Mk6 transit crew cab tray back

[spudmab]

Well no pictures from last week as there was nothing overly interesting as we just got all 4 mudguard mounts welded to the mudguards.

This week is a bit different, machined down the m10 allen bolts so they would clear when being bolted up. Then we set about making a mount to fit the first mudguard. A lot of messing about due to everything getting a bit tight for space. We used 50mm × 10mm steel, they have had to have kick outs cut into them and be bent before welding them into 1 long funky shape. Still a bit of shaping and a bit of added strength to go on the centre part.

Next up is to check it on the other mudguard and see if it sits where we want it to. Then it will be make another 1, then the top mudguard mounts can be figured and made.

Making these mudguards and mounts has been 1 of the longest jobs we have done on the truck.

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[spudmab]

Well this week we used the first mudguard mount and reversed it to make a mount for the other side. Then we fitted the mudguards.

They are close but the mounts have pulled when welding and they are not holding the mudguards quite how they need to be.

To be honest we had to start with something and work from there. At least the mudguards at in a rough position and we can manipulate the mounts where needed. We still need to make some upper mounts but we have a plan for them so hopefully when the mudguards are sitting right the top mounts should be fairly easy.

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[BROWNYS V6]

this is coming on well matey, lookin forward to an out of the workshop pic with it sat on its arse

[wurzel]

Really enjoying this project, keep up the good work, very impressed.

[spudmab]

Well there hasn't been no updates for 2 weeks as i had a family holiday. The work did continue with my brother-in-law finally getting both the lower mudguard mounts made and holding the mudguards where we want them.

Now we have also figured out the top mounts. Everything is tacked in place on 1 side and the other side is well underway. Once they are both set then we can pull them of for final weld and sand.

There wont be much progress next week as we are not working on the truck so keep watching for more updates as they happen.

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[spudmab]

Well we managed to make loads of progress this week. We made up the left hand mudguard mounts, we got both of the top mudguard brackets welded. Also the upper mudguard mounts have been ground and welded. The rear mudguards are nearly finished, just a bit more welding on the lower brackets and some sanding.

Also we made a clevis to fit on the end of the liner actuator with a nut welded inside. This then allowed us to cut and weld on a threaded bar to go from the original handbrake bracket to the liner actuator.

Made a short video of the handbrake setup. Please be aware that the rear calipers dont have pads so we left the cables of the calipers. Once the pads and discs are fitted we will be able to do final adjustment.

https://youtube.com/shorts/JC5-j67QHxM?feature=share



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[spudmab]

Well big mile stone this week. The rear mudguards are finally done. As well as the drivers side infill panel.

Once the panel was fitted at the front and the body lines lined up we set the top rear of the panel. We then needed to set the lower rear part. With this set a hole was drilled in the lower lip and a plate was welded to a bit of round bar. This has now been welded to the rear panel baracket.

Once the panel was solid we set about trimming the infill panel for clearance to the mudguard. Once this was done we rolled a panel and welded it to the end of the panel.

This has made the infill panel rock solid. The body lines are extremely close. It looks a little of due to the C-piller not having the lines in.



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[spudmab]

Well this week we have managed to get the left hand infill panel cut and shaped at the front where it joins the C-piller.

The infill panel has been trimmed at the rear where it meets the mudguard. Also the upper mount has been drilled and fitted. Then we made up the the new lower mount.

We still need to plate the end in and we are going to add some strengthen plates at the front edges of the panels.

Hopefully next week we will have the infill panels finished ready to start in the new exhaust system.



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[spudmab]

An early update this week as we are not working tomorrow evening.

This week we finished of the left hand infill panel. After a lot of cutting, followed by miles of welding and plenty of sanding the panel is done. Mounted and sitting just as we wanted it.

So we set about making a start on the exhaust system.


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[spudmab]

Well this week we carried on with the exhaust system, its been extremely challenging to get it routed where we needed.

The drivers side exit its a tear drop shape and will sit nicely out the rear of the side infill panel. There will be a matching 1 on the passenger side. We will be making a nice trim once everything is in place.



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[spudmab]

Well nothing to exciting this week. We have now fully welded the exhaust system apart from the tail trim. The welds have been sanded down and are all smooth. Just need to work out the exhaust mounts and get them made.

So its a big step forward but not much to talk about. The split in the pipe is due to it not sitting quite how we wanted it so cut run the disc cutter into the exhaust and pulled it over. This will be welded and cleaned up.



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[spudmab]

Well this week we spent more time trying to finish the exhaust system. We also had a visit from our friend who is taking on the challenge of making the new floor.

We laid on 1 of the old floor plates and its a tad big now. The shorter part used to sit before the mudguards, it now sits over half of the mudguard. As you can see the rough drawing of the new ali box section floor frame. This will be made 1 inch tall. Some parts are going to be 1" × 1" and other parts will be 4" ×1" this will give a nice frame for the checker plates to bolt to.

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[spudmab]

Well not much to show but we have made the middle and rear exhaust system mounts.

Machined down some 12mm stainless Steel round bar so it pushes into some bmw Mini exhaust rubbers. This was then sanded down to sit on top of the exhaust pipe.

The other mount is a plate with some mild steel bar gound and shaped to make a plinth for some cds tube to be welded to. Then we pressed in a bush. Once this was made we welded a stainless steel boss to the exhaust system. The boss has a 8mm thread Machined into it.

The exhaust system is now nice and strong. So nearly another job done.



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[spudmab]

Well this week we machined up some more 12mm stainless Steel bar and then formed a mount for the silencer, This was then welded on.

We sanded the exhaust system to remove old scratches due to being a used bit of pipe.

Next the opening in the rear infill panel was opened up, still needs a bit more but it is clean.

The rear mount has now been filled with polyurethane to stiffen them up and they have been bolted to the rear infill panel mounting bracket.

After all of this we started to work on the passenger side exhaust system. More of that to come. Keep watching



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[spudmab]

Well this week we have nearly made the left hand exhaust. Well new diesel tank for the night heater.

I wanted it to mirror the exhaust system on the right hand side. We have cut the same hole in the infill panel. We have made up the same rear exhaust mount. The tank matches the exhaust system all the way until it disappears under the chassis. This is where we machined up a stainless steel boss and tapped a tapered thread for the diesel pipe connection.

We also had our mate who is making the framework for the floor ect. He has roughly made the front part of the frame. Its close but needs some tweaking so we will mark where it needs changing and give it back for him to make the alterations.



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