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Post by kylarama on Oct 13, 2009 8:39:34 GMT 10
Hi guys, Sorry for being tardy, I joined this forum back in June and have now only got around to putting up my first post. I’m about to embark on a mild resto of an old 16ft Millard that we (partner, 2 kids + 3rd currently baking) will share with my in-laws. My in-laws came into possession of the van through unfortunate circumstances. They lost their house along with everything else in St Andrews from the Black Saturday bushfires. A few weeks after the fires someone kindly donated the van to them and has been sitting up their being used as storage and a kitchen while we did the clean up. Now due to the new building regulations and the effort required to build a new home along with sheds, gardens and 20 acres of fencing they have decided to buy an existing house (another 20 property further south in St Andrews) and sell what has now become known as the ‘Block’. The caravan has served its function and they would like to keep it and fix it up so we can all use it. They used to have an off-road camper trailer which we got use of too, which was also burnt out in the fires. The in-laws along with their extended family have been camping on the foreshore in Rosebud for the last 30 odd years, so the idea is to fix this van up for ourselves to use at Yarrawonga (camp about 12km out of town on the river) then at the end of January set it up at Rosebud for 3 months for everyone to use. Now the Van. It’s a 16ft Millard which at a guess is 1975ish, would be pre 1977 as it doesn’t have a Gal chassis, ali frame and the interior is in excellent original condition. From what I understand it has been a site van for about the last 20-25 years down on the coast, the previous owners upgraded to a newer van and took this one home where it sat on their front lawn until they donated it. The drawbar is badly rusted thanks to the fact its ‘boxed’ ‘C’ section, the brakes, wheels, axle and suspension are well past their used by date but the rest of the chassis is in good nick other that allot of surface rust. So the plan is to cut the old drawbar off fabricate, a slightly longer new one from 100x50 Duragal (how long can I go? Want to fit 2 gas bottles and 2 jerry cans plus the rear door on our NM Pajero needs about a metre clearance), new springs, axle, coupling and upgrade to electric brakes. Clean up the rest of the chassis, fit new stabilizers as the bottoms of the old ones have rusted away from sitting in the dirt for 25 years. Remove all the windows and J moulds and reseal them, replumb the water tank, new tail lights and a good scrub. Hopefully get all this done by Christmas, then next year I’d like to convert the van to 12 volt with LED lighting so we can run off solar when bush camping. Have to get moved on a tilt tray to a mate’s house first to do the chassis, so hoping to start in the next 3 weeks. Only have one photo of it, will try to get some more soon.  |
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Post by Deleted on Oct 13, 2009 11:01:49 GMT 10
Hi, sorry to hear about your in-laws horrible ordeal, I have heard of many stories as my works head office is in Melbourne and a lot of my fellow employees knew of someone who had been in the fires or had died in the fires and we have actually just finished working in their with the rebuilding of telecommuncations.
Your intentions to fix up van and use it sounds like a fantastic idea for all of you to enjoy, good luck.
Tammy & Dave
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Post by millard1399 on Oct 13, 2009 21:04:33 GMT 10
G'day kylarama, I can well understand why you haven't been able to post until now. Those fires were a real tragedy, and long after the cameras and microphones were packed up and gone, you guys are still battling on to get your lives in some sort of order. I really, really hope that things are a fair bit brighter for you guys now than they were a few months back. The old Millard doesn't look too bad in your photo. Should scrub up to be quite a handy van when you've finished. I'm jealous that you are aiming to have it all done by Xmas. I keep telling myself the same thing...I just haven't worked out which Xmas yet!!  It doesn't sound like the van will be towed a great distance when moving it from Yarrawonga to Rosebud. You could probably get away with lengthening the drawbar a bit more than what it is. If you were planning on any distance travelling, then that would be a different matter. You would then really need to keep the drawbar weight below the 120kgs mark to make the van stable on the roads. Maybe you could think about having the two gas cylinders on the front, and get a frame made up for the back of the van for the jerry cans (bolt it to the chassis underneath the back). Good luck with working on the windows. Takes a fair bit of time to get through them all. If you need any clues on how to go about it, you can either give kiwijim or me a yell. I'm actually taking step-by-step photos of the one I'm currently working on, so I can make up the "Idiot's Guide To Restoring Millard Louvre Windows". Might be of some use to other Millard owners down the track. Most of the parts for these louvre windows can be bought from the caravansplus website. Excellent mob to deal with. Before you chop off the drawbar, can you tell me what the chassis number is that's welded there please? Should be a five digit number, probably somewhere up around the 50000 mark. Look forward to seeing more of what you do on the van. cheers, Al. |
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Post by kylarama on Oct 13, 2009 21:41:51 GMT 10
Hey Millard1399,
I haven't aimed to have it done by Xmas, my partner has! and being pregnant who am I to argue.
Thanks for the tip on the drawbar weight, I figured I could load it up until I reached the down load limit of the car.
Forgot to mention I plan on putting a rear bar on for a spare wheel.
Thanks for the web link for the windows, will make life easier sourcing parts.
The chassis number is M46913.
Will try to get more photo's this week.
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Post by olfarts on Oct 14, 2009 13:24:41 GMT 10
All the very best with bub mate ;D ;D ;D
Dave
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Post by kylarama on Oct 25, 2009 21:22:33 GMT 10
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Post by kylarama on Nov 11, 2009 22:32:45 GMT 10
Well I haven't done as much as I would have liked in the past 3 weeks. Spent the weekend doing some slashing up at the block, so I had a play with the van. Discovered that the drawbar is not as bad as first thought, I will still replace it, but it will be fine to tow down to my mates place. So I repacked the wheel bearings, adjusted the brakes and wired up some temporary taillights (the originals had moss growing inside them). Got the fridge running on gas and discovered that all the light fittings (3 in the van and one outside) also have a 12 volt globe, which is wired back through to the trailer plug (as I gather is standard with most vans). I'm going to rewire it up to an old UPS AGM battery and fit these LED globes I found on Ebay. cgi.ebay.com.au/12V-36-LED-BA15D-1142-GLOBE-BULB-CAR-CARAVAN-BOAT-LIGHT_W0QQitemZ180424768605QQcmdZViewItemQQptZAU_Boat_Parts_Accessories?hash=item2a02277c5dI also went on a spending spree today. Rang around everywhere try to get replacement springs to match existing. Wanted the same springs as they are longer than standard trailer leafs and the existing spring hangers are massive compared to the ones that come with the new springs. Only place that had them was www.caravansplus.com.au, so I grabbed them along with a couple of wind down stabilizers, winder handle and 4 new clearance lights that match the faded and cracked originals. Then onto the cheap trailer parts mecca, Jagsingh in Thomastown. $700 later I walked out with the following. Complete pair of electric brakes with drums bearings ect. Coupling and mounting plate Handbrake cable, adjuster, clamps ect. pair of LED taillights LED numberplate light Swing up jockey wheel with pneumatic tyre 3 brand new 14x5.5 sunraysia rims with light truck tyres. Plus all the U bolts, fish plates, mounting plates ect. I still have to get an axle as Jagsingh don't sell 45mm square axles. I ending up sticking with Ford stud pattern and pre AU offset (I was going to fit 16x6 NM Pajero rims with 215/60/16, as I already had these) . When I did the wheel bearings I put the wheels from my trailer onto the van. Their 15inch rims with 205 tyres and I could barely get them between the drum and the wheel arch while trying to fit them. I figured with the deeper offset Pajero wheel, the larger new electric drum would be sitting out further plus the wider tyres. I would have to do some surgery to the wheel archs to get them to fit. If your in Melbourne's northern suburbs Jagsingh are worth checking out. They wholesale to the trailer manufacturers but also sell to the public for the same price. They are more than half the price of anywhere else. www.jagsingh.com.au/main.htmI'll pick up the steel for the drawbar and rear bar on Saterday. Then spend the weekend assembling the axle and cutting the steel. Tow the van down Monday night and then get stuck into it. After seeing how long milard1399 spent on his windows, I'm starting to think mine aren't that bad and don't need anything done to them. |
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Post by bobt on Nov 12, 2009 19:59:08 GMT 10
Hi kylarama There is nothing like having a nice little spend up. Now ya gotta go fit it all ;D ;D Good luck. Keep us posted now  bobt |
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Post by millard1399 on Nov 12, 2009 20:43:04 GMT 10
G'day kylerama, Too true...too true!! I see some of your windows are the triple-louvre type. They would be a real challenge to refurbish, I reckon. If you ever have the choice of refurbishing your windows, or eating worms fresh out of the garden...choose the worms!  The big problem with this caravan restoration pastime is that as you fix things up and renew bits and pieces, the stuff you haven't touched looks a bit "old and tired" in comparison. Then you feel you need to tackle those jobs that you were going to leave alone originally. It just keeps snowballing...  Wonder if there's an organisation such as 'Caravan Restorers Anonymous' to help fight the addiction??  cheers, Al. |
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Post by kiwijim on Nov 12, 2009 21:55:23 GMT 10
Go on Al, Tell the truth.............. "YA LOVE THE CHALLENGE" ;D ;D ;D ;D We all do, or there wouldn't be any Classic caravans around. Besides........it keeps the "Dear One" happy knowing where you are......... Locked-up happily alone in the back shed. kiwijim ;D ;D ;D ;D  ;D ;D ;D ;D ;D ;D ;D ;D ;D ;D |
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Post by kylarama on Nov 12, 2009 22:06:39 GMT 10
G'day kylerama, Too true...too true!! I see some of your windows are the triple-louvre type. They would be a real challenge to refurbish, I reckon. If you ever have the choice of refurbishing your windows, or eating worms fresh out of the garden...choose the worms! cheers, Al. Yeah, 4 triple, 4 double and 2 single windows. The upside with them is no glass is broken and all bar one operate fine. So I might just pull the frames out, scrape out the old sealant and reseal them. Then maybe after Easter next year I'll put it in the shed and rebuild them at my leisure, IF I still have the desire. I thing I would'nt mind doing is fitting a glassframe to the door. looks a bit like a site shed with only one window on that side, plus it would be nice to see who's a knockin. |
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Post by kylarama on Nov 16, 2009 16:38:36 GMT 10
Well the better half just created more work for herself.
Rach is in charge of interior decorating, she has a love affair will all things retro and the interior on this van is right up her alley. With whats in our house (not to mention whats packed away in the shed) the van will be full to the brim with era correct decor.
If you ever wonder why you cannot find those anodised soda siphons anymore, thats cause we have them all! I'm not lying when I say around 150-200 of various colours and styles.
Anyway just after the van was dropped off someone left the 4 seasons hatch open. With the strong winds we had it filled the van full of ash and dust, which left the curtains black. So today Rach threw them in the washing machine, but 33 years of sunlight has left them a bit fragile and unfortuantly every curtain was torn.
So now she has to pull out the Singer, find some matching fabric and whip up some new ones, luckily the olds are still usable for patterns. The upside is she'll do these ones with the block out backing.
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Post by bobt on Nov 17, 2009 20:38:10 GMT 10
hi kylarama
rosebud foreshore... I assume you mean rosebud proper...?
Great place... but getting a bit sick of the summer traffic.
Nice to hear someone is passionate about collecting interesting bits. Be very greatful they are not obects of a large size ;D
No sympathy for the curtains. I too have had a similar experience. Thought it was a good idea to wash the curtains in one of the caravans we had. Kids had left their grubby hand marks all over them. They came out of the washing machine in schreds.... Lucky for me I am capable of threading the needle on the sewing machine and I can cut material straight tooo.. ;D ;D
I am just a little jealous at the moment. My dear beloved can never make up her mind about what scheme should be used for any interior type thing. We can discuss and look for years before I will get an answer. These days I just go buy the colour I want and just do it. Sometimes she likes it other times she does not... ;D
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Post by kylarama on Nov 18, 2009 21:33:04 GMT 10
hi kylarama rosebud foreshore... I assume you mean rosebud proper...? Great place... but getting a bit sick of the summer traffic. To me it's like pitching a tent on the median strip of Springvale Road! Rach loves it as its a chance to catch up with her family, plus the beach is very child friendly. Never feels like a holiday for me as my sister lives up the road in Mornington and also has a business in Rosebud. I guess its a good chance for me to catch up with my family. |
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Post by kylarama on Nov 28, 2009 17:42:21 GMT 10
Well I finally pulled my finger out and got a start on the van.
Unfortunately the rate I'm going we may be camping in a tent at Christmas, work is crazy at the moment.
Last Monday we towed the van down to my mates place. The vans so easy to tow, especially when the tow car has around 700nm of torque! (Ford F250)
On closer inspection the drawbar looked like it would have been ok. Probably could have got away with a good going over with a wire wheel and a coat of paint, but having already purchased the steel and wanting a longer bar off she came. It put up a fight and took quite a few hours to get off and clean up the chassis.
New bar is 400mm longer and we have also added some trusses under the new 100x50 drawbar made from 40x5mm flat bar for extra strength.
Everything was going fine last night until we ran out of gas for the MIG welder, so the drawbar is ready to reattach to the van and the axle has 1 brake flange welded to it. We both had to work today so neither of us could swap the bottle over, so work has halted until Monday night.
Will try and get some photo's tomorrow to post.
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Post by kylarama on Dec 2, 2009 19:25:40 GMT 10
Finally some pics. Went to bolt the new springs and axles in this arvo only to find out the ubolts are too short and the fish plates are to suit 60mm wide springs. new drawbar. 400mm longer than the original. Once the gas bottles and jerry cans go on the read door on the Pajero sould just clear it. Also got the thumb screws on my plumber to get me some 150mm dia. PVC pipe for a pole carrier.   Don't think it will break off anytime soon!     Old drawbar and axle removed   New axle with electric brakes and wheels ready for installing.  Started making the rearbar too. Made out of 100x50 RHS and some 45mm dia (? I think) commercial sprinkler pipe bent around under the chassis. Will have some pics of this in a few days. |
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Post by philouise on Dec 4, 2009 13:11:17 GMT 10
Hi Kylarama.
I am a bit late but welcome to the classic caravans and millard family from me too.
Love the work youv'e done under the van - and the rear bar yet to be.
I might have to invest in one of those welders if that is what happens.
Al the best and hope you have lotsa carefree camping
Phil.
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Post by bobt on Dec 4, 2009 21:16:13 GMT 10
Hi kylarama That is a nice bit of welding you have there. Is that your handy work?? Mig, Tig ? ? ? ? Lengthening the draw bar is a real good idea, i personally reckon that a van with a longer draw bar is easier to reverse Keep at it .. looking most impressive. bobt |
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Post by kylarama on Dec 4, 2009 23:32:55 GMT 10
Would love to take credit for the MIG welding, but it is the handy work of a good mate of mine. Not bad steelwork for 2 carpenters?
The long drawbar will make for easier reversing, although anything would be easier than my 6x4 trailer. When I was 19 I bought a ski boat, the trailer was nice and long with the axle set well back. For the next 5 years other than the odd car tandem this was all I towed and reversed. So imagine my shock when I went out and bought my own 6x4 trailer and almost jack knifed it reversing out the driveway of the trailer manufacturer.
Got the rear bar on yesterday, along with bolting up the axle (it's back on wheels!). Welded 50x50 SHS to the chassis rails, 44mm dia pipe sleeves into it which is bent to follow the curve of the back of the van.
The problem I have now is with the longer drawbar and a rearbar with spare wheel fitted the ball weight is a bit light. 2 jerry cans along with 2 gas bottles are still to be fitted on the drawbar, so along with the watertank full and an AGM battery (they weigh around 38kg) fitted under the front seat it should bring the weight up. Problem is at the end of a camp trip, the water tank, jerry cans and gas bottles are empty.
Maybe a nice large low height tool box fitted between the a frame.
Keep forgetting to take the camera with me, so will post more pics tomorrow.
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Post by kylarama on Dec 5, 2009 23:32:26 GMT 10
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Post by kiwijim on Dec 6, 2009 7:16:35 GMT 10
G'day Kylarama, "GEZ" I have been mighty slow on catching up on this tread,  That's a fantastic job you are doing on the Millard Mate, I can see this van will be around Long...Long, after some of these modern Miracles have fallen to bits and become parts for other heaps of junk being manufactured today. Number 1 top welder you have employed there as well, if my welding was half as good as that, I would be more that happy, What type of welding is it, Mig, Tig, ? darn sure it's not Arc !! Talking of clearance lights, Why not go L.E.D. ? although more expensive than conventional lights, they will last a lot longer, are brighter, and would really set the Millard off a treat. Cheers kiwijim |
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Post by kylarama on Dec 6, 2009 8:32:49 GMT 10
Thanks Kiwijim, all welds are done with a 170amp MIG. I've got a 120amp MIG that I run gasless, but all my welds resemble pigeon poo not the nice fat beads you see in the photo's. The bloke doing the welding is completly self taught. I know I should have gone LED with the clearance lights. I was going too but they were $18 each, then I found the original Hella/Narva ones at caravansplus.com.au for $8ea. The LED's are much smaller than the originals so I would have to make a backing plate to cover the the old ones. The clearance lights are the crappy festoon globes and their already giving me grief. I don't think it would be hard to solder a couple of LED's together and replace the festoon globes with them. Might head down to Jaycar for a look. Also got the 12v lights in the van working, have to replace 1 globe and 2 switches. I was going to replace the globes with these cgi.ebay.com.au/NEW-54-LED-ANCHOR-MAST-CARAVAN-BA15D-GLOBE-REPLACEMENT_W0QQitemZ120501258679QQcmdZViewItemQQptZAU_Boat_Parts_Accessories?hash=item1c0e6f49b7but at $20ea plus postage (I need 4) they might have to wait until next year. |
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Post by Deleted on Dec 6, 2009 11:57:39 GMT 10
Gidday Kylarama, How are things mate - well blow me down you sure have got heaps done in the short time you have been with us buddy and what an improvement it has been as well, it certainly has given the old girl a new lease on life. As Jim said that sure is a beautifull welding job. Those mags and tyres sure look really impressive as well hmmm I wonder if I could strengthen the chasis and throw a couple of six stud landcruiser hubs on heavy axles on my old girl so I could take her down some isolated tracks etc (maybe later if swmbo lets me hahahaha) You are gonna get thousands of miles out of her and keep yet another classic from the scrap heap good on you keep it up another piece of rolling history for our kids to enjoy. Kiwicarl |
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Post by kylarama on Dec 7, 2009 23:01:14 GMT 10
Did a bit more tonight. Wired up the electric brakes. Used 15 amp twin core sheathed wire and ran it inside some spiral conduit. Zipped tied it along the back of the axle from 1 brake to the other then clipped it along the chassis to the existing juction box at the front of the van. will also run some 50amp cable from here to the coupling fitted with a Anderson plug to charge the van battery from the car. Also finished welding up the rear bar and welded on some plates to cap the ends of the bar off. Rear stabilizers are now fitted, these are welded onto 70x70 8mm angle which is welded onto the sides of the chassis rails, this was done to clear the posts for the rearbar. The angle is a bit of an overkill, but that is what was lying around. The angle by the way are from trusses out of an old aircraft workshop at Essendon Airport built before WWII. Anyhoo here's some pic's from the weekends works Hope their okay, I took them on my phone camera. Drawbar with the jockey wheel fitted and hand brake connected.   New Taillights and clearance lights fitted   |
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Post by bobt on Dec 8, 2009 20:44:17 GMT 10
Hi kylarama
Looking good. Judging by your rate of progress It will be parked on the centre strip of springvale road soon. Just in time to enjoy our wettest summer in history ;D
Careful with the weight in the rear end of that thing. The tool box on the front would be good. Handy for all those extra bits you want for the caravan.
Good to have friends that can weld. I am lucky my son can and I have a couple of mates that can too.
Lights are always a challenge, boat trailers, trailers, caravans they always seem to get water inside them no mater how well you try and seal them up. I recon the best bet is to have a water escape hole at the bottom of the lens at least that way you have some hope of getting the moisture out and some life out of the fittings..
bobt
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