After skimming the whole panel with filler, blocking flat and applying high build primer Iโve managed to get a much better result. Still not perfect but itโll do for my first panel! Got the engine lid primed too.
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Well aware that I have the entire van to shape and prime, and pretty much no experience of applying filler I decided to have a go on the rear hatch to get a feel for it. Iโm epoxying all of the outer panels, so started by taking the hatch back to bare metal (you can see the repair I had to put in along the bottom edge):
And the result of a few nights trying to get the panel flat (this is going to take me a while to get the hang of, but Iโve got to start somewhere right?!).ย
So far itโs not coming particularly natural to me trying to feel the highs and lows on the panel, and then levelling it out. Even applying the filler isnโt easy as I canโt seem to spread it particularly evenly and keep running tracks through it.ย
I decided to epoxy it anyway to give me a better idea of the panel shape, and how the filler translates into primer.
As I had the gun out I also bare metalled the engine lid which is a brand new panel so needed no filler:
Engine lid in epoxy:
And rear hatch:
It doesnโt look too bad from this angle and distance, but itโs far from straight when viewed side on:
I can apply filler over epoxy so Iโll keep going on the filler to try and flatten it out more. Practice makes perfect!
I bought a westy style seat belt mount for the rear a while back to make fitting a a 3 point belt a bit nicer. As ours is a converted panel van it has none of the factory bus mounting points so I had to make one. I used 25x50mm box section and a standard mounting bracket cut down to size:
I cut the box section at either end to sneak it behind the framework in the van:
All tacked together:
All welded up and welds dressed. The smaller piece is for the lower mounting point:
All trail fitted to the van, it was then plug welded to the side of the van via holes drilled in the van side, and seam welded at both ends:
Lower mounting point welded in and both pieces etch primed:
That should do nicely. Iโve already done the mounting points for a lap belt the other side, so we can now safely transport 2 in the back of the van!
As a small home project Iโve been sorting out the multitude of dodgy repairs and ugly bits on the wiring loom. Not many pictures of this as itโs not very exciting, but this was the type of rubbish I found. Barely crimped on insulated terminal, with scotch lock and a bare blobby solder.
Replaced with non-insulated terminals like the original, and heatshrunk soldered joints:
I had about 4 bits like the above to repair, plus a few bits that needed fresh heatshrink, the rest really wasnโt too bad.ย
A truly momentous day for Iris. Back on her wheels for the first time in 2.5 years and out into the yard!!! Wayne in the unit next to me also got his back on wheels today so we had to get a side by side. The difference in height is hilarious!
A fruitful weekend saw most of the running gear make it back onto the van.
Front Steering and suspension all on, including the shiny new Koni shocks:
Rear brakes all re-assembled. These are the shoes and backing plates that came off the van when I started the resto; they cleaned up really nicely and have plenty of use left in them:
And fitted the drums too, ready to go back down onto wheels:
I borrowed a wheel from Wayne in the unit next to me to pull the hubs into the drums and discs. Even putting one wheel on it makes it seem so much more โvan likeโ, rather than just a lump of metal:
A little further on the running gear rebuild over the last few days. New rubber boots on the ball joints, new front bearings pressed in, steering pin fitted and front beam installed back on the van. Hoping to have all the running gear back on by the weekend.
New bearings pressed in and rear suspension all built up tonight. ๐
Master cylinder and regulator installed. All new kunifer brake lines made up and fitted with goodridge flexi hoses. And the back end is off the jig for good now!
All ready to start bolting on over the weekend!
A really productive night this evening. Finishing prepping the rest of the running gear and got everything top coated in Anthracite Grey (an old beetle colour that should look awesome with the neptune blue).
