Introducing 'Manfred'

thebear · Post by **thebear** » Sun Feb 12, 2012 8:37 am

Front RHS dog leg gets the chop.

Trial fitting of dogleg

Trial fit of new door

Checking panel gaps.

What a wonderful combination of colours...

MID WEST DUBBER · Post by **MID WEST DUBBER** » Sun Feb 12, 2012 8:43 am

Top work bear! Looking good.
Cheers Rusty.

thebear · Post by **thebear** » Mon Feb 13, 2012 4:30 pm

Hey, a few more pics of the RHS inner and outer dogleg being welded in.

thebear · Post by **thebear** » Mon Feb 13, 2012 4:37 pm

Bulkhead and cabin have a few minor rust spots that need a patch up but relatively minor when compared to the fixes so far...

Unusual spot for rust i reckon but better out than in!

Patched up

Minor repair to the bulkhead

Just like new

jvm · Post by **jvm** » Mon Feb 13, 2012 5:37 pm

Top work and reading your thread this morning got me motivated to get out into the garage today

Though my work isn't quite as fast or as neat

Thanks for sharing

Dave78 · Post by **Dave78** » Mon Feb 13, 2012 6:20 pm

Lookin good. And I thought there was a lot of work to do on mine!!

thebear · Post by **thebear** » Fri Feb 24, 2012 3:36 pm

Hi, lots of work done on Manfred in the last two weeks but been flat out at work so no time to post. Have reached some critical points like heading to the blaster but not without a heap more cutting and welding. The boys at DAS are going great and the pictures are testament to their skill. However early knock off today as Team DAS head to WSID for event this weekend. Fingers crossed its better weather over the border!

The lower front nose outer skin was removed but it was decided to keep the inner panel and patch it. This kept the integrity and shape of the original metal.

Lower nose skin removed

LHS rust

Starting repair

Patched, arhhh me hearties

RHS rust

Patch

thebear · Post by **thebear** » Fri Feb 24, 2012 3:43 pm

The LHS front chassis needed some new metal. Again, the call was made to keep as much original metal as possible.

The top of the chassis rail to be replaced. Not enough good metal to weld to. Replacement made to suit.

thebear · Post by **thebear** » Fri Feb 24, 2012 3:48 pm

New metal cut to suit and welded in top and bottom.

thebear · Post by **thebear** » Sat Feb 25, 2012 9:32 am

With most of the bottom 6 inches gone or rusted through, all pillars required work and/or replacing.

LHS inner B-pillar being pieced back together

Outer B pillar

thebear · Post by **thebear** » Sat Feb 25, 2012 9:44 am

A-pillar welding work. Some care taken due to the need to realign the doors.

The lower captive nut plates for both cargo doors in b & c pillars were rusted in place so had to come out. B-pillar repair below.

thebear · Post by **thebear** » Sat Feb 25, 2012 9:47 am

C pillar captive plate repair

thebear · Post by **thebear** » Sat Feb 25, 2012 10:03 am

Both cargo doors are in pretty good nick albeit for some rust in the bottom couple of inches. Front cargo door needed an outer lower skin and part of the inner skin.

All done. Inner welded, filled and smoothed ready for paint blending.

thebear · Post by **thebear** » Sat Feb 25, 2012 10:14 am

The front RHS door was replaced but couldn't find a decent replacement LHS door so repairing the original. As you can see, its quite a job. A few man hours in this one.

thebear · Post by **thebear** » Sun Feb 26, 2012 3:33 pm

Inside and outside sill replacement on the long side including all supports.

Introducing 'Manfred'

Dog leg and door fitting

RHS dogleg welding

Bulkhead and front floor repairs

Manfred update - nose repairs

Update - front chassis repair

Front LHS chassis repair2

Update - B-pillars

Update - A & B pillars

Update C-pillar repair

Update - cargo door repair

Update - LHS front door

Update - inner and outer sill long side