59 Split 11 Window - Resto
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- chillax
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- Location: Brisbane
The body left to the blasters a week or so ago and came back yesterday!
Some parts from the blasters came up nicely, some not so nicely. The items were sprayed with single pack etch primer (black), which is compatible with two pack etch over the top where necessary.
Window frames aren’t too pretty. Still talking to Al about either repair or replace.
The black areas have been blasted and etch primed, grey areas were stripped by me previously and just need a buzz back to expose bare metal again.
Some damage to be repaired on the popout hinge sections.
The cargo floor is nice and straight overall, but there is a number of rusty sections to repair.
Cab floor is really good, only a few minor holes to repair.
Had planned to replace only the outer left dogleg however the inner may need replacing as well (Al will investigate more soon)
Left side rear sill (outer and inner) will be replaced.
Right inner arch will also be re-repaired.
A decision was made to replace the entire lower windscreen section.
The outer section was therefore cut out to expose a relatively solid inner (just a few little sections for Al to fix).
The previous repair involved brazing the rusty metal to the hinge which all had to be cut and ground off.
Here the section is almost out and the next repair section marked out...only a little hole from the outside...
However when viewed from the inside you can see why a big section has to be repaired.
While body was at the blasters, Al started on the rear hatch - inside was good only one dent to fix.
Although no rust present, quite a few dents needed attention before filler went on. Will get etched and high build primed today most likely.
There are a heap more pics on here if anyone is keen :
http://www.manxgallery.org/gallery/album568?page=2
Jack
Some parts from the blasters came up nicely, some not so nicely. The items were sprayed with single pack etch primer (black), which is compatible with two pack etch over the top where necessary.
Window frames aren’t too pretty. Still talking to Al about either repair or replace.
The black areas have been blasted and etch primed, grey areas were stripped by me previously and just need a buzz back to expose bare metal again.
Some damage to be repaired on the popout hinge sections.
The cargo floor is nice and straight overall, but there is a number of rusty sections to repair.
Cab floor is really good, only a few minor holes to repair.
Had planned to replace only the outer left dogleg however the inner may need replacing as well (Al will investigate more soon)
Left side rear sill (outer and inner) will be replaced.
Right inner arch will also be re-repaired.
A decision was made to replace the entire lower windscreen section.
The outer section was therefore cut out to expose a relatively solid inner (just a few little sections for Al to fix).
The previous repair involved brazing the rusty metal to the hinge which all had to be cut and ground off.
Here the section is almost out and the next repair section marked out...only a little hole from the outside...
However when viewed from the inside you can see why a big section has to be repaired.
While body was at the blasters, Al started on the rear hatch - inside was good only one dent to fix.
Although no rust present, quite a few dents needed attention before filler went on. Will get etched and high build primed today most likely.
There are a heap more pics on here if anyone is keen :
http://www.manxgallery.org/gallery/album568?page=2
Jack
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- chillax
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Thanks for the comments guys! But I have the easy job of just updating the forums . Al is doing all the hardwork.
Here is what the man has been up to at the end of last week.
A roof rack may have been on the bus at some stage which caused buckles in the gutter.
After a bit of massaging they are back in shape (some final straightening to come before primer)
After cutting away the lower windscreen rusty sections, more of the left a-pillar rust was exposed
A number or repair sections were required in this area but its all solid once again. All butt welded and ground smooth despite the fact no-one will see it again!
The left door rust repair sections were butt welded in and dressed smooth. Quite a few dents to pull out of the doors so a skim coat of filler will smooth this area out nicely after panel beating. No warping was a good result
Almost all of the hinge plates were rusted beyond repair so new ones were fabbed out of 5mm steel, cut to shape and drilled/tapped for the M8x1.25 thread
The inside was painted first with rust kill paint then it was sealed up (either flap welded shut, or new steel welded in) and ground smooth
More rust - this time in upper left windscreen surround
Will sort out final rust issues then shoot some paint under dash, front of heater tube etc before nose goes on.
A decision was made to remove the entire outer windscreen section rather than just the lower due to the rust in the upper a-pillar
The spot welds were ground down using a tungsten carbide cutting bit in the die grinder then the outer skin was cut back and twisted off with piliers to pop the spot welds
Once removed it was easier to see what we had to deal with
Here it is with the entire outer windscreen removed
Due to some rust in the inner windscreen section it was decided to remove the upper inner sections as well
Upper a-pillar rust was repaired, a little more to go before inner and outer skins can go back on.
Jack
Here is what the man has been up to at the end of last week.
A roof rack may have been on the bus at some stage which caused buckles in the gutter.
After a bit of massaging they are back in shape (some final straightening to come before primer)
After cutting away the lower windscreen rusty sections, more of the left a-pillar rust was exposed
A number or repair sections were required in this area but its all solid once again. All butt welded and ground smooth despite the fact no-one will see it again!
The left door rust repair sections were butt welded in and dressed smooth. Quite a few dents to pull out of the doors so a skim coat of filler will smooth this area out nicely after panel beating. No warping was a good result
Almost all of the hinge plates were rusted beyond repair so new ones were fabbed out of 5mm steel, cut to shape and drilled/tapped for the M8x1.25 thread
The inside was painted first with rust kill paint then it was sealed up (either flap welded shut, or new steel welded in) and ground smooth
More rust - this time in upper left windscreen surround
Will sort out final rust issues then shoot some paint under dash, front of heater tube etc before nose goes on.
A decision was made to remove the entire outer windscreen section rather than just the lower due to the rust in the upper a-pillar
The spot welds were ground down using a tungsten carbide cutting bit in the die grinder then the outer skin was cut back and twisted off with piliers to pop the spot welds
Once removed it was easier to see what we had to deal with
Here it is with the entire outer windscreen removed
Due to some rust in the inner windscreen section it was decided to remove the upper inner sections as well
Upper a-pillar rust was repaired, a little more to go before inner and outer skins can go back on.
Jack
- byronbus
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- Dasdubber
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No probs Bruce, I thought I'd let Jack post up what pics he wants - I upload all my pics to the manxgallery site regardless and let the owners decide what they want to show
Cheers
Al
PS I'm enjoying this resto immensely as its nice to do a job that I don't have to cut corners with....buy once cry once so they say.
Cheers
Al
PS I'm enjoying this resto immensely as its nice to do a job that I don't have to cut corners with....buy once cry once so they say.
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The bus is now upside down
Someone in its former life decided semaphores weren't cool and plugged them up
A bit of time with the cut off wheel, die grinder and angle sander opened it back up
Just a little welding will be required to fill the gaps where the previous welds had to be ground off
Rust in the upper left side of the windscreen (inner)
Rust was cut out, and a patch welded in and ground smooth
The rotisserie extensions were finished and he bus had its first flip today.
A bit of adjustment will be required to get the centre of gravity right so it spins a little easier.
Rear mounting bracket...
After the lower A-pillar was cut out, the dogleg doesn't look all that flash
The rust in the lower left inner windscreen was repaired
Same spot but different view
Right side also repaired
Viewed from the inside
More rust in the A-pillar - will be cut out tomorrow
Above the left door there were also some rust areas (bus is upside down on rotisserie)
Problem areas cut out
Top of left door frame (inside) had a few holes which suggested there was rust hiding inside
Suspicions were confirmed as it was pretty crusty!
Next resto is on the hoist being stripped at the moment! (Hoves ute!)
Jack
Someone in its former life decided semaphores weren't cool and plugged them up
A bit of time with the cut off wheel, die grinder and angle sander opened it back up
Just a little welding will be required to fill the gaps where the previous welds had to be ground off
Rust in the upper left side of the windscreen (inner)
Rust was cut out, and a patch welded in and ground smooth
The rotisserie extensions were finished and he bus had its first flip today.
A bit of adjustment will be required to get the centre of gravity right so it spins a little easier.
Rear mounting bracket...
After the lower A-pillar was cut out, the dogleg doesn't look all that flash
The rust in the lower left inner windscreen was repaired
Same spot but different view
Right side also repaired
Viewed from the inside
More rust in the A-pillar - will be cut out tomorrow
Above the left door there were also some rust areas (bus is upside down on rotisserie)
Problem areas cut out
Top of left door frame (inside) had a few holes which suggested there was rust hiding inside
Suspicions were confirmed as it was pretty crusty!
Next resto is on the hoist being stripped at the moment! (Hoves ute!)
Jack