Well after the fun and games of Friday we worked some more on Saturday and Monday, so here is a little run down of what we have done.
First job was to finish stripping out the old chassis so removing the bulkhead and engine. With the aid of an engine hoist this was made much easier.
At this point we could clear out the work space and give us plenty of room for the new chassis.
Late on Friday night the new rear roof section arrived from North Wales, so we also wanted to pop that on the tub and see how it sat.
We spent the rest of the afternoon giving the sections of body a jet wash and starting to clear the chassis to tidy it all up then prepare ourselves for the hard work to start on the Monday.
The original plan for Monday was to strip down the old and new bulkheads so we could better assess their condition, the new bulkhead we picked up with the chassis came with replacement foot wells, but we want to give the rest of it a once over too.
But the best laid plans changed and first thing we did was to fire up the diesel engine which was sold as running, so after wiring up and a bit of work it turned over and sounded pretty nice.
So after that little win for the day we decided to strip the chassis right down and start removing the protection and paint, with the plan that we will check the condition of all the metal, do any repairs that we can see then re apply some protection.
Out came the engine, gearbox, fuel tank and anything else we could unbolt and remove to the point by time we finished the only bits left on were the axles, which we hope to get off one night this week so they can be cleaned and painted. The current thinking is red axles and yellow springs with black chassis.
Great progress. It is amazing how fast you can strip them down. Your pictures reminded me of when my, then 6 year old, daughter and I stripped my Series 2 to a bare chassis in little over a weekend. Mind you, that was three years ago and it still isn’t back together again yet 😉
To be fair we found, like you, that the chassis and bulkhead were badly rotten so decided to get a galvanised chassis. That cost a fortune and once we had a shiny new chassis we (or rather I) decided I might as well do the job properly and rebuild everything else to a high standard too. Unfortunately my desire to do this far exceeded my ability to afford it all hence the long build as I have to save up for each major part.
With my wifes 109″ refurbishment she refused to let me take it off the road for any longer than a weekend at a time which meant I had to concentrate on one specific item at a time, say an axle, then strip and rebuild it over a weekend and have the vehicle back on the road for the following monday. This actually worked really well and her truck has racked up over 6K miles since purchase two years ago while at the same time being thoroughly refurbished. I would have liked to do similar with my truck so I could have been using it but the difference was that her truck already had a galv chassis so we could do everything else in small sections at a time and most if not all could be completed at weekends.
My advice for anybody doing a big rebuild is to concentrate on one item at a time (like an axle) and strip, clean, paint and rebuild that before moving onto to the next job. If you don’t do this and instead start stripping everything down all at once you end up with bits everywhere and get a bit depressed when it seems to take forever before you see any progress. Always nice to have high points (eg. completing an item or having a delivery of nice shiny new parts) in the build at regular intervals to negate the long periods of inactivity due to lack of funds, bad weather or lack of parts. Thankfully you have a good workshop so bad weather shouldn’t cause you too many problems. Most of my work has to be done in the garden so I don’t get much done at all over winter.
Yeah it was a good weekend for sure, and throw in a days paint allying it was a good Easter.
Yes with the work space we have, with a good jumper we are warm and if the enclosed garage space is cleared soon we will have full protection from wind and rain. At the moment we are under a roof but still exposed to wind.
The concentration so far has been strip down, assess the condition of everything and then we can go from there, starting ground up with the axles. They came off the new chassis last night and will be rubbed down and turned red soon hopefully.
The next major bump we are going to come to is the bulkhead, we did some measuring last night and the outriggers are an inch shorter than the originals so the bulkhead won’t align.
“The next major bump we are going to come to is the bulkhead, we did some measuring last night and the outriggers are an inch shorter than the originals so the bulkhead won’t align. ”
That is odd, I’m guessing the previous owner of the chassis welded replacement outriggers on AND put new bulkhead feet on (a common rot point as I’ve had to have one of mine replaced too) at the same time and in situ otherwise I can’t see how you could get them that far out of alignment?
I can’t weld to save my life so I ended up using a local LR parts supplier who also had a workshop and did repairs. He did a pretty good job on our bulkhead which needed new footwells, new feet and tunnel repairs. When we got it home it lined up pretty near perfect on the Richards galv chassis other than a slight twist on the new foot but that was soon pulled square with a very large mallet and a spare:-) The only other problem was a couple of the pre-drilled holes in the new footwells were approx 1/4 inch out when lined up with the corresponding holes in the chassis/bulkhead brackets but 5 mins with a dremel solved that.