Sunliner ....Jailbarjuice Restoration

[Deleted]

From jailbarjuice:

"I'm about 20% paint rubbed. The van as I bought it had a horrible off white 2 pack primer with runs everywhere, it is difficult to sand off as the exterior skin on the Sunliner is very thin, & moves
around a lot.

To solve this, I'm stiffening the internal side of the outer skin ( my van has a fully removeable fibreglass inner skin), using plastic 3/8' airlinr tubing taped to panel, then fibreglassed in
with about 3 or 4 layers of chopped mat.

It doesnt look pretty inside, but the internal skin will cover it. I replaced the enormous side vent that was fitted with a small one, & had to fill 140+ 1/2" holes
that had been drilled. As i rub back panels I find a very poor quality gel coat, with major cracks & holes everywhere.

I'm re glassing a lot of areas as I go, & I've got some PPG 2 pack flexible primer to put on when i get it ready.

As you can see I'm doing it in the open. Ive got repro 64 VW indicators ($25 each) & 58 Hillman taillights new old stock for the rear. Next pix will be when its primed."

[humptydumpty]

Loved the pics Dennis. Makes me want to get out and get stuck into mine again, but there are so many other things to do and work is getting in the way of leisure time.
Have you mastered crapbucket or did you send your pics to Mark??

[humptydumpty]

Our friends pick up the big Sunliner this weekend, can't wait to see it, wish I had bought it, but 5 vans in my yard??!!!!.
I WILL get some photos soon and send them off. I don't have anywhere near the size of the problems you look like having to overcome.
I am looking at getting down to Coledale, just which van to take??? more the question which one is finished!!!

[willandlyn]

;D

Dennis my main man
fibreglass caravan restorer extroadinaire

One of the members who is not on the net his name is Greg or as we know Him in the group the plymouth Brethren
The other half is Noeline are doing uo a sunliner at this moment he is burning the paint of the exterior
They have just fitted out the inside and it looks just great
Greg has rounded edges on all the cupboards and is using 100mil plastic cut into 4 pieces Greg has fitted 1 piece to each corner it looks super retro
he is a man after your own heart Dennis a dyed in the wool Rodder

The theme is white walls and furniture and red curtains and cushions etc
It suits the roundness of the van

Greg was thinking of the Roadrunner as his mural But he may just stripe it white exterior with a red Swirl

Greg has about fifteen patterns made up as over lays so they know exactly how the van will look finished

I will take some photos and post them next time I call around there

So keep on burnin the Van Man ;D

Regards
will

[JBJ]

hi will, When I got this van it was totally apart, no front or rear perspex windows at all, all side windows out & 3 broken. 75% of internal removeable linings were laying on floor with the hatch. a few of the cupboard doors missing, and most split at the edges of the ply. So my plan of attack is to get the outsidse into reasonable condition & lay some good primer surfacer on. Then I can 2 pack paint around the openings. i can then finish repairing the fibreglass window frames that I have in hibuild primer to fix the jelcoat after I tried paint stripper on them. Never use paint stripper on old fibreglass. Ever. Still you to find these things out for yourself. Lucky I didnt try it on big pieces.
After I get it weatherproof I can start putting the jigsaw puzzle inside back together. Yea I know its a big job, but I think its worth the time, money & effort. I didnt think burning paint off old fibreglass would be a good idea, how well does it work. wouldnt it leave a surface that stilkl needs pretty major sanding to allow paint to bond? jailbarjuice

[Roehm3108]

You're a gamer man than I am Gunga Din. What a massive resto job you're doing!! Good to see you doing the fibreglassing outside, where there's plenty of ventillation. I remember years ago, the number of glass boat factories that literally blew up because of poor ventillation.
Keep up the good work, and keep us posted.
Cheers
Ray

[willandlyn]

;D
Hi Jailbar hows the Resto coming on mate
waiting for some more pics
What colours are you thinking for the exterior

Regards
Will

[JBJ]

Hi will, hoping to get back on it this weekend, if it stops raining. We're thinking black doors with light yellow cupboards, & probably a wrap around fixed front seat in velour. No stove as we got an annexe with the van.
But its still a fair way off. I work pretty long hours like you, but on the computer drawing plans. I dont get as much time as I want on the van, & then theres maintaining & modifying 3 old cars, feeding the chooks, making juice, talking to Sue, etc. Boy I'm tired thinking about it. might go back to bed. Jailbarjuice

[willandlyn]

;D

Hi Dennis
I know what you mean we have a labour shortage in W.A. I have stripped one panel the first night I got Trevs Tram home and thats it
lucky ive got no chooks to feed the poor buggers would have to starve
Ive been leaving home most mornings around 6am and getting home around 6pm
I thought the expression was work smarter not harder
I got it wrong
Im working harder
but thems are the breaks
colours sound good my cupboards in elvis van are black (doors) its always a good complimentary colour and matches any colour you like to use
Ill let you go back to bed Dennis Im off to work

Lucky bugger (Mutter Mutter Mutter)

[humptydumpty]

Dennis, did you see the article on the Sunliner that was done by a "Rodder" with the Club lounge. You will be very interested in the way it was done. It was in 'CARAVAN WORLD MAY 2004. The owners name is Brenton Creasey from Victoria.

[JBJ]

hi humpty, i've seen brentons van, its well done but a bit over the top for me. I'll stick with basically stock with a few mods. I 've just trial fitted replica VW indicators on the front corners, & they are fairly easy to adapt provided your interior panels are out. At $27
each in new plastic they are cheap. They needs a bit of work, but I'll send Ditzy some pix tomorrow if it stops raining, so she can post them for me. I'm finding major gel coat pitting/cracking as I sand the paint off. I'm stiffening the inside coat, & applying a superfine 2 pack filler as I go, hopefully that will work. I am amazed at how lite weight the sunliner construction is, it was pretty hi tech for the 50's. jailbarjuice

[humptydumpty]

I thought it was abit over the top too, but he likes it I suppose. Just thought I might mention it re the 'club lounge'. Sorry we won't see you at Coledale.and I like the idea of next year, and might like to throw in the idea of Forster -Taree - Manning point as more central.

[Deleted]

From Jailbarjuice :

"I,ve been trying to make some progress in the rain. Ive managed to rub my window frames again, as well as fit one VW indicator. these are
plastic replicas of a 64 up beetle front indicators. At $27 each complete from a dealer, they are cheap & pretty fair quality.
Amazingly the curve on the corner of the sunliner is identical to the lights.
I found liquid nails becomes liquid inhighhumidity/rain.Here
is a pix of one in place, & I think it will look right. made a wooden
block as backing, fitted some T nuts in the wood, & glued that inside
the body. As I said the rain affected the glue, but we'll see what
happens when the sun comes out again. I like the lights on the van."

[JBJ]

Hi humpty, I,ve just placed an order for my 4 new rear & front fixed perspex windows. They work out at $95 each, plus $120 to make a timber box and pack/dispatch, & $80 freight from Liverpool to here. I think the freight company must be bringing them up by Taxi, but thats what they insist on doing, & $638 a set delivered is what they will cost. I suppose I'll have the clearest set of Sunliner windows for a while, until the sun affects them in about 10 years. Oh well, back to the drawing board (computer) & draw some more plans to pay for them now. Jailbarjuice

[JBJ]

Hi Humpty & Spyder, I finally got my windows from Spyders friends. They turned up in a fully sealed very well built box like the people promised. I hope to open it this weekend if the weathers ok & take some pix. Ended up costing $665 delivered, but I've now got a big storage box as well. jailbarjuice

[humpty2]

G'day Dennis....my windows arrive this weekend..in the back of Spyders car!!.so at least I have no delivery charges (Ihope!)

My No2 Sunliner is nearly finished inside now, some rubbers for windows and lino to lay..Missus is making new cushions & curtains......photos will come soon!

[Deleted]

Hi Dennis.

Pleased to see you have bit the bullet and made a start back on the Sunliner. There is nothing harder than finding renewed enthusiasm for a project that had come to a stop some time back.

When i last seen the sunliner she was in a pretty sad state with bits and pieces stored away everywhere and sorely needing a lot of attention around the panels. The fibreglassing looked to be Too much work for the average backyarder DIY person but it sounds like your mate has it under control.

Always good to find a few goodies in amongst the bits and pieces that come with these old vans. It makes you feel that the purchase price is more justifiable. Especially if it is a full annexe that can easily cost around $1000 to get made.

Naggs Canvas ( 02 49307394) at Oswald Lane near Lochinvar have been in the game for as long as i can remember. A well established company. I see a lot of tarps on trailers and trucks running around locally. They do a lot of work for locals down this way. Specialising in "one off' annexe modifications for camper trailers and vans etc. Never heard a bad word about them. Often hear thier name mentioned on radio advertising.

Keep up the good work. I know what your going through.
There is light at the end of the tunnel.

Reddo

[JBJ]

Hi Reddo & All,

Another day's progress resulted in one very rigid external body on the Sunliner, with half the interior panels refitted.

A word of wisdom to anyone that removes the interior linings from the early Sunliners. They come out reasonably easy, if you cut or break the glued/filled bond at some joints, but they deform when stored, & dont go back in real good shape. I believe I can refit mine reasonable, but will have to paint the roof linings in a non shiney finish, as the panels are not real even any more. I dont think there is much I can do to straighten the bends/flat spots caused by laying around.

Its nice to have a semi complete Sunliner .
Jailbarjuice

[sl1963]

Hi Jailbarjuice,I've just picked up my new project-a 1963 Sunliner.Rather rough but with TLC I will prevail.First up I will need a set of perspex windows. Could you please tell me where in Liverpool I can get them from. Also any hints re the shocks in the suspension, mine are leaking,are there ones readily available to slot in. Ta, SL1963

[sl1963]

SL1963 again,I am also in the market for a complete set of rubber seals. Are there any leads or contacts that you could pass on? Thanks SL1963(Paul)

[JBJ]

Hi Paul,


I bought my perspex windows thru Spyder, who had some made that work . He arranged to get mine done for me, so you should contact him, or even ( especially? ) Humpty. Those pair know more about Sunliners than most. I dont know wether a 1963 has wrap around windows or not.

Same deal goes for rubbers. probably Peter Jackson in St Marys is the best place to buy, but you will need to either take your originals in, or know the correct part number to order. I have a part number that I was given for the perspex windows, but I dont know if is the same as your later model van will use. Your side windows should be aluminium framed, unlike my fibreglass framed ones, so I cant help you there either.

The only other rubbers are for the hatch & door. I think you should be able to find one that works easily enough, possibly even from Clark rubber or an auto upholstery supplier. Thats where I'l be looking when it comes to that.

Lastly the suspension , I'm planning on replacing my independent system, and I dont think the ones I have are going to be very good, based on the condition of the rest of the van. Again Humpty & Spyder will know heaps more about this stuff than I do.

What general area do you live in? If you're anywhere near me, I have a few bits I'm not using as I rebuild mine, that may help you out. Send me a PM if you are stuck & I'll see if I can help.
Jailbarjuice

[spyder]

Hi sl63

Good to know you are one of us plastic people, in gegards to the information you require on your windows and rubbers you can contact me on phn. 0247218451 or email [e-mail]

Regards Spyder.

[JBJ]

Hi All,


A bit more progress made. It’s a fight to get time on it, time seems to go faster as you get older. I,ve had a worker on the glass interior, & a few other bits.


So far we’ve bought a fridge & modified the butchered icebox hole to accept the new fridge.

All the new wiring is in place, & the fiberglass headlining & wall panels put back in. They still need a lot of finishing, but at least there in place.

We made new shelves across top of windows front & rear & glassed in place.


Framework for front club lounge has been rough shaped & glassed in place.


I’ve been working on the rear end, fitting the 59 Hillman taillights I’m going to use. Building up the panels in glass & bog to get the shape I want. I’m pretty happy with how they are coming along.



That’s all for now. Jailbarjuice

[Deleted]

Hi Den
I said it before ... I'll say it again. You deserve a bloody medal.
I could not go through a project like that. I would get frustrated with not being able to nail something in place.

Slowly , slowly the wheel turns.....keep it going old mate.
Put a dollar in a jar every time you swear and when you are finished you will have enough to import a fully restored Airstream

Reddo

[earlee]

yep - I agree Reddo - JBJ is doing a great job and needs a medal for perservering with cancer causing fibreglass.

At least he has a good wooden caravan to use at other times.

The Hillman lights are great - they are a neat all-in-one light. ;D

Reddo - if you are really wanting to nail someone something then my old van is on the market
2 bids- $600 - and 58 watchers - 4 days to go.

earlee