My latest project mk2 CI Travelhome LWB

[montym100]

Loads of work done there, well done

Interiors looks great

[davev6newman]

Thanks fellas, shame the weather is going to be against me for the outside now, but ill do what i can.

[montym100]

shame the weather is going to be against me for the outside now, but ill do what i can.

Tell me about it, stll trying to get mine finished but the weather has been Cr*p here for the last month

[davev6newman]

Im dodging rain showers most of the time, this could be a big problem when i want to weld the windscreen surround up.

[davev6newman]

Right.............This is the last time i seal these windows up!!! I dare them to leak now, just you dare!
As you can see i carefully masked up around the windows and put plenty of mastic on, then smoothed it over with the base of the mastic tube and removed tape, almost looks like theres a rubber there.





It was time to remedy the leaking exhaust gasket as the sealer kept blowing out, i wasnt sure that it would be possible as the bolts can be siezed solid. The top 3 are easy to remove with a socket as well as the first bottom one, but the two remaing bolts under the manifold can only be acccessed by a spanner, and a short one at that. Luck would have it that they shifted.





I had this trouble on my Jennings V6, the bolts were solid and had corroded so badly that a socket or spanner kept slipping, i had to resort to taking the head off just to do the exhaust gasket.

Fitted a new washer pump and new airfilter as well




When i got some different tyres fitted, i wire brushed the rims and painted them, what a difference it makes!!

[davev6newman]

I thought i would blow the dust of the welder and hopefully find minimal rust on the underside...who was i kidding!







As you can see im no expert welder but that spring hanger needed some extra love as well as the surrounding metal.





This is the back of the drivers side step and sill after i had taken a rotary wire brush to it, the passenger one doesnt look any better,as well as the other hanger. So MOT not any time soon!

The rear step was falling apart, so i made up a new frame using the old one as a pattern






Used hardwood decking for the tread, aluminium angle for the edge and chequer plate for the back.





Trouble is it dont fit as it is a bit chunkier than the original. It relies on the towbar as its support, so i will have to lift the supports 10mm, but am pleased with it all the same.

[davev6newman]

Now to tackle the back 0f the step and sill.



There wasnt much metal to cut away actually and this is what i found~:



There had been a replacement sill fixed on at some point and im guessing that the old one was left in place as judging by all that rust.

New metal welded in







The outer sill had rusted away , so i cut that out and welded new metal in



The bottom of the near side wing had rusted away completely, so new metal welded in also (look better with a skim of filler).





And this is how far i got when the welder decided to pack up on me! Grrrr.......



Got to borrow one now

[jerry2]

getting there m8. looking good so far.

[malta transit]

[davev6newman]

Well thats been a long winter, its been 4 months since i last done anything, so im going to make the most of some time off.

The cab area was soaking wet, so it was time i did something about it. I removed all the sodden carpet and removed the seats, heater box, glove box and dash panel and it was obvious that the windscreen scuttle was pretty rotten. I had already bought a used scuttle section off a member some weeks back, so it was time to bite the bullet.

Removing the windscreen was pretty easier than i had thought it would be, i just used a screwdriver on the inside and pushed the rubber back inside the lip, worked my round the screen and it just lifted out.



As i expected some bad rot but not the whole of the scuttle, so i only needed to replace a section which made life a bit easier.






I cut out the middle section of the scuttle and ground out the spotwelds to remove the rest. I also had to do this to the repair section which was quite time consuming.



Careful overlapping and marking and the section fits well.



I drilled 7mm holes around the repair panel and plug welded it in place.



Thats as far as i got today, but i got to make good the "A" post and top of the dash and the other small section on the drivers side.

[davev6newman]

Cutting out the rot on the other side was going to be a bit easier than before.





Now to patch up behind the "A" post




I had some large corroded areas on the firewalltoo. So i cut them out.



And welded in new repair sections

[Neil]

GETTING THERE DAVE

[transitandy]

Indeed great work

[davev6newman]

The dashboard was next, where the rain had been getting in it had dissolved along the window edge, up the "A" post and around the ball vent. So i welded some metal to the underside of the dash and along the frame edge.










And now for some filler.









A quick coat of satin black to seal it up, (i shall flat that back and apply some stopper at a later date).



I painted all the lip of frame with black and then replaced the windscreen, this went in easier than i thought especially on my own, and i will seal up the rubber with some black Tigerseal polyurethane sealant, expensive but perfect for the job.

[blue estate]

You must have rust blindness by now but it's worth doing keep plugging on