59 Split 11 Window - Resto

chillax · Post by **chillax** » Mon Oct 13, 2008 10:38 pm

Hey Guys,
Finally most of the remainder panels have arrived today (Gerson floor sections and doglegs), so we are pretty much now good to go.
The only panels left we are waiting for is the roof sections (autocraft) and the rear corners (autocraft).

Here are some update pics

Middle seat bases looked okay upon initial inspection but around the edges, you could see problems lurking (like everywhere else on this bus!)

After the base plates were removed, the rust was evident, thus cut out and to be replaced with fresh metal

After much discussion, the best option for floor repair was to use Gerson side repair sections (as full floors weren't available quickly enough), so the existing floor was cut and prepped

Trial fit got us a little excited as finally things feel like they are moving forwards!

Jack

OMR_007 · Post by **OMR_007** » Mon Oct 13, 2008 11:43 pm

WOOHOO ... got to love new metal going back in after seeing so much come out!

I'm guessing the Gerson sections went in like a breeze?
Keep going, keep going!

chillax · Post by **chillax** » Tue Oct 14, 2008 10:46 pm

Another day, another update

This was the last remaining rusty section in the engine lid to repair

A donor section was grafted in (after reshaping) from the bay window lid which donated its inner hinges etc

After some careful welding and grinding it came out very nicely

The floor on cargo door side was welded in today (Cleco fasteners shown here before welding)

The cargo doors were stripped further today and rust treated on the inner frame

After the rust converter was applied (neutralised with damp rag, then metho), some rust preventative paint was applied

Both doglegs are now removed (lots of spot welds!), and Gerson legs ready to go in after some final repairs of leading edge of b-pillars

Jack

Hoves · Post by **Hoves** » Wed Oct 15, 2008 7:25 am

There is no doubt about it Jack - this is one full on resto. Great to see it all coming together.

byronbus · Post by **byronbus** » Wed Oct 15, 2008 3:35 pm

Wow, wish i had those skills, thanks for the detailed pics, loving watching.

kombi_maniac · Post by **kombi_maniac** » Sun Oct 19, 2008 9:52 pm

Jesus that is thorough Al! very impressive stuff, shes gunna be like new when its done!

Chillax u must b stoked!!

chillax · Post by **chillax** » Tue Oct 21, 2008 8:49 pm

Cheers for the comments guys, its def a full on resto

A heap of work has happened over the past 2 weeks!

I finally got to look at the pics, as we only just got the internet reconnected (moving house).

Anyway, here is the overload of pics

The top hat sections were rust converted then painted before the new floor section went down

The rust is everywhere in this bus

We will have to count the number of repair pieces in the bus once all done - a lot of new metal has gone in, here are a few more "to do"

Colour was squirted on the inside nose section (beige grey)

Same pic without flash - base coat/clear coat used

Inside of the nose was also painted before the skin goes on

Inside windscreen section also painted before it is fixed in place

Engine lid was finally painted in epoxy primer then high build primer ready for a guide coat and more sanding

Cargo doors were refitted today to manipulate the gaps before the lower inner frames were cut out

Engine lid was trial fitted today to check gaps and do any adjustments necessary before it comes back off

The outer nose was trial fitted today finally - Cleco fastened in place along with outer valance to get the alignment right

Steve welded up the outer valance and applied rust preventative paint on areas that will be inaccessible once nose is on

The Gerson sections fitted extremely well apart from a slightly excessive length - thus had to cut a small section out and trim to fit in the corners

This cut and shut process resulted in a correct profile and better fit

Same door, different view

The door pin guide had to be salvaged from the old door and welded in the correct position so the door would shut and stay in nice and tight

Same process was undertaken for the front cargo door

After all the welding of the inner frames and realigning the hinges things were looking pretty good (fit wise)

Outer skin on the front cargo door was trial fitted to check gaps etc

Then the rear was fitted with Clecos temporarily - both skins will now come off to paint inner frames and inside door skins

The nose skin was welded in place today and the lips were folded over the a-pillars and outer valance

Jack

chillax · Post by **chillax** » Tue Oct 21, 2008 8:51 pm

Almost forgot, a huge thanks to Hoves for the help with the colour codes of the top colour, beige grey,

warb · Post by **warb** » Tue Oct 21, 2008 9:00 pm

lovely.. makes me feel lucky for the first bus being non crusty.... just the second one that worries me..

Hoves · Post by **Hoves** » Wed Oct 22, 2008 7:50 am

Very good stuff Jack. This will be one hell of a bus.

OMR_007 · Post by **OMR_007** » Wed Oct 22, 2008 8:26 am

You must be getting excited Jack, even seeing a little bit of paint go on is a sweet thing

Moving house? What happened to reppin the 4171?

morts · Post by **morts** » Wed Oct 22, 2008 5:09 pm

Very impressive re-build - this one will be better than new I expect!

chillax · Post by **chillax** » Wed Oct 22, 2008 9:21 pm

I know i know, moving from the 4171, after being born and raised

Now we are 4178 (to the bay), will not be the same

Oh and here is the update for this week so far

Autocraft windscreen surround was not a great fit so needed some work during trial fits

Cargo door skins were tacked in place - upper joint is fully seam welded but is a lap joint rather than butt for strength (weld through primer used on mating surfaces to avoid corrosion plus seam sealer on inside joint)

Both upper and lower horizontal surfaces of the windscreen surround had to be cut and shortened, then rewelded

Cleco's help to keep it in position during trial fits and plug welding

Both cargo door skins were fully welded in - finally the bus is coming together!

Apart from fabricating a new inner skin closing plate around the windscreen the nose is finally done

After about 4 days solid of work just on the nose it is looking like a bus once again - well done to Steve for his persistence on this one!

Jack

joshroom · Post by **joshroom** » Wed Oct 22, 2008 10:00 pm

that exelent stuff man, please tell us more about these clecos ive never seen or herd of them before

Dasdubber · Post by **Dasdubber** » Thu Oct 23, 2008 7:32 am

Cleco fasteners were designed (I think) primarily for the aircraft industry - they basically allow you to hold together two pieces of metal (like a temporary pop rivet) but is easily removable as many times as you want with the pliers. They are great when trial fitting panels as you only need to drill a small hole (1/8in for example) which is easy to weld up.

If you pop in "cleco" in egay there are always pliers/cleco's for sale - not too exy.
Al