Cab doors – Inner frames

 A bit further this week with the cab doors. The inner frame is pretty thick metal (2mm) however on the N/S it had started to rust through in places so I cut out a huge chunk of it and replaced it with some fresh steel. The O/S frame wasn’t too bad (some pitting in places) so just got a clean up and rust converter applied:

The inside of the doors has a style line which the door cards sit inside, on both sides these were sculpted out of filler! I’ll need to make some repair pieces for this as the panel I’ve got from schofields doesn’t have this. You can see in the below where I’ve chipped away at the filler.

I’ve zinc primed these areas, and will get some epoxy in there on Friday. Then I should be able to get the panels from schofields in over the weekend and make a start on fabricating some further repair panels for the rest. 

I’ve just bought a nice 3 in 1 sheet metal machine which will help in making up the curved corner section and some U channels. Quite enjoying repairing these! 

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Out in the sun today. Made a start on this cab door. Inner frame needs the pitted metal cut out and replaced. Now I know why most peeps replace doors with imported ones!

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Starting the N/S cab door. This looks like fun!

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Front End Complete

It’s taken 2.5 months but it’s finally done! I finished up the front panel today, unfortunately I cracked the windscreen trial fitting it; but at least it fits ok!

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I got it lining up pretty well with the A pillars but it’ll need some filler to be perfect.

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It looks much better now, and I’m really happy with how it’s turned out.

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There’s very few like her. Helped me prep the front panel today and get it into position. Just needs welding. Carvery treat too!

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And a spot of neptune blue today! My first go at spraying top coat. Really pleased with the outcome and it’s given me some more confidence to paint the whole van.

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Deformation panel welded in tonight and applied some seam sealer to the seams which will be tricky to get to once the front is on.

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Epoxy mastic’d everything this morning. Well chuffed.

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Bulge section of the a pillars repaired today. Bare metalled and zinc primed the inside of the inner valance. Epoxy mastic on it all tomorrow morning including the front and def panel and I’m just about there with the front end.

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Bulge section of the a pillars repaired today. Bare metalled and zinc primed the inside of the inner valance. Epoxy mastic on it all tomorrow morning including the front and def panel and I’m just about there with the front end.

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