stooy
Junior Member
Posts: 67
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Post by stooy on Sept 12, 2019 10:30:33 GMT 10
G'day Everyone, As some of you know, I found last year that I had quite a bit of movement between the body of my Don and the chassis at the front. I have finally cut a hole in the front of the van to take a look and the news doesn't look too bad. There is a triangular piece of timber that joins the skin to the front main rail which is totally rotten and doing nothing, but the front main rail is quite serviceable. The question I have for you guys is if there is something else at the front that takes the load, or is it just the skin where it is connected via this triangular piece? I am thinking of replacing the triangular piece, bracing the corners with two pieces of angle iron in an L shape and putting a bunch of new screws down the sides into the side rails from the skin. Is there anything I am missing? Thanks! Photos here
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Post by shesgotthelook on Sept 12, 2019 11:15:16 GMT 10
Not sure if I have photos, but my builder man replaced the timber beam underneath the front & back & secured with coach bolts.
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Post by Franklin1 on Sept 12, 2019 17:36:12 GMT 10
G'day stooy, The triangular timber is really just a means of fixing the skin to that section of the front. The majority of load-bearing is done by the seatboxes inside the front section, providing the boxes are interlinked with the flooring, plus both the front skin and side skins. When you say you had a fair bit of movement previously in the front area, it would seem to me that there wasn't enough interlocking of bits and pieces ABOVE the steel cross-beam, rather than just the triangular timber rotting out. Cheers, Al.
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stooy
Junior Member
Posts: 67
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Post by stooy on Sept 13, 2019 12:40:41 GMT 10
Thanks Guys,
Really appreciate the input.
Hi Al,
As best as I can tell my seat boxes are 100% intact with no rot or split joints.
However I think there is no connectivity from the skin to the frame rail timbers all the way across the front and as far back as the door on both sides. Does that make sense?
Cheers
Stewart
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Post by Franklin1 on Sept 13, 2019 15:07:02 GMT 10
G'day stooy, These photos show how the seatbox framework in my van locks the floor, the front, and the side of the van together... Missing from the photo is the laminated curved strip that was positioned against the front skin in the front left side of the photo. The curved lamination looked something like this... When the plywood skins were glued and nailed to the seatbox framework, plus with additional bits of timber glued at floor level across the front, it makes for quite a robust structure that is able to withstand shocks from hitting potholes, etc, in the road...
The more you can lock the floor, front, and sides together, the more the van will stand up to the rigours of travelling along bumpy highways. And the beauty is that you don't need great hulking timber sizes...you just need to interlock in as many places as possible within the design.
Cheers, Al.
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stooy
Junior Member
Posts: 67
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Post by stooy on Apr 6, 2020 14:06:10 GMT 10
Hi Everyone, An update, on the repairs is coming. I wanted to share something with you guys. My uncle was cleaning up during this lock down time and has found the original brochure given to my Grandfather when he purchased the van new. You will find the second page most interesting with the dual front window drawn in by hand in pen! Cheers Stewart
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stooy
Junior Member
Posts: 67
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Post by stooy on Apr 6, 2020 14:41:54 GMT 10
G'day Everyone, A long overdue update on the repairs to the front of my Don. Thanks everyone for your help and advice along the way! When we got the skin cut off it turned out that the front rail wasn't in too bad a shape, but all of the timbers connecting to it were. All of the bows that run from front to rear were rotted off, and the two side rails that connect to the floor and support the jacks were also rotten. Many options were discussed, but we settled with making a steel frame which will support the front cross rail, and firmly connect the new side rails and all the bows together. Below is a photo of it being fitted. We have now completed almost all the structural work and soon will be re skinning the van. Hope everyone is doing well and staying safe! Cheers Stewart
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stooy
Junior Member
Posts: 67
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Post by stooy on Apr 20, 2021 16:53:21 GMT 10
G'day Everyone, I know it has been a long time since updates. Our Don is now back on the road! We have finished the structural repairs, and also finished the install of electric brakes which are great. So far we have done two trips, one to Wilby in Northern Victoria and one to Glenchromie in Drouin. My wife and I are expecting a baby in October and are planning to take the Don to Queensland with the XB GT to escape winter 2022 in Melbourne. Lots more to do before then! 20210206_195551[1] by Stewart Perry, on Flickr Cheers Stewart
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Post by Don Ricardo on Apr 21, 2021 11:20:43 GMT 10
Hi Stooy, Great to hear that your Don is back on the road and you have been able to do some trips in her. That's fantastic news. She's an unusual Don, so it's great that you've been able to work on her and fix her up, even if there's more to be done. Congratulations also on expecting a baby. That's fantastic news too. I hope everything goes smoothly. Remember that the bath in the van makes a very serviceable bassinet - without water in it of course! That's what my parents used for me - true story! Don Ricardo
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stooy
Junior Member
Posts: 67
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Post by stooy on Apr 30, 2021 11:49:34 GMT 10
Thanks Don Ricardo! I hadn't thought of using the bath as a bassinet, but I will now
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stooy
Junior Member
Posts: 67
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Post by stooy on Jul 10, 2022 19:45:44 GMT 10
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stooy
Junior Member
Posts: 67
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Post by stooy on Sept 24, 2022 21:01:04 GMT 10
G'day Everyone, I hope you are all doing well. We did manage to make it on our Queensland Trip. So far we have covered 3500kms and counting. Fairly happy with how the Don is adapting to family life. My daughter is sleeping soundly in the double bed at the front. Fishing Haven Caravan Park at Yamba 20220914_154204 by Stewart Perry, on Flickr 20220909_172438 by Stewart Perry, on Flickr Story time 20220829_190840 by Stewart Perry, on Flickr Cheers Stewart
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stooy
Junior Member
Posts: 67
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Post by stooy on May 1, 2023 8:01:00 GMT 10
Hi Everyone, Since my last post the Don has FINALLY had the paint job I have been planning for 6 (or probably more) years. I also fitted all new window, door and roof hatch seals which keep us much warmer. We have done two more trips to South Australia and covered another 4500km with no issues. 20230315_173135 by Stewart Perry, on Flickr 20230309_152036 by Stewart Perry, on Flickr 20230321_101838 by Stewart Perry, on Flickr Cheers Stewart
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Post by Don Ricardo on May 1, 2023 10:57:42 GMT 10
Hi Stooy,
Congratulations. Your van looks great, and I'm so glad to hear that your out and about in it. Based on our experience, I reckon that the Don is a pretty good touring van.
Nice to see the update on your daughter as well. She is growing so well.
Don Ricardo
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stooy
Junior Member
Posts: 67
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Post by stooy on May 2, 2023 8:13:15 GMT 10
Thanks Don Ricardo,
I am very pleased with how it looks now.
We are very much of the same view. We have done 13 weeks in the Don since August and I suppose 10,000kms or so, and we are very happy and comfortable in it.
Cheers
Stewart
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