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Post by JBJ on Jul 7, 2007 17:52:26 GMT 10
Hi All, Did a bit on the tow hitch & brakes today. I decided long ago to throw away the original tow hitch, & instal a new unit rated with a higher load than the van could ever be. I bought an Alko 2000kg rated overide brake hitch, & brake lever handle/mounting plate to suit, from my friend/neighbour MR. Fixvans. Around $130 all up. A little work elongating the mounting holes with my die grinder, a couple of 1/4" steel plates made to fit with the new bolt pattern under the original metal mounting plate, & I have a new hitch. I then started seriously looking at how to hook up the overide cable brakes, & found the person that started on my van had forgot to fit the small wheels that the cables change direction around, between the front of the van & the brakes. I went to my local hardware shop, & bought a couple of Zenith 50mm awning pulleys. I ground off the retaining pin, punched out the pin, & I had a cast iron pulley wheel the perfect fit for the job, except that the pin hole , as well as being drilled off centre in China, was too small. Simple to drill the right size in the right place with your vice & bench drill. Pretty good for $ 6.50 each. Now just gotta buy some D shackles tommorrow to fit the leftover stainless turnbuckle into the brake system. A lotta work, when I'm not ever likely to use the overide brakes. But they have to work for registration. There is no rule that says you have to use them that I know of. I reckon if your driving a decent sized & weight car, you dont need brakes on a lightweight van( under say 1 ton) Jailbarjuice
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Post by humpty2 on Jul 9, 2007 21:05:51 GMT 10
Dennis, most screens for the hatch were attached around the perimeter of the hatch with 1/2 inch timber and a wire hoop secured to the van with a simple clip...........seems you are well progressed with the system you have developed though.
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Post by JBJ on Jul 10, 2007 5:38:54 GMT 10
HI humpty
All I've done really is used steel to give the hatch screen assembly I have a secure& level mounting point. I've kept the 4 screws it used to retain it in the same place, & from inside or on top of the van you wont be able to tell that I've changed anything.
My concern with the hatch at present is the method of holding it closed, using 2 ball detent retainers over the 1/4" brass rod that is used to raise & lower the hatch.
How secure are they? They dont look real safe to me. I'm thinking I might make a positive catch fixing system.
I'll post some pix off the assembly when the screen is reassembled. Its being painted & renewed at present.
Got my tailights working last night, so when I get another coat of single colour primer on it, its off to the mechanics to go up on his hoist so I can tidy up underneath & adjust the brakes.
I'm also hoping to have been able to get all the bits to rebuild the coil over shock absorber units like Spyder did on his , at the same trip.
Jailbarjuice
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Post by JBJ on Jul 15, 2007 19:35:46 GMT 10
Hi All, More progress. I've just spent 2 days sanding, & putting another good heavy coat of hifill primer over the whole exterior. As I've got all the lights working, I'm going to tow it to the mechanics soon, & call in a t my Rego Inspector on the way back home to find out what is the minimum standard of completion he will accept for registration. Lots of market vans are minimal in their completion, so maybe I can get it registered before I tow it around getting work done, which is quite legal in NSW. I dont want to tow it far without having insurance on it, after the work I've put in.I need it registered for insurance purposes Here in the bush I have to travel 25 or so Km between towns to get various tradesman to do work on it. I'm not doing any further work on the body exterior until after I get it registered. My next task is to rebuild the side windows, & after trying to polish one of the 1/4" aluminium sections that retains the glass, I need to buy some new aluminium. I've got one glass panel, so I can get the windows cut now. Coldale or bust. jailbarjuice
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Post by humpty2 on Jul 15, 2007 20:05:14 GMT 10
Don't quote me on this, but I think you will need the glass in before rego. I think Clydes van has the same fixing system for the hatch too.
Looking bloody good mate!!!! ;D ;D
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Post by JBJ on Jul 24, 2007 21:44:35 GMT 10
Hi All Finally got some primer on the inside. A bit of puttying up the small marks & Boots can finish painting it. Shes already got most of the doors already done in finish coat. Its all working well, except for where Bob the Builder put the rough side of the ply to the visible side. I made the panel to fit the club lounge lounge at front to convert it to a double bed. It stores in the big drawer under the bed. I can sit on the edge without it moving, so it should be good for a couple of Kids I fitted the window frames, & some of the sailtracks for the annex. Hopefully Friday I'll get the 1/4" aluminium section I need to remake the windows from the Gold Coast. We also hope to order our custom fit mattress on the same quick trip to Brissie & back in the one day. Starting to get tight for time with these damn windows, for rego in late August/early September. Jailbarjuice
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Post by JBJ on Aug 14, 2007 21:40:13 GMT 10
hi all. More pix, after the thousands of requests & postcards I get every day for more pix. Ok, today Boots got pretty well all the interior in close to final undercoat. just gotta remove a few marks. we've found the ply is shrinking a tad, & causing a few hairline cracks. I've gouged them out & put in acrylic gap sealer, & hopefully that will solve the problem. We got our laminate the other day, so thats sorted out. managed to fit the rear perspex windows last week. What a job. 2 of us spent a lot of hours on each one, only to find the left hand (rear) one has the wrong curvature. We got it in, but its pushing the rubber out about 1/4". Hopefully it'll settle into place with a bit of sun on it. If not I'll have to buy another, but that wont happen until after rego. I made up my version of the side window operating mechanism, & got one window working. I had nothing to copy off, so worked off memory of what Groovin had. It seems to do the job. Tomorrow gets new wheel bearings fitted, & I just adjusted the brake cable to where it should be to make the brakes work. All things being equal, I'll have the front windows in this weekend, then the other 3 side windows, then hopefully end of next week rego should happen. Boots has the house full of painted interior doors, so a coat of internal colour during the next week, & we'll get the doors all back on. Electrician comes tommorrow to finish off the wiring. Theres not enough hours in a day. jailbarjuice
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Post by Don Ricardo on Aug 14, 2007 23:55:42 GMT 10
Love your work JBJ!! It's going to be magnificent.
Admiringly,
Don Ricardo
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Post by Deleted on Aug 15, 2007 8:35:18 GMT 10
AAAhhhhhh When does a hobby become an obssession Add to the obsession a deadline of October 13th and the obsession becomes compulsive madness ;D That rod you made up for the side opening window should have 2 or 3 notches in the top edge about 2" apart. The bracket you have screwed to the window sill should have a flat metal tag that is pop riveted to the top outside edge and it swings down and locates into the grooves in the rod to hold the window open at varying angles..... ... clear as mud aye. Keep at it old mate. Tell Boots .. warm the tin of paint, nice even strokes and dont strangle the brush. Might catch up with you sunday week on the Lismore FJ mission will bring bib and brace overalls and fresh set of 6" brushes for the fine detail work. Its looking good mate.. hope your window stays in place Reddo
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Post by JBJ on Aug 15, 2007 17:25:00 GMT 10
Hi Col,
I'm still able to keep motivated, even though its a much bigger task than I first thought. I believe in the philosophy of Silastic Q. Chromium, whose motto is " NEVER WEAKEN"
The sparky hooked up all my switches & power points, lights, etc. today
Another bit done.
Having a bit of fun getting wheel bearings & seals, but the local hicks think they might be able to get them in a few days.
Its all FUN
Jailbarjuice
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Post by kingy on Aug 15, 2007 17:33:15 GMT 10
Really taking shape now Dennis, bet your counting the days when you can get to enjoy it. Looking forward to seeing the three of you at Coledale - - Kingy
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Post by JBJ on Aug 17, 2007 23:36:30 GMT 10
hi all,
Some info on early Sunliner wheel bearings.
There a strange one, & not real easy to get in the bush. I thought they would be FE Holden, as the wheels are 13" Holden, & it was built in 1958.
It turns out ther something unique, close to FX-FJ the bearing guy thinks. I just paid $245 for 2 pair of bearings & seals.
Inners are a combination of Nachi 1988R race & Timken 1929 cone, & outers are FKC 05068/05175
we couldnt get inner seals (or so they told me) so I ended up with some W12523737 rubber seals which I'll narrow to fit. The original seals are steel 1/8" wide, with felt sealing material.
The ones I ended up with are the same inside & outside diameters, but 1/4" wide instead of 1/8". I think I can cut the outer back in width, & the inner rubber bit should work OK, but I wont Know till tomorrow when I instal them.
One of the reasons for this posting is to let Sunliner owners know that if they lose a wheel bearing on a trip, Thers NO WAY you'll find replacement bearings quickly & easily.
I'm keeping the ones I remove in my van as emergency spares.
Sutcac can tell about wheel bearings , as his van lost one near Dunedoo on last years East Coast tour. Luckily they were early Holden, & luckily Kaybee was there with his experience & knowledge, & managed to fix them. If these Sunliner bearings took 2 days to get in a major regional town like Lismore, from the largest bearing supplier in town, imagine your chances in hicksville, with a closed down service station.
Nows the time to check the bearings in your old van, regrease & adjust them properly. Replace them if there worn. CARRY A SPARE SET IN YOUR VAN. Even if its only the set you replaced.
jailbarjuice.
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Post by jailbarjuice guest on Aug 18, 2007 17:59:10 GMT 10
Hi All,
well another hectic day. Got Bob the builder back to make & fit the two remaing cupboard doors that were unmade.
Darren was working madly grinding the roughly shaped perspex windows, & I was trying to keep both of them working as well as sort out the wheel bearings.
ended up with bobs job completed,& both front windows fitted.
Found out that there is heaps of clearance to fit the wider grease seal that I was supplied with.
Got the first coat of colour in the interior last night. Its looking pretty well as I hoped.
Darren & I are going to try to fit the new annex sailtrack to the roof tomorrow, & try to finish rebuilding the side hinged windows.
Weighbridge here I come Monday or Tuesday
I'm going to be registered in time for our Tweed Heads get together, which is what I've been pushing myself to achieve
The fun exceeds the pain.
Jailbarjuice
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Post by humpty2 on Aug 18, 2007 19:35:43 GMT 10
The wheel bearing problem would probably be unique to the independent suspension on the Sunliners I would think Dennis. The solid axles I am pretty sure are Holden........... Guess who will be double checking tomorrow Watching for more 'piccies'. ps Attacked that little bit of floor rot today.....not as hard as I thought it would be!
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Post by JBJ on Aug 21, 2007 21:46:55 GMT 10
hi All,
geez its been along time since I started on this ***** thing in early 2005.
I'm trying to get the last side windows made & fitted, & the wind & rain is coming in horizontally.
All I've got to finish for rego & using it, is assemble one more side window, fit 3 of them, make the opening mechanisms for 3, put the annex sailtrack on ( so I can refit the hatch assembly, then its off to the weighbridge.
So we get a bout of bad weather. Never rains when you want it to.
I think I'll take up playing croquet, or something equally relaxing.
Jailbarjuice
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Post by Deleted on Aug 22, 2007 6:57:44 GMT 10
JBJ Wrote: "I think I'll take up playing croquet, or something equally relaxing". Jailbarjuice ;D ;D ;D ;D Now this i GOTTA SEE!!! A croquet stick with bagged suspension , blown 429 and a heavy metalflake paint job. Reddoriginal
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Post by humpty2 on Aug 22, 2007 20:04:11 GMT 10
Geeeeeeeez Dennis, do you know how much them bloody big hammers weigh!!, could get a hernia here and the concentration required to aim them balls, head ache material, stick to what you are good at.....Restoring & Rodding, cars & vans More pictures coming soon? ??
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Post by JBJ on Aug 22, 2007 21:27:30 GMT 10
Hi Humpty,
If the weathers a bit better tommorrow I'll try to post a couple more Pix.
I'll see you guys on Sat. AM (probably around 9am) when I pick up the step.
Jailbarjuice
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Post by JBJ on Aug 29, 2007 13:57:49 GMT 10
Hi All, Well towed it out today & went to the weighbridge, about 25Km round trip over some pretty rough roads. towed like a dream. Pretty good seeing its being sitting about 6 or so years minimum, & possibly quite a lot more. It weighs 720Kg, without any cupboard doors, drawers, or fittings. About what you said Humpty. Jailbarjuice PS Boots has decided to cancel the divorce proceedings now.
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Post by Deleted on Aug 29, 2007 14:55:02 GMT 10
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Post by Geoff & Jude on Aug 29, 2007 15:19:24 GMT 10
good-on-ya dennis
it looks really good and the dodge and the van look terrific together.
is it staying white or are you painting it to suit the rod?
well done,
geoff 'n jude
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Post by JBJ on Aug 29, 2007 16:14:00 GMT 10
Hi all,
The exterior is hifill primer, so I can work on finishing it as I use it. its still pretty rough, but OK from a couple of feet.Final colour at this stage is still going to be Metalflake to match my hotrod.
The interiors fully painted now. Boots finishes off the insides of the cupboards tommorrow, then I can put the finish painted doors back on
We've got our custom made mattress, the vinyl for the floor, & the laminex for the splashback & bench tops sitting on our spare bed. We,ve had the fridge for a while.
Hopefully the sailtrack will go on the roof this weekend, & then the hatch can then be final fitted. The hinged side windows are assembled & painted, waiting for the closing mechanisms to be finished.
That leaves only to finish off around the front seat.
We intend to register it & use it while we finish it. Otherwise I could see me working on it for another 12 months without a useable van. I'm trying for rego early next week, to give a week to tow it a bit before its maiden trip. it towed good today, but Boots noticed a scraping sound in one wheel when I reversed it back into its carport. I'll pull the wheel off & look at it tonight I hope.
Boots wants me to use the Dodge as the towcar, but I prefer my hotrod.
Whatever happens is OK , because the Dodge aint too bad, with 351 Cleveland & Auto on dual fuel.
jailbarjuice
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Post by aussietanker on Aug 29, 2007 16:35:56 GMT 10
Looking very, very nice JBJ ....
a credit to you ..... almost looks good enuff to make me "cross over" to the "glassy side" ;D ;D
i am guessing that the joy of seeing it at this stage almost makes up for the frustrating times when you were tempted to "hit it with a spanner" ...
i also love the look of the tow car ... but i am sure that it will look great behind whatever you decide to tow it with ...
congratulations on a job very well done ..
regards A|T
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jrod
Full Member
Franki Alli & The 4 Seasons!
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Post by jrod on Aug 29, 2007 17:04:24 GMT 10
Hi JBJ,
I cant tell you how much i am spewing that my works internet access that i use to surf the net blocks all the pics on the forum......
From what i can read, the Sunliner sounds great so i hope the finishing touches come along quicly so i can check it out for real on the ECST, which cant come quick enough incidently!
Cheers, J-Rod
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Post by humpty2 on Aug 29, 2007 20:01:08 GMT 10
Looks great just in primer............'specially behind the Dodge. Makes me think my other one in the shed could get a paint job to match the Belvedere (Missus really doesn't want me to sell it!) I reckon that no matter what colour you do it in Dennis it will look great. Maybe we should lower our standard just a tad..........others are seeing what a great van these Sunliners are ;D ;D
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