Observatory's Restoration 60s Ambassador Viscount D919

[DC3Td]

Interesting point you brought up Pete re the escutcheon pin - was this method used by other brand makers? Can`t recall any one mentioning this either. gordon

[Observatory]

Hi Gordon, sorry no knowledge of other branded vans.  But because my rear window had already dry rotted, with no signs of escutcheon pins attaching the cladding to it; I only just became aware of the way the front lower cladding is pinned into the window frame.  Anyways, back to deciphering this puzzle.  Pete

P.S.  On another subject..  Written in red texta located under the alum. flashing, on the front vertical support of the wrap around window frame is the model number D 919   UPDATE:  and D 919 on the opposite wrap frame as well.  (no date ...yet)

[Observatory]

Front window frame is out:

• virtually fell out once the screws were removed due to old dry sealant... also clear to see the dried up grey d-mastic sealant still on the lower cladding (looks like it was put on with a caulk gun)
• Can see how the 3ply sheet has pulled the wooden shelf beam up and out.  i.e. it's bent!   
  

[Observatory]

Some design notes:

• Notice the 3ply shim (with 3 pins) that sits under the wrap around window; to make it level with the 3ply bendy front panel. 
  
• Some frame work to be replaced. 
  

[Observatory]

Front End diagrams; prepping & shining:

• front (inside view)
• bulk head
  
• cladding panel prepping - last one
• window trim cleaned and polished (metal scourer pad/water; steel wool-00/purple polish; cotton buffed w/drill; shined w/clean white rags)
• J-moulds (00-steel wool/water; purple polish/rag; buffed with clean rag)
  

[DC3Td]

Gday Pete.You do realise by showing your expertise on polishing ali (amongst other attributes) that you could be called upon now to put your magic touch to work on other vin vanners vans.

[Observatory]

Hi Gordon, since this is a monogamous affair with the Observatory; other VV's may be sadly disappointed.  .... I only shine for my love.      Pete
PS.  If I'm anything close to an expert, (not yet) then I learnt it all from you and this forum   

...more deconstructing & diagramming the front:

• showing how the 4mm structural ply wants to spring up; which put the shelf out of whack (bendy ply has arrived to replace it).
• old shelf beam becomes the studs for the new front window frame.  
• more diagramming (front end - outside view)
  

[Observatory]

Cutting out/making new window frame...

• cut top and bottom beams with a jigsaw (already ran through a thicknesser)
  
• Me old mate who runs a local laminating business cut out; glued & routered the new bottom shelf in 10 minutes flat. (carton of beer is still paying )
• routering the rebate for the original laminated shelf panel
• test fit - ali window frame
  

[DC3Td]

Given the incentive i would have thought he`d do it quicker!

[Observatory]

Making window shelf support beam and painting:

• Two 18mmX30mm meranti beams glued and screwed to make new shelf support
• Some exterior paint to seal the grain, on the window frame bits
  

[Deleted]

May 8, 2015 15:11:25 GMT 10 Observatory said:

Making window shelf support beam and painting:

• Two 18mmX30mm meranti beams glued and screwed to make new shelf support
• Some exterior paint to seal the grain, on the window frame bits
  

[Observatory]

Front panel is off:

• pulling out lots of nails and staples to release the panel
• she's off! 
  

[DC3Td]

What every caravan should have - flow through ventilation! Looks like an easier plan of refurb to work with Pete.

[Observatory]

Gettin' there Gordon.. uum... a bit more ventilation flowing from the floor

Fixing the floor...

• black texta marks the ply section for replacement - section will screw onto the metal chassis
• (more paint for the front window bits)
• more floor ventilation
• plugging the hole (9mm - 5ply marine grade hardwood)
  

[DC3Td]

Diggin` for gold & all you found was wood rot.Bugger.See you got ventilated shoes too Pete!

[Observatory]

Routering the door-jam kick:

• routering the rebate
• cutting the mitre with a saw and file
• test fit with ali - and tile
  

[Observatory]

...more door jam woodwork:

• dry rot needing replacement
• making the new stud
• test fit #1
  
• test fit #2

[Observatory]

...more frame replacement

• the bottom front chunk of timber is blackbutt - overly strong
• lap joint repair to bottom beam (glued; screwed; clamped)
  

[Observatory]

Bottom bulk head locked in:

• 2 screws/glue to hold bulkhead (showing my clever little right-angle driver)
  
• 3 screws/glue main anchor/tie in point (one nail you can't see - vertical/upward thru anchor block and frame)
  
• clamped + door stud screwed/glued at lap joints
  

[Observatory]

New timber for shelf bulkhead: 

• chiselling to make the shelf beam joint
  
• test fit with ali flashing
• new shim for alignment of wrap window and bendy panel (4mm structural ply) 
• bottom/middle bulkhead frame glued;nailed;clamped
  

[Observatory]

Shaping timber frame and fitting right shelf bulkhead:

• shaping the new timber frame to the original 3mm wall panel (using panel as template)
• test fitting new timber shelf support using screws to attach (ready for glue) NOTE: using original ali flashing for alignment

EDIT 3/6/15 - ...more shaping and joining:

1. shaping the frame and patching the inner wall 3ply panel NOTE:  used ali cladding as template
   
2. bottom front beam now pinned/screwed NOTE: used bottom cladding flap to find alignment

[Observatory]

Swinging the door - test fit revealed the door jam to be out (i.e. wider at top than bottom)

• wall/bench seat panel (only screwed) not locked yet - so jammed it forward plus planed/chiseled down the new door stud
• door is a swingin'
• wall/bench seat position locked (with one screw - so still repositionable)
  

[DC3Td]

Really great progress & attention Pete.As a matter of interest,how far out was the door fitment? gordon

[Observatory]

Hi Gordon, the door jam at the bottom was about 3mm - 4mm too skinny (see the 3rd photo above - there's a faint pencil line on the bench seat panel; marking the amount to remove off the stud).  Had to move the position of the stud/bench seat back a little - the single anchoring screw being a good foresight.   Pete

Doors are tricky!

• starting to get a nice fit around the door jam - (one trick was to use the door jam - ali trim, to get all the original dimensions... a bit like a picture frame where the door is the picture)

EDIT: 11/6/15 Bench seat panel in:

•   glued/screwed/clamped (originally stapled with 3/4 inch staples but opted for screws because that's what I had). 
  

[Observatory]

Front right bulk head:

• unstitching the 3mm ply panel to access/repair dry rot in frame
• removing ply panel so it's bordered by frame on total perimeter
• No nails!  Suspicion confirmed: cabinetry suspended by battens but not linked together (to allow flex i.e. prevent window being cracked by compression from bumps in tow?)