Bananna Split WA

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Greypow
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Location: Perth Hills WA

Bananna Split WA

Post by Greypow »

Hey Gfresh hope you don't mind another Bananna Split about the place :| but I intend to keep it yellow!

Had this one for a while but the time has come to make a start :D

Image

Image

Ready to take to the welder split66 - thanks Dave :D
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martinigreenbus
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Re: Bananna Split WA

Post by martinigreenbus »

That's a long way from being a banana split.....

Looks awesome in comparison ;)

I've asked bob/ash to keep a lookout for info on the shaqille o'neills Jor-GE......

I've had a positive answer from down here too 8)
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Greypow
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Re: Bananna Split WA

Post by Greypow »

OK bus is on the hoist and Dave has started the rust repair work. Fortunately only a few small areas above the waistline, most off the work required below the waist line in normal areas.

Front suspension and gearbox removed. Plan is to rebuild the bus basically to factory specs. Certainly takes a while to clean off nearly fifty years of grease and crud. Got to love my sand blaster - made short work of the front backing plates.

Front drums came off easilly but the rear axle nuts refused to move. Cheater bar - no, rattle gun -no, heat - no so had to cut them off. Drums and shoes now off to Brakes West for a skim and new bonded fricton material
Attachments
Big_Nuts_Cut.jpg
Backing_Plate_2.jpg
Backing_Plate_1.jpg
Ready_for_Rust_Removal.jpg
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Rossco WA
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Re: Bananna Split WA

Post by Rossco WA »

Looks sweet, with Dave on the job, be on the road in no time :wink:
paul willans
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Re: Bananna Split WA

Post by paul willans »

that's the easy way to get axle nuts off had to do that a few times,get 3/4 way through with grinder and they pop
clk500 AMG
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57 Boronia Brown bus
59 Pmg ute
62 Beryl Green bus
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GFresh
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Re: Bananna Split WA

Post by GFresh »

Mmmmmm banana split 8)
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Greypow
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Re: Bananna Split WA

Post by Greypow »

Dave has done a great job replacing rust holes with new metal. Knowing how you guys enjoy some photos, here is a few charting the work done.

Repair panels used were
- middle left out rigger
- middle right out rigger
- 2 x inner sills
- top hat section
- front inner valance
- front outer valance
- lower front nose
- right hand front floor section
- left hand cargo floor
- left hand outer sill and strengthener
- left hand rear outer sill
- right hand rear corner
- cargo rear door inner
- cargo rear door outer
- cargo front5 door inner
- cargo front door outer
- numerous small fabricated repair part panels

A total of $1,767 in rust repair panels

In addition the following work was also completed
- hidden nuts in b pillar for seat belts
- front radio ariel hole welded up
- crude air deflectors removed from rear vents and pop rivet holes welded up
- a hole cut in the right hand engine bay for air vents to an oil cooler plated and welded
- a type 3 engine inspection hatch welded in above the engine (as a repair and enhancement to the crude hole cut by previous owner).
Attachments
rivet holes welded and dressed
rivet holes welded and dressed
rivet holes left after removing the sheet metal air rams
rivet holes left after removing the sheet metal air rams
Dressed
Dressed
welded
welded
The holes hacked into the engine bay LHS to get air to oil cooler mounted in the engine bay - what were they thinking?
The holes hacked into the engine bay LHS to get air to oil cooler mounted in the engine bay - what were they thinking?
General shot under the bus
General shot under the bus
Steering box - rather oily
Steering box - rather oily
gearbox prior to removal
gearbox prior to removal
Front end prior to removal
Front end prior to removal
Dave the rust repair guru
Dave the rust repair guru
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Greypow
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Re: Bananna Split WA

Post by Greypow »

Some more photos
Attachments
Nose once all the filler had been removed. There was even a welded up area
Nose once all the filler had been removed. There was even a welded up area
Like almost all 50 yr old buses we found a few surprises. When stripping the nose there was filler almost 15mm thick in places coving an old poorly repaired accident damage
Like almost all 50 yr old buses we found a few surprises. When stripping the nose there was filler almost 15mm thick in places coving an old poorly repaired accident damage
Fortunately once the rain lip was cleaned up, the rust turned out to be just surface rust
Fortunately once the rain lip was cleaned up, the rust turned out to be just surface rust
Inspection of the roof rain lip showed some rust shots
Inspection of the roof rain lip showed some rust shots
B pillar replated and welded
B pillar replated and welded
Hidden nut and strengthening plate for upper seat belt mount
Hidden nut and strengthening plate for upper seat belt mount
A hole was cut in the B pillat to enable a hidden nut for the upper seat belt mounting to be fitted
A hole was cut in the B pillat to enable a hidden nut for the upper seat belt mounting to be fitted
Type 3 hatch welded in place - worked out to be a great fit
Type 3 hatch welded in place - worked out to be a great fit
Type 3 engine hatch trimmed to fit, trail fitting before welding
Type 3 engine hatch trimmed to fit, trail fitting before welding
Hole cut by previous owner above the engine
Hole cut by previous owner above the engine
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Greypow
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Re: Bananna Split WA

Post by Greypow »

Next the right hand rear corner repair
Attachments
Rear corner showing damage and rust
Rear corner showing damage and rust
Dented area roughly panel beated
Dented area roughly panel beated
Pin holes revealed in panel beated corner so decided to replace the corner
Pin holes revealed in panel beated corner so decided to replace the corner
Closing plate welded in
Closing plate welded in
New panel grafted in to good parts of old panel to retain overall shape
New panel grafted in to good parts of old panel to retain overall shape
Battery tray welded in
Battery tray welded in
Battery tray spot welded in
Battery tray spot welded in
Corner dressed and painted
Corner dressed and painted
Closing panel area
Closing panel area
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Rossco WA
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Re: Bananna Split WA

Post by Rossco WA »

Very nice work, Dave does the business, wonder how many dubs he has welded up to date....many. 8)
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Greypow
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Re: Bananna Split WA

Post by Greypow »

Photos of the rust work on the nose
Attachments
Old rusty inner and outer valances
Old rusty inner and outer valances
Significant rust in the inner valance
Significant rust in the inner valance
Old rusty inner valance
Old rusty inner valance
old inner valance cut away
old inner valance cut away
Inner valance fitted
Inner valance fitted
Outer valance fitted
Outer valance fitted
Ready for nose replacement panel
Ready for nose replacement panel
Nose replacement panel cut to size
Nose replacement panel cut to size
Nose replacement panel welded in
Nose replacement panel welded in
Nose completed
Nose completed
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Greypow
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Re: Bananna Split WA

Post by Greypow »

Yes Dave does an excellent job and there are quite a few of us sand gropers who have made use of his expertise.
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Greypow
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Re: Bananna Split WA

Post by Greypow »

The drivers front needed repairs to the A pillar, dogleg and floor. Fortunately mostly small fabricated sections to repair localised rust :D
Attachments
Drivers side front completed
Drivers side front completed
Drivers floor welded in
Drivers floor welded in
Top of dogleg plated
Top of dogleg plated
Top of dogleg preped
Top of dogleg preped
A pillar plated
A pillar plated
A pillar rust cut out
A pillar rust cut out
Edge of floor cut back showing holes in the A pillar and top of dogleg
Edge of floor cut back showing holes in the A pillar and top of dogleg
Hole repaired
Hole repaired
Inner dogleg
Inner dogleg
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gaz
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Re: Bananna Split WA

Post by gaz »

Good work its coming along well - nice welds 8)
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Greypow
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Re: Bananna Split WA

Post by Greypow »

Yes Dave does excellent work :)
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