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  1. #101
    Metal-Glueing Idiot
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    h'okay, I've been neglecting this thread a little -- not that there's been a massive lot of progress, but even so -- so here's a catch-up update:

    Some weldering happened with the driver's door:




    Done with stick. A few holes were where I was using 1.6mm rods that are mostly flux and spite, which meant longer arc times to deposit metal; turned out to be easier to use 2.5mm rods on the same power setting... probably because they were putting more metal down so could actually build it up quicker, and reduce the amount of heat I put in.

    While welding with MIG is quicker, it's the set-up time that gets me. Sometimes it's just easier to set up my little suitcase stick set than it is to hunt down a working MIG welder that isn't in use, chase down a 3-phase extension (or two... or three... depending on how far away the nearest socket is) and perhaps a Y-splitter, and get it all hooked up before someone runs away with the welder.


    Since then, the door was re-re-welded in places (Apparently, my inner reinforcement bar was not stuck where I thought it had stuck, so broke free and pulled a few little holes in the door skin in the process. Sigh.), and the tab for the bottom of the mirror arm has been welded on.

    I've also treated half of the inner surfaces of the door with rust converter, so I have to follow that up to the other side, and then go back in with some paint. Then I can put that back together, and re-fit it to the truck, which looks a little silly without it.

    The generator in the background is foreshadowing. The arc-air rods, I really really hope aren't!

    Then, some more chopping & hacking ensued... This time, with video evidence! I don't think I'll be making another video this way again; it's a pseudo timelapse involving lots of sped up footage, which was very time consuming and tedious to edit together.

    Nevertheless, here it is:



    Now closing in on the present-day...
    Thursday last week, I rolled out the generator and the big grinder ...and the little grinder when the big one turned out to be big enough to be even more cumbersome, but not big enough to have sufficient reach to overcome the cumbersomenosity.

    ...and then the little grinder started turning out to be too cumbersome, so I finally managed to dredge up a sufficiently circular Tuit, to head out to Nuts (our local Hobbyweld supplier) and rent a bottle of oxygen for the baby cutting-torch.

    Here's where I left off after that week:




    So some fire had to happen, which brought progress along with it.


    And that progress means I am much closer to being able to put metal back in; which is good, because as it is, I feel more like the scrap-man with how much cutting I'm doing!


    Those two outings resulted in this scrap pile:


    I'm getting closer and closer to having that new bit of box section welded in place; whereupon I can see what space I have left to wiggle a rubber body-mount into, in place of the original, and will have a place to start building the floor back out from. Thankfully, the floor is pretty solid for the most part; around the rear and side of the passenger seat is where it's the worst, but there's enough of it left that I can work out to it.

    I'll claw this back, one piece at a time! Might not be quick, nor particularly pretty; but it'll be solid. I can always come back and re-do the uglier parts in the future, when I've gotten better at it and improved my skill. But, for now, "ugly & solid" is better than "gaping hole"... or "pile of dust where there used to be a truck"... or "bean tins that used to be Bedford"

  2. #102
    Might as well be part of the furniture.
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    Slow and steady....you'll get there one day

  3. #103
    Might as well be part of the furniture.
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    Nice to see things are still progressing, rather you than me I must say, Keep on going

  4. #104
    Metal-Glueing Idiot
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    Quote Originally Posted by fabphil View Post
    Slow and steady....you'll get there one day
    I hope so! I really really hope so.

    Quote Originally Posted by stilltrying View Post
    Nice to see things are still progressing, rather you than me I must say, Keep on going
    Yeah, it's kinda overwhelming if I step back; but as long as I just think of it as one little job, then another little job, then another... it's not so bad.
    Last edited by Tamber; 26-02-18 at 11:08 AM.

  5. #105
    Might as well be part of the furniture.
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    That is definitely the right way to go about it, I do the opposite and then don't get anything done

  6. #106
    Metal-Glueing Idiot
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    In some startling news, I did some work the other day! (Well, it was last week, now. I only ever seem to end up working on this thing every other week or so, at best. ) It involved cooking for a little bit in the sun.



    A little bit of drilling and metal-sticking later, I had this; which was sprayed with weld-through primer.



    And that fine bit of engineering fits...


    ...here! This surprisingly only a little jiggery-pokery involved in getting it to fit; mostly in shortening the weld-through tab on the near-side until it fit with the not-exactly-stock battery box.

    And, a major milestone reached today, with the first metal going back in, in a long time.



    Still quite a bit more welding to do, particularly on the near-side where it's only tacked into place for now due to access being slightly restricted by cabling; however, with a bit more welding on the offside, I got it to the point I could lift the cab up off the chassis by jacking it by the end of the new cross-member, which is a good sign.

    This was the result of about 4 or so hours, including about an hour spent trying to get the generator to start, because the battery was flat and I didn't have any jump-leads. Hence the wobbly-looking lash-up with the truck battery. However, progress was made.

    From here, there's:
    • a couple other little weld-through plates to make that finish sandwiching the original cab frame, and join in to the new cross-member
    • Fully weld up the back of the cab frame.
    • Start bridging the gap between the new cross-member, and the cab back
    • Put some metal into the floor, and reduce some of the excess ventilation

  7. #107
    Might as well be part of the furniture.
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    Nice when new stuff goes in, rather than cutting old stuff out

  8. #108
    Metal-Glueing Idiot
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    Quote Originally Posted by stilltrying View Post
    Nice when new stuff goes in, rather than cutting old stuff out
    Definitely. Starts to feel a lot less like doing the scrap-man's job the hard way.

    Hoping to roll on out and get a bit more done tomorrow, after not getting a great lot done last week, when I stuck on an Überbräcket at the back for another twirly light amongst some other puttering about

    The Überbräcket, named because it's only holding up a twirly light the same as the one on the roof, yet I made it out of a piece of 10mm (3/8" in old money. Yes, okay, I know it's not quite; but there's only about a 0.5mm difference, so it's close e-bloody-nough! ) steel that I had laying around that was the right size, and severely welded it. It's not bloody coming off without taking the crane with it, I think!

    Our victim, after a little marking out:


    After some weldinating:




    It feels surprisingly high up; but that plate is just about eye level if you're stood on the bed of the truck. Well, as long as you're short, like me.


    And with the twirly stuck on it... Not too worried about it not really being visible from the left hand side, it's mostly just to act as a 'repeater' to the rear of the truck, where the jib blocks the view to the one on the roof.




    Anyway, the lesson here is: if you see a chunk of something getting chucked in the scrap bin that looks useful, snag it and put it in your overflowing box of "Might be useful, that" bits.


    Some other trinkets while I was re-exploring the side lockers...

    How old d'ya reckon this is?


    Fairly sure it's older than I am, anyway. And it has not aged terribly well...


    Looks pretty cool, though.


    On more practical matters, I think I have a solution to the brake booster valve problem. Now, since I haven't really had much luck finding out what sort of bits were supposed to be in there, and not really wanting to go through a bunch of R&D to come up with new internals, I've decided to take another route.

    I'm taking an off-the-shelf part and using it... as it's intended to be. I got myself a foot brake valve/treadle valve from a DAF CF (But they're all pretty much using the same, or very similar, parts). It's basically the equivalent of a brake master cylinder, but for air brakes.

    The intent is to mount it up near the brake pedal, such that I can fit a little push-rod, much like the one in the truck that the valve comes off, and plumb it so that the primary circuit applies on the hydraulic brake servo, and the secondary circuit runs back to the trailer suzie connections.

    Two nails, one hammer; or something like that. Should give me proper control over the brake servo, while also letting me have trailer brakes without needing a reaction valve (Normally fitted to tractors, to let hydraulic brakes control air-braked trailers. They've usually also got completely the wrong type of seals in them, and apparently don't get along well with DOT4 brake fluid. Oh, and they're usually eye-wateringly expensive.)

    Some measuring will be required to figure out travel, pushrod-length, where to put the valve, etc etc. Hopefully it doesn't consume the space that is tentatively earmarked for the air-horns; because those are also fairly critical items!

    To be continued...

  9. #109
    Might as well be part of the furniture.
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    More progress. Looking forward to the video of it finished

  10. #110
    Metal-Glueing Idiot
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    Continuing on...

    While I was fiddling about last week, I also did some playing about with a modern truck wheel that was laying about nearby. (I think it belonged to the bus company that was here before.)

    Not so keen on the stock silver, but gloss black would look good.





    As good as it looks, there's some slight clearance issues. Some faffing about with measuring offsets, widths, etc. ensues. Currently trying to work out what I can get away with, wheel-wise, that lets me fit a fairly standard modern tyre.

    This test wheel is a 22.5x7.50 (shod with an 11R22.5 tyre), and the norm appears to be 22.5x8.25. The problem comes with trying to find tyres that fit, since most are meant to go on an 8.25" wide wheel. Oh, and that the offset puts the inner lip of the wheel hard up against the track rod end, which is less than ideal.



    I don't think I want that to self-clearance... (And yes, I know the track rod end needs a new boot! )

    I have a total of 250mm from the mounting face on the hub, to the track rod end interference; so I shall have to hunt down another wheel, ideally without tyre, and do some more measuring. And some more thinking. And a bit more measuring... and some cursing...

    While I'm a long way off having this beastie drivable on the road, it's nice to have some sort of idea of what parts I'll need. (Definitely going to go with an off/on M+S all-position on all corners, though. Something nice and knobbly. I've also run the numbers for max gross weight, and it looks like I can get away easily with running single wheels on the rear axle, which makes life simpler. Also cheaper!)

    Definitely looking forward to getting it finished, though that's a long way off yet.

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