Picked up the bumpers, front grill and track covers from the shot blasters. The only bit that needs some further work is the rear bumper. Shot blasting revealed some rot on one side, and some impressive dents:
Luckily it was just isolated to this section so I let some fresh metal in, and got the worst of the dents out with a hammer and dolly:
And there were 5 holes drilled in it (presumably for a towbar?):
I have no need for them so welded them up:
I gave the welded sections a skim of filler, and then into epoxy and high build along with some others bits I had cluttering up the workshop (rear bumper needs some further shaping yet):
As are the indicators (front ones are yet to go in):
Not so much success on the horn front:
I’ve traced this down to a dodgy steering coupler. I’ve a new one on the way from heritage, and if that doesn’t work C&C have said theirs definitely will as it’s a copy of the original.
Steering wheel painted and ready to go back in:
And I’ve finished up my spare wheel carrier. It’s pretty solid, and looks the part to me.
Tubing bent to shape:
Top mounting plate welded to the tube:
Main plate welded to the tube to support the wheel studs:
And then studs welded to the plate. I just need to cut the threads into them:
And a test fit of the wheel. Wheels on the front are a bit of a love ‘em or hate ‘em item, I love the look personally:
Because I’m a careless moron the bottom third of the poptop was covered in grinding dust.
I couldn’t remove the dust with a fingernail so went over the affected areas with some wet and dry, followed by 3000 wet on the DA over the whole roof (first time I’ve been brave enough to machine colour sand, figuring the roof isn’t easily seen should I screw up):
After buffing and waxing it looks miles better:
With the help of some of the lads down the yard the poptop is now back on the van and out of the way:
Second corner now cut and polished, with both rear light clusters and engine lid seal in:
And before I forget, I put this stubborn little devil in. The fuel breather hose tucked up the left corner:
Stripped the steering wheel of its peeling paint job:
And gave it a coat of etch followed by a few coats of high build.
I’d repaired a few cracks in it with some epoxy putty. With some primer on, there are a few further hairline cracks I need to fill, before I can paint it.
Drilled the bumper to take my new hella lamps:
Made a start on my front wheel mount. Thus far I’ve fabricated the top mount which consists of a plate bolted to the airbox with a 10mm rod poking out of it (this needs cutting down to size, I’m not planning to impale any pedestrians!). This will support the top of the A frame, which I need to finish this week (one of the guys opposite has a tube bender I can use).
Started cleaning up the poptop to get it onto the van and out of the way:
And have started testing the electrics. This is a very good sign as it means I’m getting power to the cab, and to the engine (I heard the shutoff valve click so it’s getting to the coil).
A much overdue update! I’ve had three days off this week, following New Year’s, to try and get a move on with the van mechanicals.
First up a nice easy job, fitting the gear shifter. This is the Scat shifter I took out of the van, I’ve had the base powder coated (of course!) and the springs etc plated:
I then finished building up the engine. I’ve not changed anything substantial with the engine as it was running fine before the resto. It’s just had a good clean up, the original tinware powder coated, a proper SVDA dizzy (with pertronix ignition) to replace the 009, reinstated cooling flaps and thermostat, and a nice vintage speed exhaust! Looking pretty clean and tidy:
I also kept the original Bosch coil which was looking a bit tired with surface rust coming through, so gave it a clean up and paint with some left over ‘koni red’ paint:
With the engine pretty much built up it was time to get the gearbox and engine in!
First up, the gearbox. It’s had a good clean up and then a coat of Dynax UC (probably overkill but it can’t hurt):
Much grunting and swearing later, and the gearbox is in, plus the drive shafts:
At this point I realised I had a bit of a problem when I came to fit the clutch cable bowden tube. The steel tube under the van that it connects to was around 10cm too short, meaning the bowden tube wouldn’t fit! This must have snapped off at some point in the resto and I’d not realised. Keen to avoid having to weld under the van this late in the game, having spent a huge amount of time on it, my mind started churning for a neat workaround.
Cue the following day, and I scrounged a 15cm piece of thick wall stainless tube from Ali across the yard, with an OD thick enough to fit into the bowden tube. I then got the first 5cm of the tube turned down in a lathe to fit snuggly inside the tube that runs under the van:
And all installed under the van, problem solved. (the bowden tube may still need some washers at the other end yet, I’ll see how it goes):
And finally this morning’s job, the all important engine install! All ready to go with the van jacked up and engine on my manky old rug:
Much more grunting, sweating and longer than I’d care to admit and the engine is in (they’re doable on your own, but it’s a bit of a workout!):
Not too shabby:
I need to finish plumbing the engine in this week, fit the front brake calipers, bleed the brakes and finish some of the steering column and then I should be in a position to try and fire the engine up!
Brake calipers are pretty much ready to go, and of course got the koni red treatment (Max wanted the “Porsche” look!):
