Two coats of epoxy mastic on the chassis tonight. Nice and shiny!
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Zinc primed all of the chassis bits I’ve been working on. Epoxy on tomorrow then first floor pan in at the weekend! A long night made easier by fresh pizza at home from Max.
Final repair around the rear torsion beam. Now to paint all the chassis!
Some more chassis fun from over the last few weeks.
I decided to finish off the chassis work before the floor goes in and I’m glad I did. Annoyingly I had to remove the brake cable guide tube I’d welded in as access would’ve been awkward (it only takes a little while to unpick it anyway). So chop chop. You can see the rear of the repair I had to make to the other side, and the welds for the cone section.
I fabbed the easiest bit first.
I then realised the piece I’d made wasn’t following the curve of the chassis rail properly so ended up making this repair piece (made from a few separate pieces for simplicity):
There’s some nice looking welds on it too!
And trail fitted, looking a bit neater.
While the paint dried on this side, I started looking at the N/S chassis rail which also needs some work, but is no-where near as bad as the O/S.
I’ve managed to retain most of the cone section on this side (I replaced it entirely on the side I’ve just done). Left overnight in rust treatment.
I then epoxy’d the inside of the O/S:
And began fabricating the repairs for the N/S. I managed to get away with just two simple sections on this side. A piece here:
With flanges bent into it, and a cover piece to go on top of it.
Everything then got a coat of paint on the inside surface:
And all welded in:
The chassis section around the rear torsion beam is now solid again. I need to weld a small cone section on the N/S, I’ve made the piece so just need to fit it. Bring on the floor!
Todays efforts. Welded in the cone section that strengthens the rear torsion bar. It was a bit of pig getting the welding torch in position for some of it and the welds could’ve been a little neater but the penetration is good. I’ve drilled a hole in it so I can cavity wax it and fit a bung later. I’ll be glad not to have to do this section again!
Welded a small patch on the only floor support I didn’t end up replacing:
Redid the welds joining the front top hat to the floor (these were some of the first welds I did and penetration wasn’t great on them).
I’ve welded on two new tabs for securing the wiring loom to the chassis:
Given the floor another coat of zinc primer and a first coat of epoxy mastic. The mastic went on much better this time; I think last time I didn’t thin sufficiently and had the inlet pressure too low. Starting to look shiny:
I also cured the paint on the stove build. My mate now has this, and I think he liked it. I need one now!
Today I reinstated the guide tube for the gear coupling:
And fabbed up the first cone section for the rear torsion tube. I ended up having enough of the old cone section to get the right curve profile. Hammering it around a dolly gave me the right shape so it shouldn’t need too much more work before it’s done.
Little bit more from today. Repaired the two holes I put in the gear shift tube when I removed it (backed the holes with copper tubing to help protect the inner).
Gave it a lick of zinc primer:
Got some paint on the stove build. Just need to cure this now with it’s first burn.
I’v also started cleaning up the rear lip that the floor attaches to. It’s in good nick but has some rust which I’m treating.
With a project like this it’s often easy to forget how much you’ve done, when the list of bits to do is so vast. Today felt like a significant milestone was hit though as the last outrigger and brake cable guide tube went in, completing the majority of the frame on which the floor sits:
There isn’t much in the below picture I’ve not replaced, but the result is worth it (5 floor supports, 2 cross members, 6 outriggers/jacking points, 2 inner sills, 2 brake cable guide tubes, numerous chassis repairs).
Now I just need to finish up a few minor welding bits, get some more paint on it and get the floor in!
I got the penultimate outrigger/jacking point welded in today. Annoyingly I somehow have a nick in the wiring loom (It’s not damaged the wires inside though so I’ve just put some electrical tape around it).
I also welded the last edge of the repair piece I made to the chassis that sits behind the rear outrigger. I ended up seam welding it for strength.
