rusty nail to sow's ear

1st November 2013
Right then, here we go....









A bientot Mr VS.







Just 6 bolts left.
The most frustrating thing was removing the VS exhaust, all the nuts and studs stripped, snapped or rounded off.

4th November 2013
After a weekend of bad weather, and with no excuse not to decorate Chloe's bedroom, I wasn't able to press on with the engine removal.
I did manage to grab about half an hour tonight though.





Got a bit dark, and I need to recover my ramps.
For some reason it's lower than last time I dropped the engine and I can't get the jack under the engine.

6th November 2013
Rained off at work today, so a bit more time stripping the single port and in the garage.



Got my ramps back, so just need some assistance to push it back up onto them so I can get the jack under the engine and drop it.



The single port may be diminishing, but the stroker is getting heavier.





Just waiting on the full flow oil fittings and then the moustache bar can be bolted up.
The alternator, stand and breather stuff is getting a clean before fitting, and then it's ready.

9th November 2013
Many thanks to Justin who came round on his way to the yard and helped get the bus up on the ramps.
And then the rain started again.



But when it stopped I was ready to rumble.



Only took 8 days to drop the engine.

I'm sure the sunroof liner's not supposed to sag like that....



Looks like it's not waterproof any more.







Oh well, another job that's moved up the list. Anybody got a roof cut handy?
I was a bit worried when removing the fuel partition screws as bits of rust kept appearing from behind the panel.
And I eventually found the four hidden screws.



But it doesn't look too bad on first inspection. Breather pipes are shot though.



Unfortunately I've run out of suitable containers to store the fuel that's left in the tank, already drained 30 litres and there's plenty more left to go. Damn the AA for saving me fuel on the way home from Woolacombe.
The gearbox has been removed as well now, but I can't start cleaning up the engine bay until the tank's out.
Didn't think I'd be using the cover again, but it'll help reduce the amount of water getting into the bus if/when it rains again.



Time for a pint or four I think.

10th November 2013
So off came the engine bay partition, and after draining 40 litres of fuel out came the petrol tank.
Doesn't look too bad on first glance.



Perhaps not then.







After a bit of a grinding session and clean-up. Got rid of the regulator bracket as well.



Splash of rust converter, and now I'd better get some gas.
I think the decision has been made that it's ready when it's ready, and not to rush for the Santa Cruz at the beginning of December.

16th November 2013
Managed to make a start today.
The holes have got slightly larger.





A rain shower meant that I only managed to get one side plated, as I don't think the welder is water resistant, and a coat of rust converter on.
Hopefully get the other side done tomorrow if the weather stays dry.

17th November 2013
Bit more done, unfortunately the tank platform metal is like tissue paper.









Still need to repair the section below the tank where it meets the engine compartment side plate.

24th November 2013




I seem to have lost a bit of enthusiasm this weekend, so all I did this morning was clean up under the tank platform and spray a bit of primer on.







And put a couple of coats on the alternator tin, although it was a bit cold for painting if the truth be told.

30th November 2013
Slight pause as I've got something else to do now.



Little trip up to Brightlingsea to collect a tin top roof cut.

1st December 2013
Looks better already, just needs a couple of spotwelds.





Although I'd better take the sunroof off first....

2nd December 2013
Finally got the tyres on the banded steels today.



Managed to pull my finger out and get one of the many jobs on the list sorted.
Drilled out the (very hard) captive bolt on the petrol tank straps, so now they're almost ready to be refitted.

7th December 2013
Slightly more progress today.
I went down the yard this morning to paint the rear valance.



And while I was there I caught a bit of enthusiasm again.
So came home and had a good afternoon's grinding and welding. Just one more plate to go and then I can paint and re-assemble what was a perfectly functional bus 5 weeks ago.

13th December 2013
Lots of little jobs to do while I get a few minutes to spare.
Fuel filler neck cleaned and primed.
Top coat tomorrow evening, and then I can fit the new filler hose.

14th December 2013
Another productive day.
Finished painting the valance down the yard this morning.



Nice Beetle in for some MOT work.



Then home and out with the grinder and welder. Time for a coffee first though.
Fully repaired and new seal channel fitted.









Off-side isn't the prettiest, but it's not comprised of rust and underseal any more.
Now I can start re-assembly tomorrow morning.

15th December 2013
Coat of Rustoleum "Rust Reformer" on first, I'll let that cure for 24 hours and then start priming, seam sealing and painting.



As it's persisting down here I'll soldier on and start prepping the firewall.



Two coats of household gloss to remove, one green and the other black. The picture doesn't show the actual brightness of the green gloss.
Apparently at some point in it's history the whole bus was painted in the stuff, wouldn't mind trying to find a pic though, just out of morbid curiosity.





Had enough for today, I'll have another crack at it tomorrow evening.

16th December 2013
Long day at work today, just got home.
Painted the fuel filler neck.



I suppose I'd better go inside now and say hello to the family.

Loving your work Si

19th December 2013
Had an hour seam sealing and painting tonight, only to find a fucking cat sitting on the still uncured sealer on the tank platform.



Good job I only painted the underside.

Mr Scoops wrote:

Loving your work Si

Ta

20th December 2013
Pics of the underside of the tank platform.





After removal of cat residue, bloody things roughed all the seam sealer up, and a coat of paint.



All done (at last), ready for the new tank tomorrow afternoon.

21st December 2013
Fuel filler opening primed and painted.
Now it's all ready for refitting the tank.

23rd December 2013
Nick decided I wasn't getting enough done, so he arranged for the bus to be picked up.
And off we go.
Picked up this morning and dropped at the yard. Luvverly weather.

27th December 2013
Heaven is a 2 post ramp.
A couple more jobs done today.
Another hole in the chassis leg repaired.



Rotten brake pipe replaced



And a new starter connection soldered, crimped and heat shrunk.



Still a couple more jobs to be done before the engine goes in though.

28th Decemeber 2013
Tank's in at the second attempt.





Must remember to attach earth fly lead before installing tank.

30th December 2013
Got a bit done today.
Tank fully fitted, filler and breathers attached, fuel cut-off solenoid connected and 25 litres of fuel added.
Wiring loom replaced and spliced, and gearbox installed.



Forgot to paint the tank firewall, so did that when I got home. Painted body colour, as the stock grey looked odd.



Where's the engine gone?



In the back of the van, ready to bolt in tomorrow.