The Dwyer's Bondwood Skyline

[kyliedwyer]

Hi all starting a thread so we can keep you updated on the progress of our resto :-)

[King Fisher]

Week 1 stripping the insides and taking all my cupboard doors off. I began sanding the doors and repairing them where the internal ply was coming unattached.












(Posted for Kylie)

[King Fisher]

Insides stripped and roof braced ready to take the wall off





Prying the wall off we wanted it in one piece so we could use it for a stencil on our new wall.





Side off and roof braced to keep the shape



Side off and ready to use as a stencil to crate a new one

[King Fisher]

A few nasties were found, but not as bad as we thought that it was going to be

[King Fisher]

We built the new wall using 12mm marine ply. As the van only has a single skin we decided to increase the original 9mm to 12mm for extra insulation and strength. We joined four sheets together to form one large sheet, using a router (thanks for the idea King Fisher) we routed out a 60mm wide overlapping step to form each join.


The joins were brought together before gluing



Glued with Sika – Super Grip 30min





Once the glue dried the old side of the van was placed onto the newly joined side pieces, where it was used as a stencil to mark out the shape, for cutting.



Carefully my brother cut out the new side wall.









We didn't cut out the windows as its best to keep her water tight until the windows are ready to go back in. We did cut 2 small holes where the windows will later be, to use as handles while handling the sheet.

[King Fisher]

We used old floor boards as our framing (helps when your brother is a chippie and has all the tools) he cut and milled the pieces to size, and fitted them.

[King Fisher]

The site foreman arrived to check all was above board (Elijah our 15 months old) he is loving the new caravan. 

[King Fisher]

Fitting our wall. We sikaflexed the new ply to what little framework is there.



We didn't cut the windows out as we want to keep it water tight until the windows are ready to go back in. We made little handle holes (in windows) to help lift the wall on.



Had a little trouble getting the aluminum to go over the wood.




We got there in the end and the new side looked great once it was on.

[Roehm3108]

You've taken on a virtual rebuild there. Good luck with it all.

It does raise that hoary question of restoration vs rebuild

[King Fisher]

We braced the side by tying a piece of timber against the wall. We went through our hand holes and tied the rope around the clothes line then chocked it with a piece of timber to help hold it in place until the glue dried.

[King Fisher]

All packed up until next weekend



To be continued...

[King Fisher]

Feb 9, 2015 15:33:09 GMT 10 Roehm3108 said:

You've taken on a virtual rebuild there. Good luck with it all.

It does raise that hoary question of restoration vs rebuild

From what I understand it was necessary as there was a fair bit of water damage in the cupboards, framing, roof and sides.

However knowing Kylie it will end up being a very respectful rebuild, with keeping the character in mind, so don't worry too much.

[Don Ricardo]

G'day Kyliedwyer and King Fisher,

Great work you're doing there. Glad to see the van just needs a few minor repairs and a bit of a cosmetic touch up before being ready for the road again...

Seriously though, it looks as if the work you're putting into it will turn it into a top van when you're done. We're all cheering you on.

Don Ricardo

[Franklin1]

Great detailed report, kingfisher!

I like the way you joined the sheets together. I thought of doing the sides on my van that way, but I didn't think the 6mm ply I used was thick enough to do it accurately.

I see in some of your photos that the Lysaght brand mark is showing on the mudguard. I can't see the year number showing under the Queen's head though. Is the day and month branded either side of the Queen's head? (There's a piece of timber blocking that view).

Nice job you're doing. Don't worry about that old "restoration or rebuild" bone that CONTINUES to be chewed on. If you didn't post the details of what you had done, very few would have picked up it wasn't original.

cheers,
Al.

[akeepsake]

Fantastic thread Kyliedwer and Kingfisher! Love your work ! And it's happening so quick! It's a credit to you all. I have the same thing to do on my Phoenix on both sides so seeing this thread is a real help to the future Reno!
Keep up the good work !
Cheers Andrew

[kyliedwyer]

Thank you all for your encouragement and King Fisher for posting these for me.

Hi Al I will endeavor to get a better picture of the guard up to see if its marked with a year.

As far as the "rebuild vs resto" we are endeavoring to keep our gem as original as possible however we want to make it sound and safe for use with our family for many years to come so are doing what is necessary to make that happen :-)