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Post by bendot on Mar 2, 2015 20:22:52 GMT 10
Righto, I better start with an apology cause I reckon you guys are gonna get pretty sick of me by the end of this...this is a big (small van) project and my first caravan resto - I'm gonna need some help/advice. I'm hoping you guys are friendly! Now that's over with lets get started. In 2011 me-n-the wife (and boy) 'invested' in a little 10 foot 1959 Modern Van. Previous owners stuck a photo on this site "Down History Lane"...Modern fans may recognise her? Not a big investment and we knew we were getting into a pretty big job - but we liked the van and entertain ourselves by imagining the polished aluminium finished product?!?! She has sat undercover for a few years (in York, WA) until I finished building our house (back in Perth) but now that's done I have no more excuses. I mentioned this is gonna be a big job - certainly not very much inside that can be saved...only the hint of what might have been. Clearly a lot of water has been inside - and some damage to the roof frame was visible - previous owner had 'fixed' the roof and replaced the draw bar (with 1 7/8 coupling that may prove problematic). Before I get too deep I better explain 'Plan A' and 'Plan B'. Plan A - is to restore her to her former glory - as original as I can. Get her re-registered, pack the family and start touring (every other weekend). Plan B - is not the preferred option, but due the state she is in - may well be where I end up. Plan B is - get her watertight and refit a suitable interior to use as a spare room for the kids at the holiday house. SO NOW ITS DECISION TIME... stripped her out and I gotta work out if I can save her. Oh, by the way - name's Ben... TBC
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Post by sarahlou on Mar 2, 2015 21:20:41 GMT 10
Hi Ben, I'm kind of new here too so I don't want to get into anything too technical but in my opinion whether to go for plan A or plan B depends on how much time and money you have to spend on your van (nice looking van btw) and how far your skills go. To a lesser extent the rarity of the van might come into the decision making and also maybe the value of your van. When it comes down to it you might find that the plan changes as you get into it and you might find it hard to resist doing that extra little thing to make it 'just right'.
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Post by DC3Td on Mar 2, 2015 22:06:21 GMT 10
Gday Ben & welcome.Good looking van albeit a tad untidy but we have seen a lot worse.Money always comes into the work to be undertaken certainly but have a good look through our members projects currently underway.If you reckon she/he can be saved with even basic tool skills then its worth saving.Theres plenty of advise available so don`t be shy.
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Post by bendot on Mar 2, 2015 22:36:40 GMT 10
Yep...this is going to come down to money...and that's where I need the advice because I don't want to spend the money if she's too far gone to get re-registered (or if unsafe to tow). That first post was more an introduction - seemed rude not to introduce the van. Now comes the nitty gritty. Am keen - and reasonably capable - so intend to do most work myself. Non-structural welding should be fine but will get someone who knows what they are doing where it matters. Some experience working with metal - and plenty with wood - so that should keep some costs down. I spent the long weekend stripping out the rotten interior to reveal the good and the bad. I think I can fix her but not yet too sure - couple of tricky issues... The GOOD: some of the aluminium - untouched by water leaks looked brand new and showed the promise of the finished polished exterior...(wishful). Above the undercarriage - there were only a few areas of rusted frame. As most will know - the Modern Vans were steel framed. NOT SO GOOD: any steel under the floor was rusted - most was surface and I will wire-brush the lot, ranex rust bust and paint. Needs new axle, wishbone, hubs and tyres - I expected this - and have budgeted for mechanical braked DIY kit. Probably up the 40mm axle to 45mm and am thinking of a straight axle rather than the drop axle she wears now? (Comments? What do I need to consider - has a pretty low tow height now) [Plan B will be simple non-braked DIY kit - so I can move it round the block and onto a trailer if needed] Most obvious problem is the roof - which has leaked a lot. Previous owner reckons it is fixed but I have my doubts and never tested it as she has been undercover these past years. The leak appears to be around the 'skylight'. Which should be easy to remove (angle frame screwed/riveted to roof sheet) and reseal. The front roof seam also looks like it has leaked and this has caused the roof frame to corrode badly. Some repair and rust kill has taken place (silver paint in photos) but I'd prefer to cut this out and rebuild frame. I had thought I could just drill out rivets in the roof sheets, cut the rusted frame out, weld up a new section and bolt it in to existing sound frame, But now I can see the repair there are 1 million rivets and assorted bolts and screws thru the roof sheets and the whole mess has been covered in some sort of silver (maybe butyl backed??) tape. Anyone know what this is and how to remove? Rear sub frame member is made from cornflakes! and also rear left lower curved frame... Curved frame I can kill rust and brace - the rear section appears to be 2x25mm box sections - I will cut this whole piece out and weld in a new one. The other main concern I have is the draw bar - and registration in future. This has been replaced fairly recently (previous owner) but in an old photo on this site I can see there is no draw bar. This looks sound but has ugly, ugly welds - I think I need an expert to look at it and see if it needs attention. Anyone know someone willing to visit York and look at a van?? Anyways some pictures below tell some of the story. Most of the silver painted metal is new - one piece is a hybrid new welded to old!!! The coupling hitch is old - 1 7/8 inch ball I think - weird to add this to new drawbar?? - if I add brakes this will go anyway I suppose... Ok - that's my first batch of issues.... Anyone leaning towards Plan B yet? Not me! Once I get rid of some of that rust I'll post more updates on the major works. But wont be in York for a few weeks. Until then - to amuse myself - I may post a list/plan of attack - for comment or whatever. And better get started searching for replacement period parts - thank god I found this forum! Window rubbers and auto lights here I come. Ben.
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Post by akeepsake on Mar 2, 2015 23:15:09 GMT 10
Gidday Ben! by geez we are a friendly bunch here on the ol forum ! Everyone I have met personally have gone outer their way to help a bloke ! So I think your in safe hands ! Here's my two bobs worth for what it's worth. Having just about finished my first vintage van restoration money to me isn't the issue as much as time . Now don't get me wrong, money is always an issue but if you are handy and are having a crack at it yourself your van is really a black hole where time and space disappears at a drastic pace! The other day I hit the shed to work on the van and when I came out hungry and went back into the house the kids were older than me! Something to do with that curly grey headed old bloke Einstein and his theory of relativity E=mc2..........,,,,Seriously You have a great lookin van there a dimond in the rough ! If you have the time go with plan A And keep it as original as you can , that's up to you, but if you do you won't regret it Cheers Andrew
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Post by mibosa on Mar 3, 2015 5:29:52 GMT 10
Hi Ben, have noticed that your frame is quite small, what is it? 25 x 25mm? In the first two photos it appears to not have an inner skin (wall), am I right? Will create some thought if you want to insulate the walls and ceiling space and what to use. I am planning that process now and my aluminium framed van has a decent wall space so I have the option of using polystyrene foam or other types of more modern insulation. I have now sourced a large quantity of foam which I will use on the walls and am going to do some research as to which is most effective, foam or batts, for the ceiling space. Regards, Bob.
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Post by bendot on Mar 3, 2015 9:50:18 GMT 10
Gidday Ben! by geez we are a friendly bunch her on the ol forum ! Everyone I have met personally have gone outer their way to help a bloke ! So I think your in safe hands ! .... Cheers Andrew Thanks Andrews - looking forward to the project actually and am prepared to spend some time on it...not one that sits around doing nothing very well - and this is a project that the wife is right behind! Took hundreds of photo's and measurements and saved all reusable hinges, knobs, handles etc - the rest I can fabricate (I must have too much time!) So she will be as true to original as I can get her - May tinker with the floor plan slightly though. I am 1.9m tall and she is 1.8m wide (and high) - either gonna cut off my feet or swing the bed around Thanks for the encouragement (/warning re: time black hole) Ben
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Post by bendot on Mar 3, 2015 10:04:39 GMT 10
Hi Ben, have noticed that your frame is quite small, what is it? 25 x 25mm? In the first two photos it appears to not have an inner skin (wall), am I right? ... Regards, Bob. Hi Bob - you're a bit ahead of me - not quite ready to insulate as yet but I have given it some thought. I have removed all the lining - it was masonite (Swan Board made in Sweden actually) it was in pretty bad shape due to the water leaks. You can see it in the first post photo's. It was just riveted (yep) to the metal frame - I tried to drill these out but they just spun so I had to pull off the masonite and now have to grind all the rivet heads off. Fun times. The wall frame is actually 15mm square hollow section - so I have even less space than you! (roof frame is similar but 15mm u-shaped section) I was thinking of using a combination insulation/thermal break/vapour barrier I used on my house - it is about 8mm thick and is 2 permeable foil sheets with foam insulation sandwiched between them. R value 0.2 - so not great but better than nothing - should provide some sound insulation too. I'll be interested to hear the results of your research! Ben
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Post by DC3Td on Mar 3, 2015 15:06:59 GMT 10
Gday Ben. Good to hear you`re keeping as original as can. Swan Board? Got a pic of the stamp/logo for Cobbers collection? Polystyrene is probably better as it won`t soak up any condensation over time as batt insul does.But each to their own.We have a Parts Suppliers section to check for hinges/interior/exterior lights/fittings etc.Brake/indicator lens can be reproduced if need to. gordon
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Post by bendot on Mar 4, 2015 18:10:05 GMT 10
Gday Ben. Good to hear you`re keeping as original as can. Swan Board? Got a pic of the stamp/logo for Cobbers collection? gordon Geez Gordon - about the only thing I didn't take a photo of you request!! I'll dig through the rubbish pile when I'm back in York in a few weeks and see what I can do for Cobber - looked at his(?) threads and found one about plywood - I had masonite lining my van but I assume this is where I stick the photo?? Thanks for the tip re: suppliers spent all of last night sourcing various bits and pieces - cant believe how much I can still get hold of - she'll look great when I finish! First job however it to deal with the rust in the chassis - this will really determine how for I take this resto.
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Post by DC3Td on Mar 4, 2015 20:20:54 GMT 10
Gday Ben.You`re not going to let a couple of bits of steel come between a resto or a cubby are you? Couple of folks (& more) have done chassis rebuilds or part thereof.Have a look through Members Photos.Personally i think the frame sections will be tedious but certainly do-able.If you go through the process of removing rivets/screws from roof its all par for the cause.Once done the rusty spars can be removed/new pieces welded in & you can still use the existing holes to re-rivet probably going up a size using blind rivets.These don`t allow the rivet nail head to fall through meaning no water seapage.Btw,if you decide to use poly insul (fruit box lids) dont try & glue them in place - glue eats through - just a couple of pieces of tape to hold in.Your wall lining will do the rest. gordon
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Post by bendot on Mar 5, 2015 11:52:47 GMT 10
Gday Ben.You`re not going to let a couple of bits of steel come between a resto or a cubby are you? Couple of folks (& more) have done chassis rebuilds or part thereof.Have a look through Members Photos.Personally i think the frame sections will be tedious but certainly do-able.If you go through the process of removing rivets/screws from roof its all par for the cause.Once done the rusty spars can be removed/new pieces welded in & you can still use the existing holes to re-rivet probably going up a size using blind rivets.These don`t allow the rivet nail head to fall through meaning no water seapage.Btw,if you decide to use poly insul (fruit box lids) dont try & glue them in place - glue eats through - just a couple of pieces of tape to hold in.Your wall lining will do the rest. gordon Thanks again Gordon - I did have it in my head that removing all the cladding would be a step too far but have spent some evenings looking at various threads and it doesn't look as bad as I expected. And to be honest I'd kind of concluded I'm not gonna be able to properly rectify the leaks and frame damage without removing aluminium. Really means I can do the job properly and know there will be no hidden surprises down the track. Stay tuned - will re-start this as a restoration thread for the van in the Members Photos as I get underway. Ben
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Post by Franklin1 on Mar 5, 2015 14:12:57 GMT 10
G'day Ben, Nope, just continue adding to this thread, and all your story will be contained in the one thread. The Mods will shift this thread over to the Members Photo Album section if you ask them nicely (or YELL LOUD ENOUGH AT THEM!!) Cheers, Al.
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Post by bendot on Apr 7, 2015 13:53:18 GMT 10
Okay...got some progress to report. Would the Mods be so kind as to bump this thread to the Members Photo section please? Thanks,
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