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Post by Deleted on Jan 15, 2015 10:35:31 GMT 10
Going.. 
Going..... 
Going..... 
GONE 
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Post by Deleted on Jan 15, 2015 11:06:38 GMT 10
What a day yesterday was...! The humidity was ridicules. I took my time checking and marking exactly where the different chassis and supports were, drilled out rivets in the way of where the cuts would go and using a tenon saw, the cuts were made. I then removed wiring and then drilled out the remaining rivets. 
Using some old 3mm ply pieces, I carefully lift the side frame and placed them between the ply floor and frame, double checked everything holding the floor was removed and start to carefully tap the section away, only hic-up along the way was a nail had been shot through the frame into the floor hit the chassis and then bent and turned itself back up, it was near where the vans 12v light wiring was drilled up into the frame and because that area had some rot as the floor moved forwards it dragged and pushed out some of the rotten timber and revealed itself, so a bit of work with a small chisel and my Stanley knife had the offending nail exposed and a quick snipe with the side cutters had it cut and then removed the top "t" bit with some multi grips and after that it was just a case of slowly tapping the old floor out checking the ply packing and placing 13mm spacers into the area left by the floor to hold the frame away from the side chassis.
Why 13mm...  the floor is 12mm ply but they had the vinyl on it before the frames are attached so it is a little thicker 
Due to another heat wave passing through, won't be doing to much till next Monday plus I'm going away fishing again...but next week will clean up the chassis and any burr's in the frame or chassis and then go and get some 2mm gal sheet to go under the middle section plus bevel the edge back for joining. Thinking I might get some 3 mm mdf first and cut it as a template before using the 12mm.
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Post by Deleted on Jan 21, 2015 15:24:13 GMT 10
Well I have been hard at it for the last 2 days and the new section of floor is just about ready to be installed. I fitted an extra chassis support so when I mount the battery it will have something other then just ply under it. Went over the exposed area with a light wire wheel and a buffer/ paint remover wheel and clean the chassis and the alloy frame, filed all the old rivet holes in both the frame and chassis and have just now finished cutting the ply.
Now before I fit the ply, a few questions.. 1/ Will this glue be OK to join the sheets ? Now if you wish to recommend a particular glue, it has to be available local to me ie Ipswich Qld. AND not be expensive or only come in 1ltr sizes, there is only approx. 4 ft of join to be glued and it is only 12mm think so bulk amounts are out.
Can I seal the edges of the ply with enamel primer ?
Also is there any reason I cannot use countersunk screws with nyloc nuts to hold the floor down ?
I think that is everything at the moment.
Cheers
PS Also - Do I seal the edges that are to be glued or leave natural ? |
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Post by atefooterz on Jan 21, 2015 22:50:36 GMT 10
So 35ml or the 200 tube?
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Post by Deleted on Jan 22, 2015 6:00:48 GMT 10
Will get the 200ml containers
cheers
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Post by Mustang on Jan 22, 2015 7:14:41 GMT 10
My road has smoothed out some, after reading your journey, wow. That humidity, I have been here 22 years & don't remember feeling like this, perhaps I'm just 22 years older.  |
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Post by Deleted on Jan 22, 2015 7:25:33 GMT 10
Well
What a week...it didn't start so good but it got better as the week went on. All my 12v cabling has arrived and my Anderson plugs, the chassis and frame were all cleaned up and any burr's removed and smoothed, I measured and measured again and cross checked the measurements with the piece of floor that was removed. I cut the new ply allowing for a tight fit, sealed the bottom of the ply, the edges and around the top where the frame sits and late Thursday morning the fitting was made 
It took a good couple of hours slowly getting the sheet in, making sure all the packers were moving and the ply wasn't grabbing underneath either, but slowly is came. 
At 20mm out the gaps were all checked and one edge was 1mm wrong so a quick hit with a mouse sander and the glue was mixed and applied to both edges and the gal sheet below, then the eagle was landed ! 
..
Over the last couple of days I have been mixing up epoxy and adding some filler and pouring into any of the gaps up to 1mm. So in 48hr it will be ready to be sanded. Have fitted a few bolts to keep the new section in place. Will be replacing the fridge and attaching the wall frame back to the chassis.
Cheers |
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Post by Deleted on Jan 28, 2015 17:57:40 GMT 10
It is amazing how you slave away all day but it looks like you have done nothing, well this week is the same seems like little has changed but was able to go and get more bits for the van and the floor is now totally in and sanded and the joint sealed. Also have sorted and fitted the 12v system for all the driving lights and tested, just need some new light assembles and a new plug/connector and that's finished. While out and about picked up some "C" section and have trimmed and cut it to be fitted to the front of the frame. Finished painting the bottom of the van and cleaned approx. 1/4 of the old sealants from the trim area's. Time for some photo's... 
A bit of 12v surgery
The fold up table/tool bench is starting to get a few nic's and cuts
Now the deal of the century - I have been looking for some 5 stud 13" rim's for the van, well I spotted an ad on Gumtree, and I thought to myself if it sounds to good to be true it is - why did I think that well the ad read Brand New 13" Sunriaysia Rim's Ford 5 stud ......$15....that's gotta be wrong - well it wasn't and I now have 3 rim's and before you ask there all sold approx. 60 of them..
Cheers |
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Post by Deleted on Jan 31, 2015 15:43:24 GMT 10
And the march continues.....the checker plate
A couple of "c" sections are added across the front 
Cutting and bending the checker plate had a few issue's. Word of warning checker plate does not like to be bend at 90 deg ! 
Mounting holes have been drilled and excess area marked for removal, will not be fitting it until I get some neoprene rubber strips for the edges and chassis 
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Post by jdmac2312 on Feb 1, 2015 12:56:05 GMT 10
Hey,
You are making us have a strong think about doing the treadplate at the front of our Micro.
We want the easy way out. Heheheheeh
Jacquie
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Post by Deleted on Feb 2, 2015 8:43:22 GMT 10
Hey, You are making us have a strong think about doing the treadplate at the front of our Micro. We want the easy way out. Heheheheeh Jacquie It will give your van better protection using the tread or propeller plate, but it adds to the overall weight as well...
Cheers
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Post by jdmac2312 on Feb 2, 2015 8:54:31 GMT 10
Yes I agree with that.
We will most likely do the treadplate as you said for protection.
The weight will not be an issue as we are replacing the old heavy fridge with a lighter one.
Thanks for the support and keep up the good work as we will be watching your progress eagerly.
Jacquie
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Post by Deleted on Feb 10, 2015 9:22:57 GMT 10
Sorry no photo's today..
Well I have striped the old ply from the kitchen cupboard, which is stapled and glued so working a couple of hours each day using a chisel and sander and it was back to just a frame. Cut and glued and stapled some new sheets into place after I primed them. Also asked my sparkie mate to come around and fit the RCD, so now have the safety switch in the cupboard above the stink. I have rebuilt the damaged mudguard from the passage side and will coat with some anti chip paint later this week and fit over the weekend or early next. On the weekend we went to the Toowoomba swap meet and picked up 2 tail/stop lights for $9 new..so will look at fitting them shortly as well, will be heading to Brisbane this week to collect the new axle/brakes etc plus have an order ready to go to Caravan Plus for some plumbing/gas stuff.
Cheers |
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Post by Deleted on Feb 19, 2015 11:10:08 GMT 10
It has been a good week with plenty of jobs now moved to the completed list. First the checker plate is finally sealed and fitted 
I will be fitting some trim and sealant across the join when I seal all the trim sections.
The damaged mudguard is now looking like it should and is fitted back into place with the foam seals and sealant 
Basically I had to panel beat it, then pop rivet the joins that had opened up, then coat all the joins with flexi sealant/glue, etch primer, anti chip paint and satin black enamel and refit.
Having friends with benefit's helped with the next addition, a new gas line for an outdoor BBQ  
My friend was not happy with the hoses going to and from the gas regulator, so have ordered a couple of new hoses.
In the top photo you can see the gas bottle sitting in place, I repaired and straighten the holder and got some bolts and a wing nut etc, gave it a paint and is loosely bolted in place.
On Friday I popped into Brisbane and picked up my new axle/brakes/hubs and bearings and plates and U bolts etc and will look at welding the axle all together sometime next week, will also be removing the copper water line running to the stink and replacing it with plastic/nylon stuff the big green shed sells. I also dropped off a few items to Jacquie & Kevin's place while in Brissy, had a lovely lunch and a good look at there van, we swapped idea's and I learnt a few things too.
I removed all the counter sunk rivets from the floor and replaced them with C/S 1/4 bolts and nyloc nuts and didn't that make a difference, straight away the floor movement stopped 
I also fitted the new clearance lights (no pic's) and have removed the old tail lights and have lengthen the wires to them and fitted some earth wiring for the lights, will fit up the new tail lights maybe next week ?? Also will get some tyres fitted to 2 of the rims so that once the axle is fitted I can move the van.
Once the van is mobile again I will be removing the front half of the roof and will look at strengthening and repairing and replacing whatever is needed.
OK at this point in time the completion date has been moved foreword from end of April to mid April or even end of March.
It has been nice to have something to keep my mind busy and fun in learning now they all go together.
Cheers
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Post by jdmac2312 on Feb 19, 2015 20:56:00 GMT 10
Wow, you sure are plowing along
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Post by pisces51 on Feb 19, 2015 21:01:04 GMT 10
G'day lockyer, It would be a very, very, rare occasion on this forum that somebody has said they'd moved their end-date FORWARD!! Good on you for getting it all sorted quicker than you anticipated. Nice job on the mudguard - darn hard things to fix up, but you've done well. Looks like you're gonna end up with a pretty nice looking van!  cheers, Al. - |
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Post by Deleted on Feb 20, 2015 8:52:07 GMT 10
Hi Al
I keep waiting for that "Ohh sh*t" moment, you know when you find that spot that looked fine but was really just paper and paint/rust etc and I have runs into a few bumps but I found by carefully working out how things are put together you soon have a easy way to fix/repair...except caravan doors...I cannot believe now the plastic trim looks so close to the aluminium in colour and shade.
cheers Lawrence
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Post by Mustang on Feb 21, 2015 11:32:43 GMT 10
Great pace man!!!
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Post by Deleted on Feb 22, 2015 17:30:23 GMT 10
The new axle getting the axle pads and brake locators welded on 
Notice the new tyres on those brand new $15 rim's in the background..! Time to fit the axle and brakes to the van 
It was only a couple of months ago the van had 12" wheels, today she has 13" wheels, new axle and brakes 
Well I said once I could move it I would do what ?? 
So next week will be a short one as I have no choice but I have to go away for a fishing and camping trip with a good friend...such a hard choice....work on the van or go away fishing and camping....!
I hope to at least have the roof off by Wednesday evening, will see what condition everything is in and repair or replace as needed, plus I have to strengthen the side the awning is going onto as it will be fitted to the roof and not the side wall and what I've seen so far is there's is nothing up there except 2 bits of timber that hold the pop top in place!
Cheers |
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Post by Mustang on Feb 23, 2015 6:04:08 GMT 10
Go Fishing..... I detect a burnout coming?  ? |
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Post by jdmac2312 on Feb 23, 2015 8:29:56 GMT 10
Go fishing, nothing better
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Post by Deleted on Feb 23, 2015 8:34:53 GMT 10
Go Fishing..... I detect a burnout coming? ? Hi Brent
Mate every month, myself and a good friend go away either overnight or for 2 nights camping and fishing the western rivers and dams, we are setup with stretcher tents and our cookers and it always feels like we have been away for 5 days not 2 or 3. Plus it has the opposite effect, as some of the places we go I see caravans free camping and think I gotta get back and finish my van. I put up some photo of this trip when I get back.
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Post by Mustang on Feb 23, 2015 10:25:37 GMT 10
I love " fresh fish" good luck. You know how to treat yourself? |
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Post by Deleted on Mar 5, 2015 11:22:29 GMT 10
Progress report
I have removed the roof cladding and found some interesting modifications 
The blue carpet stuff on the ceiling, was hiding the water damage to the ply - I already knew this and had planned on removing or repairing as needed, but I didn't realise that they had used other bits of timber to try and fill the missing section 
The other side was only slightly better 
So I went and ordered some 3mm ply and found some 14mm timber as I wanted to replace the timber beam from then pop-top support as it was a little soft on one end, the side frame timber spacer had some rot from the door foreword on the door side and even less on the other side. I am fitting a 4wd 3m awning and this requires 3 supports to attach too, so I decide to replace a bit more of the side frame timber but would run the pop-top support right across and onto the side frame not just onto it's edge and after fitting the new ply ceiling I then fitted the new pop-top support using glue and 16mm staples, I then screwed the support directly into the alloy side frames. It turned out to be a nice finish. 
The inside looks a bit better with the new ply and the carpet gone. 
The rear section of roof is in good condition just a little bit of rot on the ply edge but the rest of the sheet/s are fine, and the timber on the side frame is good as well and same with the rear pop-top support. So after a careful check, I fitted some small metal brackets on the awning side and added extra screws into the side timber frame as well, I then mixed some bondcrete and coated the ply and timber frames across the back and down the sides, twice. I will be painting all the framing and timber supports before I re fit the roof cladding. They have also glued that carpet stuff onto this section and after consulting with the boss, she was happy to leave it as it is, which is why no new ply going into the rear section.
I need to make a support for the middle awning bracket 
I could not find any 15mm ply sheets in a smaller size and buying a 8x4 sheet was not going to happen !  So using some of the floor offcut - 12mm and some 3mm, I was able to make a support and glued, pop riveted and stapled it on to the ceiling and side and pop-top support frames plus using some 4mm ply I reinforced the ceiling/cupboard bringing that under the pop-top support on the inside of the cupboard and it is glued - riveted and stapled.
So that's where I'm up to, as soon as this heat wave passes, will paint the rest of the internal roof and clean the roof cladding and put it all back together using a butyl mastic.
Cheers |
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Post by bobt on Mar 5, 2015 22:24:37 GMT 10
You just gotta love those cheap previous owner repair jobs.
It is looking good.
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the floor is 12mm ply but they had the vinyl on it before the frames are attached so it is a little thicker 
So using some of the floor offcut - 12mm and some 3mm, I was able to make a support and glued, pop riveted and stapled it on to the ceiling and side and pop-top support frames plus using some 4mm ply I reinforced the ceiling/cupboard bringing that under the pop-top support on the inside of the cupboard and it is glued - riveted and stapled.