and bonnet

What the f***?!!?!? a***holes

This happened to a mate of mine. Some c*** stole the sliding door off this Bedford Rascal in front of his house one night. He didn't notice till he got in it do drive it, walked straight past a line of bolts on the pavement too

Seriously though... Can you find a more secure place for your bus? Good parts are getting harder to find!

Anyway, chin-up and keep going

[Nadjenka]

Andy don't give up!

I hope the thieving b@$&#rd just caught his d#&k into a zipper this morning

I have a spare bonnet kicking about, if there is a good soul (or couple of them) who could get it closer to you!

[madbri]

Andy don't give up!

I hope the thieving b@$&#rd just caught his d#&k into a zipper this morning

I have a spare bonnet kicking about, if there is a good soul (or couple of them) who could get it closer to you!

nice 1 see theres some brill people on here keep going

[Big_Andy]

Well, Police have been around to take details, and he's never heard anything like it. He agrees that it was possibly a theft to order. I'll just have to wait and see if they find out anything.

Nadjenka, thanks for the offer. Even if I paid £20 to get it couriered up here, it'd be cheaper than some of the prices I've seen on eBay today. Time to ring local breakers tomorrow and see what they have in stock. I need to get over there tonight to see what else is missing from the back, and empty it of everything I can.

[rob-xcar]

Really sorry to read that this has happened , hope the little fecker gets caught either by the old bill or some one you know .

I do have a pair of front doors, side door and bonnet as well as a pair of almost new rear doors(with windows) from my old mk3 swb all painted imperial blue but in need of tlc .

[Big_Andy]

Well, finally got over to visit the van as the re-enactment group packed for our annual trip to Northern Ireland. It's strange. Up until I actually saw that gaping hole in the back of the van, part of me still didn't believe this had happened. They've left the hinges on the van, and although they removed the catches that hold the doors open, they left them behind, along with most of the bolts. Strangely, as we were packing the rental van, to lads passed in a car (back street) and asked if I was selling the van. My son swears the driver was smirking as they left, and I'm sure the passenger who asked if I was selling was the same person who called at the house just before we moved asking if I was selling. So very suspicious.

As for the van, well as long as nothing else goes missing while we're away, after a very nice offer from Nada, I intend to press ahead. I'm considering buying the alarm system early that I'm planning on installing, fit it with a battery hidden inside the van, and keep the alarm active whilst I'm not there, even if I have to buy a new battery and charge one while the other looks after the alarm. A secure lock up is just not available, so I guess this is the alternative for me. I'm also giving serious thought to perspex/lexan windows like the police use, and plating the rear window holes as I planned two years ago when I bought the van (turning it into more like a crew bus rather than a minibus).

Well, time to get some sleep as I have a 10 hour drive (including 2 hour ferry crossing) then upwards of 5 hours setting up the camping before I can turn in again. I'll catch up again in a little bit, once things get moving again.

[Big_Andy]

Well, I'm back. After a 2 year hiatus, I'm starting to get work done on the van. I took the bull by the horns and rented an engine hoist on Thursday. I spent 2 hours on Friday evening (kids last day at school so needed to be around) with eldest son moving front of van sideways 1 foot to give better access for the engine hoist. Engine came out easily on Saturday afternoon, some engine oil put down exhaust ports to lubricate top end of new engine, and started removing bits and pieces ready to power wash the engine bay in a little bit. I'll get some photos of current progress and state of van after being stood (rust has attacked some panels).

I'll check engine bay for any deep rust, repair anything needed, then paint everything with Rustol No Rust white paint, put new soundproofing sheets on, then put new engine/gearbox in Tuesday or Wednesday (depending on progress and obtaining rear oil seal). If local Ford garage doesn't have oil seal available in two days, I'll have to obtain one off ebay and just put engine in as I can't afford to rent hoist again.

I have my Rover diesel car to sell, and the money from that will go into new wings, inner and outer sills and driver's step. I need to overhaul brakes (have new discs and pads for front and slave cylinders for rear) and then once van is mobile, I'll bring it over to my house to do the welding as and when I can spare time. Hopefully rust monsters have not got into chassis etc too bad.

Well, that's all for now. Couple of jobs to do for wife and I'm off to do some work and take photos, which I'll post tonight. Cheers for now.

[Big_Andy]

Firstly, here's the pics of the van as it stands now







Rusty driver's step




Rundown of the last few days.

Sunday didn't happen as wife unwell and I needed to look after kids.

Monday, I stripped out the engine bay and found lots of rust on the passenger side chassis rail/inner wing.


and on the top of the inner wing


Driver's side not too bad


General views of stripped down front end



Tuesday what little time I had was spent trying to extract the crankshaft rear bearing (that input shaft of gearbox slides into), with no success.

Today, I'm about to go over and weld a nut onto the bearing and use a bolt to force bearing out, then weld patches onto the chassis leg.

Write more progress later, but as readers of the thread will see, someone stole the rear doors and bonnet two years ago. Nada kindly donated her spare doors and bonnet.

Perfect bonnet

O/S rear door, only needs slight work

N/S rear door, had rusty bottom section where they always go. Now cut out and replacement sections bought from guy on eBay who makes them himself




TTFN