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Post by Swellwillys on Aug 22, 2007 12:29:54 GMT 10
It has taken some time but I have finally MADE the time to share the build process of our 1964 Sunliner. We hope you enjoy the ride as much as we have. Thanks go to Mr Jailbar for his assistance in the technical wizardry of Photobucket. More pictures are available of the build on picasaweb.google.com.au/gavanjoolesWe'd love to hear your comments on the van. It may not be everyone's piece of cake but we wanted something different - something special. We are on the way to achieving exactly that. Great when your mate has a forklift to assist in the removal of the chassis and floor. The chassis looks great, however it had some cancer. It was decided to replace it with a lower, galvanized, long draw bar unit. Chassis off. Now for the floor removal. It also had major damage from water. We decided to install a new ply floor with a glass internal skin. After many thoughts on how to install the new floor I decided to install stilts. The new chassis under way. Chassis bolted on with the new floor. Hate that ride height though. It will have to go. More thinking to be done. The straight edges used to ensure that we achieved a level and straight floor. Timber blocks to rest the ply on before fiberglassing to the body shell. The ALKO axle solution to getting that ride height down low. What a great piece of engineering this is. Rubber torsion bar suspension. Right hand side dinette seat . The furniture framing coming together. LHSide furniture. All the furniture will be finished in the Sen ash veneer. The new 3way fridge will not be placed in this spot, but in it's original location. Aluminum bulkhead prior to polishing and installation of Sirian timber beading. Sen ash veneer. Bed bulkhead . The polished bulkhead with Sirian timber inlay. i194.photobucket.com/albums/z283/Swellwillys/Bubbles1013.jpg[/IMG]The right ride height! 1950 Pontiac stop/tail lights with the stainless steel bumper installed. The final piece to the bumper. The surfboard theme will continue throughout the van. Taking shape,with new Camec windows and Moon discs. The aluminum nose cone is a cover for the battery,gas bottle, toolbox and spare tyre. The original windows were fixed glass. As this provided no cross ventilation to the interior we decided to install opening windows. With the priority to have a water proof interior we decided on new Camec windows.
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Post by firefighter on Aug 22, 2007 12:46:56 GMT 10
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Post by Swellwillys on Aug 22, 2007 13:31:34 GMT 10
Hey Jailbarjuice,
The ceilings down to the window bottoms and cupboard height are Acacia veneer- 1.5mm. Very very nice.
It contrasts beautifully with the Sirian bench tops and window surrounds. The cupboards are Sen ash - a contrast in white.
The van is growing each week and I can see it finished - bar the exterior paint in 5 weeks time. It has progressed beyond the photos I have posted thus far.
Thanks for the positives. Very sorry for not catching up with you in July.
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lulu
New Member
Posts: 4
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Post by lulu on Aug 23, 2007 10:05:10 GMT 10
WOW its gonna be a beauty! Looking forward to seeing all your progress..Well Done
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Post by shelby007 on Aug 24, 2007 16:13:33 GMT 10
WOW Looks great. The outside of my van is exactly the same. Inside is different though, I have moulded fibreglass cupboards. My van is 1960 shazy 6. Good luck I know once you restore it you will never have to do it again in years. What are you using to paint the van?
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Post by shelby007 on Aug 27, 2007 13:37:54 GMT 10
I know this is way off trak for your rebuild but Iwas wondering whether you have an annex and what are the measurements. Can you help...
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Post by Swellwillys on Aug 28, 2007 7:57:29 GMT 10
Hi Shelby 007 , No I do not have an annex for the van as yet - sorry I can not help . Suggest you take up Jailbarjuice's offer . I probably will ! ( if that's ok Mr Jailbarjuice??)
Regards the van painting I have many ideas on the type, product and colour/s of Bubbles but putting it all off until the interior is finished. Somewhat backwards I will admit , however with the interior removed the van's exterior looks like a packet of Smiths chips. More dinks than dunks. So with fitting the new 19mm pine bracing throughout the interior it should reduce the filling process required to have a smooth body for paint. We'll have to wait and see.
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Post by Swellwillys on Aug 28, 2007 14:37:24 GMT 10
Thanks Jailbarjuice I value your input.
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Post by shelby007 on Sept 3, 2007 14:19:43 GMT 10
Thank you for your offer jailbarjuice I probably will be up that way in about 2 months in the mean time I will soak the old one in wax. I will contact you again about this when I am nearer to the day.OK.
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Post by Swellwillys on Sept 10, 2007 17:51:23 GMT 10
I commenced the process of installing the internal veneer walls over the weekend and would like to share the process with you guys. The photo above shows the 18x18 pine that will be used for the latitudinal section on the interior walls. Epoxy glued to the walls. The various cuts in the timber assist greatly in molding to the curves of the van. The longitudinal sections are much longer as you will see in the following photo.
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Post by Swellwillys on Sept 10, 2007 18:07:49 GMT 10
After these pieces are installed they will be shaped with a grinder to ensure the fitting of the veneer is precise. As the veneer is 6mm every little indentation will be magnified if this is not carried out. This piece will be the frame work for the surfboard. It will be suspended from the ceiling - starts above the bed and finishes above the dinette table. It will carry the downlights. The rear of the surfboard above the dinette table. The pine showing the epoxy glue filled cuts.
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Deleted
Deleted Member
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Post by Deleted on Sept 11, 2007 7:31:34 GMT 10
Hi swellwillys
Certainly going about it the right way. will look great when shes done. Keep the progress pix coming. Oh .... and cut your toenails and where your steelcapped boots ;D
Reddo
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Post by Swellwillys on Sept 11, 2007 8:20:06 GMT 10
Hey Reddo thems my balinese safety boots.
Veeeeery cumfy !
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Post by Swellwillys on Sept 13, 2007 17:50:18 GMT 10
Completed the port side longitudinal sections yesterday with the help from the wife. The sections held in place with uprights I have left gaps in the framing to allow the various 12/240 wiring to pass through. Once I finish the starboard side I'll return to these sections and fill with epoxy.
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Post by Swellwillys on Sept 19, 2007 16:30:57 GMT 10
I've been fortunate over the past few months to have the time to work consistently on the van. Over the past weekend I was able to complete the framing for the roof and sides of the interior walls. The photo shows the area completed above the sink . Once the framing was sanded level ( on the exterior side of the pine ) the template made of 3mm MDF was constructed . This will allow easy cutting of the exact shapes required for the walls and roof. This photo shows the PORT side template. I have today commenced the installation of the insulation. It is affixed with Liquid Nails FAST.
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Post by Swellwillys on Sept 19, 2007 16:34:36 GMT 10
Sparky this weekend, finish off the insulation, cut the veneer and rough fit .
Swellwillys
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Post by Roehm3108 on Sept 19, 2007 20:27:15 GMT 10
Wow Swellwillys what a fantastic job you are doing. This will certainly be one unique Sunliner. Thanks so much for the pictorial progress, a great educational tools for us amateurs. Some questions, if you don't mind: What are you using to attach the ribbing/surfboard frames etc to the glass shell? Assume it's liquid nails or something similar? Will it hold the imitation surfboard up there? How do you get the epoxy glue into the cuts you made in the framing? Why the MDF mould, and not just attach the veneer panels straight on? Could you show us some pics of the flooring you attached to the blocks? I think there are lessons for us all in what you are doing, so please, explain what you are doing in simple terms Thanks Ray
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Post by Swellwillys on Mar 19, 2008 12:15:16 GMT 10
Well though she is not complete, she's received her Qld Safety certification and was registered Friday 14/3/08.
Picking "Bubbles" up from the canvas guy this arvo (annex & flooring)
Jooles and i are off to Crescent Head tomorrow evening for our annual easter surfing sojourn .
YEEEEEEEEEEEEEEEEEEEEEEAAAAH !
Got a bundle of progressive build photos to post when we return so keep tuned.
Swellwillys ;D
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Post by Swellwillys on Mar 19, 2008 12:43:39 GMT 10
Long delay in a response - sorry bout that ROEHM3108.
Thanks heaps for the positive comments .
My responses to your questions are as follows.
I have used a heap of epoxy glue with micro balloons to adhere all the woodwork to the van shell. Strong as ! The liquid nails would not be a suitable adhesive as it does not have the strength to bind. I have however used liquid nails to secure the insulation to the van walls.
The glue is placed into the small cuts of timber with a spatula, which is also used in the mixing process.
The mdf timber provides a perfect shape and takes the guess work out of the cutting process of the veneer. A template is made of light/flexible mdf ( see photos) to the exact shape/size to be fitted. This is then placed on the veneer and cut to the perfect shape.
Regards the flooring replacement, the photos I have submitted are all I have -sorry again. If you view the photos you will see the chassis was removed from the van and discarded .
I then placed - 4 bolted legs onto the van perimeter. (See photo)
I then measured where I wanted the floor to be located, placed the locating blocks around the perimeter, placed the ply on top and proceeded to glass the ply onto the van internal walls.
Once complete the flooring was sealed with glass and resin.
During this process the chassis was completed and rolled beneath the van's floor.
The process was completed by securing the floor to the chassis.
As you can see a very easy process( NOT)
Hope this helps out
Swellwillys
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Post by atouchofglass on Apr 3, 2008 17:49:51 GMT 10
Swellwilly Been thinking about your top van.... the idea of the surfboard on the roof is an absolute cracker The thought is .... how about putting a fibreglass fin on the roof outside.. make it look like the board is poking through the roof? ;D ;D Silly perhaps but I have even seen BMW station wagon 4wd with a similar looking thing on the back of them .... They don't even have a surfboard on the roof ;D ;D Come on ... have some fun and give us a good laugh as well... Atog
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Post by Swellwillys on Apr 14, 2008 16:55:36 GMT 10
Thanks for the interest in Bubbles mate !
Yep the thought went through my mind some months ago when I nearly purchased an Aluminum - forged -early 60's fin from the states -ex ebay 8it would have been awesome polished up and i intended to place it at the rear of the van - too high a cost so didn't pursue the thought any further !
Anyways the duel fishtail exhausts get some laughs !
Thanks again !
Swellwillys
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Post by Swellwillys on May 30, 2008 12:14:36 GMT 10
Rainy, miserable canceled our planned trip to Byron so thought I'd update this post . Anyways, as mentioned previously the van is up and running and we have enjoyed a number of weeks and weekends with the van now. It has been a blessing in disguise that the van is not complete as after living in it we have changed some design plans. On the exterior front I have added the clearance lights And the 3rd stoplight And the fishtail; exhausts On the interior the 3 way fridge has been installed the ceiling lights are all 12 volt and are brilliant ! I really recommend these strip bar lights for anyone considering 12 volt lighting, they are amazingly bright and compact! The 12 volt light switches continue the surfboard theme The interior cladding is almost complete bar the end sections and cupboard fronts The energy available for the van is 12 volt/240 volt and LPG . Swellwillys
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Post by Roehm3108 on May 30, 2008 18:56:53 GMT 10
Coming on real nicely guys. Amazing how modifications always happen once you actually test things out!
Have you made sure that your 240 volt safety switch and power point is double poled?
That pic of the side clearance light might give you an inspiration about your paintwork too - did you notice the silhouette of the palm trees against the van - would look reall great of you could do that in real life, to keep the surfing theme going!!
Keep up the good work
Ray
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Post by Swellwillys on May 31, 2008 9:25:10 GMT 10
Dear Mr Roehm 3108,
Yep all double poled fittings mate - that's the beauty of this family site - we are happy to help others out! Thanks yet again!
Regards the paint scheme we have settled on a bright silver and am having artwork applied to the exterior - but you'll have to wait and see!
Thanks again !
Swellwillys
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tonyh
Full Member
"Dolly" 1967 Riviera
Posts: 256
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Post by tonyh on May 31, 2008 23:38:12 GMT 10
Swellwillys, ;D Taking on two projects at once - big job, and both looking great. Congratulations, a lot of imagination used on both - I will look forward to checking out the finished product in person. ;D Cheers, tonyh
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