Yorkshire Van restoration

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Re: Yorkshire Van restoration

Postby A35revisited » Fri Dec 30, 2016 12:13 pm

I've now completed the first gutter, the second should be easier as the curve is not needed.
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A pillar gutter 2 - Copy.JPG
I chose to fabricate the bend because I didn't want to cut notched in it but when I made the first fold, I finished up with a curve which I could not get out without cutting notcheds along its length.
A pillar gutter 2 - Copy.JPG (41.34 KiB) Viewed 472 times
A pillar gutter 3 - Copy.JPG
Folding the rain channel profile.
A pillar gutter 3 - Copy.JPG (40.89 KiB) Viewed 472 times
A pillar gutter 4 - Copy.JPG
Welded in place just awaiting grinding flat.
A pillar gutter 4 - Copy.JPG (38.42 KiB) Viewed 472 times
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Re: Yorkshire Van restoration

Postby David Swain » Sun Jan 01, 2017 12:56 pm

Fantastic work as usual, well done! :thumbs:
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Re: Yorkshire Van restoration

Postby A35revisited » Mon Jan 02, 2017 8:14 pm

I was being unduly optomistic when, in my last post, I said the other side should be easier. When I removed the old gutter, it took with it a substantial amount of A pillar with it.
A pillar os 1 - Copy.JPG
A pillar os 1 - Copy.JPG (39.51 KiB) Viewed 437 times
Nothing for it but to cut out the remaining metal and start again.
A pillar os 2 - Copy.JPG
A pillar os 2 - Copy.JPG (39.51 KiB) Viewed 437 times
Opening the innards of the A pillar allowed them to be cleaned up and treated with Hydrate 80 and zinc primer.
A pillar os 3 - Copy.JPG
A pillar os 3 - Copy.JPG (38.4 KiB) Viewed 437 times
I made up two pieces in much the same way as I had for the the near side gutter but without the actual gutter part to replace the metal which had been cut out and welded them into place.
A pillar os 4 - Copy.JPG
A pillar os 4 - Copy.JPG (36.81 KiB) Viewed 437 times
I now have a sound A pillar onto which I shall plug weld a new gutter.
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Re: Yorkshire Van restoration

Postby A35revisited » Sun Jan 08, 2017 5:39 pm

There's been lots of boring patching jobs this week. I don't see why I should suffer alone so here are more pics:
I completed the off-side A pillar gutter and turned my attention to the windscreen surround. The top rail had become detached from the side-rail so, first I tacked it together as best I could.
Screen surround 1 - Copy.JPG
Screen surround 1 - Copy.JPG (30.81 KiB) Viewed 411 times
Then I added in a half inch plate over the joint, welded to stronger material.
Screen surround 2 - Copy.JPG
Screen surround 2 - Copy.JPG (34.13 KiB) Viewed 411 times
The flange is tatty all round so I started in the easier bits. Here, I replaced a rotted out inner skin section of the bottom near side corner.
Screen surround 3 - Copy.JPG
Screen surround 3 - Copy.JPG (32.46 KiB) Viewed 411 times
The off side was worse, both skins has rotted.
Screen surround 4 - Copy.JPG
Screen surround 4 - Copy.JPG (27.49 KiB) Viewed 411 times
I grafted bits in both inside and out
Screen surround 5 - Copy.JPG
Screen surround 5 - Copy.JPG (26.17 KiB) Viewed 411 times
The two skins had de-laminated leaving significant gaps so I clamped them and edge-welded them together.
At this stage, it looks truly horrible but I am trying to convince myself that when ground down and fettled up a bit, it will be quite presentable.
So much for the easy bits. I am now retiring to a darkened room for a lie down to prepare for the top flange.........Advice will be most welcome!
Screen surround 7 - Copy.JPG
Screen surround 7 - Copy.JPG (34.02 KiB) Viewed 411 times
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Re: Yorkshire Van restoration

Postby Neil Evans » Mon Jan 09, 2017 9:31 am

A35revisited wrote:The top rail had become detached from the side-rail


They were never properly welded, often only the paint holding them together...
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Re: Yorkshire Van restoration

Postby tonyg » Mon Jan 09, 2017 8:34 pm

My van was very bad in that area as well, with both the outer and inner windscreen surround rotted. The A30 windscreen surround is the same as the van but they tend to be very sound on the saloons but rot on the vans. What I did was to find someone who was breaking an A30 saloon and cut out the required sections and let them in as required
Attachments
windscreen3.jpg
windscreen3.jpg (163.42 KiB) Viewed 374 times
windscreen2.jpg
windscreen2.jpg (182.22 KiB) Viewed 374 times
windsreen1.jpg
windsreen1.jpg (207.12 KiB) Viewed 374 times
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Re: Yorkshire Van restoration

Postby Paulc » Tue Jan 10, 2017 2:49 pm

I have this piece if you are interested, just about 4" of gutter missing.
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IMG_3346.JPG
IMG_3346.JPG (103.41 KiB) Viewed 357 times
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Re: Yorkshire Van restoration

Postby A35revisited » Tue Jan 10, 2017 4:12 pm

That would be great, thanks. I just found that the roof is perforated behind the gutter so that will solve two problems.
pls pm address and price.
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Re: Yorkshire Van restoration

Postby A35revisited » Tue Jan 10, 2017 4:35 pm

p.s. That for a van or car? I presume the gutter is the same but the roof line differs though that should not be a problem.
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Re: Yorkshire Van restoration

Postby Paulc » Tue Jan 10, 2017 6:37 pm

Came off a van, I did pm you the other day!! :whistle:
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Re: Yorkshire Van restoration

Postby A35revisited » Sun Jan 15, 2017 12:27 pm

PaulC's offer of the windscreen top panel was a life-saver. Once I started to prepare the top gutter, I found that the roof had perforations just above it along what appears to be a seam and the only solution would be to cut out part of the roof as well. Just awaiting the call to make the 400 mile round trip to collect it. The things we do for our Ausins!
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Re: Yorkshire Van restoration

Postby A35revisited » Tue Jan 24, 2017 5:59 pm

This was the most nerve-wracking job to date. Paul C's section arrived safely and was perfect for the job. Thanks Paul.
Windscreen 1 - Copy.JPG
Windscreen 1 - Copy.JPG (36.67 KiB) Viewed 280 times

First job was to carefully split the body panel from the top rail.
Windscreen 2 - Copy.JPG
Windscreen 2 - Copy.JPG (38.78 KiB) Viewed 280 times

Then I cut the panel to the shape I wanted and grafted in the missing four inches of gutter. The thick top layer of paint was also removed.
Windscreen 3 - Copy.JPG
Windscreen 3 - Copy.JPG (35.46 KiB) Viewed 280 times

The old gutter was cut out to allow the new panel to be marked on the van.
Windscreen 4 - Copy.JPG
Windscreen 4 - Copy.JPG (35.93 KiB) Viewed 280 times

No going back now, I'm fully committed.
Windscreen 5 - Copy.JPG
Windscreen 5 - Copy.JPG (34.53 KiB) Viewed 280 times

The panel tacked into place.
Windscreen 6 - Copy.JPG
Windscreen 6 - Copy.JPG (35.27 KiB) Viewed 280 times

Finally the new top rail clamped in place ready to be welded in.
Windscreen 7 - Copy.JPG
Windscreen 7 - Copy.JPG (37.28 KiB) Viewed 280 times

In order to help offset the effects of my less than skillful welding. I first tacked a strip along the edge giving me something to weld into and reducing the expected distortion. Overall, the shape worked out surprisingly well and I'm pleased with the result.
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Re: Yorkshire Van restoration

Postby A35revisited » Fri Feb 17, 2017 5:52 pm

Just a few incomplete jobs to report today. First up is the rotten front ns wheelarch.
First the corrosion is cut out, back to solid metal.
Wheelarch nsf 1 - Copy.JPG
Wheelarch nsf 1 - Copy.JPG (33.41 KiB) Viewed 186 times

Some corrosion in this panel - no idea what it's called - but rather than cut it out, I chose to wire brush it using the angle grinder and treat with Hydrate 80.
Wheelarch nsf 2 - Copy.JPG
Wheelarch nsf 2 - Copy.JPG (37.31 KiB) Viewed 186 times
The bottom of the wheelarch cut back to good metal, exposing the new floor pan fitted oh so long ago!
Wheelarch nsf 3 - Copy.JPG
Wheelarch nsf 3 - Copy.JPG (36.33 KiB) Viewed 186 times
A large spreader plate plug welded on, much larger than the affected area.
Wheelarch nsf 4 - Copy.JPG
Wheelarch nsf 4 - Copy.JPG (36.3 KiB) Viewed 186 times
The wheelarch was plated up and sprayed in primer, now just awaiting the arrival of the Tiger Seal.
Wheelarch nsf 5 - Copy.JPG
Wheelarch nsf 5 - Copy.JPG (30.52 KiB) Viewed 186 times
The nearside sill was originally covered by a home-made cloaking sill which I had removed previously leaving only a strip of original sill.
Inner sill ns 1 - Copy.JPG
Inner sill ns 1 - Copy.JPG (34.59 KiB) Viewed 186 times
My recent investment in a 6mm spot removing drill paid a handsome dividend, the inner and outer sills being separated with no damage to the inner.
Inner sill ns 2 - Copy.JPG
Inner sill ns 2 - Copy.JPG (33.76 KiB) Viewed 186 times
Just a coat of primer to prevent rust and to make me feel good as the @old@ van slowly becomes covered in primer, highlighting my progress.
Inner sill ns 3 - Copy.JPG
Inner sill ns 3 - Copy.JPG (31.17 KiB) Viewed 186 times
On inspecting the, now open rear end of the sill I identified two layers of panel not attached to anything. I welded on a patch fastening the first skin to the inner sill then another on top fastening the second to the patch and through that to the inner sill.
Inner sill ns 4 - Copy.JPG
Inner sill ns 4 - Copy.JPG (29.58 KiB) Viewed 186 times
Whilst I await Management's approval of the cost of a new sill, I went back to a job I have been avoiding for months. The rear wheelarches have corroded where the rubber seal fitted. Using my trusty spot removal drill to remove what was left of the strip designed to hold the now missing rubber, exposed a rather frilly gap between wheelarch and body. Much energetic use of the wire wheel in the angle grinder and liberal application of Hydrate 80 got me back to good metal then, using a length of 2"x1/2" angle made a trimmer piece which fitted snugly.
Wheelarch trimmer os 1 - Copy.JPG
Wheelarch trimmer os 1 - Copy.JPG (35.56 KiB) Viewed 186 times
This was then drilled for welding and primed.
Wheelarch trimmer os 2 - Copy.JPG
Wheelarch trimmer os 2 - Copy.JPG (38.7 KiB) Viewed 186 times
The story ends here as, through all the angle grinding at full stretch, lying on my back, on cold concrete, something went in my back so it will be a few days before I resume activities. I am, dear reader, bearing my pain manfully (personfully?) and hope to be back on the job, so to speak, quite soon.
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Re: Yorkshire Van restoration

Postby Dave Clark » Fri Feb 17, 2017 6:37 pm

I thought I had a rusty van when I started out but this is incredible.
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Re: Yorkshire Van restoration

Postby A35revisited » Fri Feb 17, 2017 9:32 pm

Only good panel was the bonnet lid!
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