Ally the type25 restro

As some of you guys may know I had plans to swap my 1.6D AP engine that let me down big time on the way to Bugjam 09.
The plan was to swap it out for 1.9D 1Y engine and to do that there were a few mods and swapovers from one engine to the next that I had to do.
Unfortunately I was involved a bad RTA the day before the engine arrived and six month's later I am still recovering so I haven't been able to do any thing on the bus.
Fortunately some good friends tuck on the project and well although they have been trying to fit it in with there own stuff this is the story so far.



This is the 1.6D AP head, note the damage to the water ways.
Using the pink anti freeze over the blue can prevent this from happening although this damage had started a long time a go.
Heres a few picks of the new engine as it came.


Then they started to strip ready for cleaning and part swaps.




What needs to be changed-
SUMP
OIL PICKUP
SUMP GASKET
OIL PUMP
OIL FILTER
FLYWHEEL
ALTENATOR
A pivot bearing has to be fitted in to the Y1 engine because the gearbox drive shaft on the van has to be supported other wise it may shake itself to bits, as the 1Y came from a golf it never had one.
The engine will be painted black.
And the 1.6 rocker cover may be used instead of the 1.9's.

Updates soon

Cool.

I know its been a wile since I posted anything on this put Due to being run-over, a new baby and redundancy Oh and fixing shed loads of kit for people I have neglected my bus

After a hard winter I managed to wash it only to reveal what I new was going to kick me in the arse at some point.

So a plan has formed and a budget set.
I will be replacing the following -
Both rear arch panels.
lower and mid front panel.
both front arches.
rear lower panels.

I will also be doing repairs to -
Tailgate inner and outer. (I did try to buy one but there are no new units and the second hand ones are all the same)
Both gutters where the old roof rack was mounted.
Both sill's around the A pillar.
And a lot of bad pint and stone chips.

Unfortunately I spent allot of money about three years ago on making it look nice, Unfortunately the people who did it bodged it and now I am having to do it again, OK so the tin worm on the seams was unpredictable but I did ask them to treat and seal them witch never happened. Any way I digress.

Here are some photo's of the current condition and I plan on doing a stage by stage thread on this so this is the start.

I know I know... I forgot to wash the roof

I am planing on starting this mid April, so if any one wants to lend a hand they are most welcome.
This is a learning curve for me but planing and prep is the key before starting me thinks.

good luck bud, part of the reason i sold mine lol couldnt be fooked with the seam rash.

keep the pics coming

you are going to needd a new tailgate there, as rust is coming from inside out.

you could really do with getting the seems blasted, then get some rust converter on there.

something like por 15 metal ready.

clean and strip wheels are very good for rust as well.

http://www.rightlines.ltd.uk/Stripping-Discs.aspx

andy

joker 67 wrote:

you are going to needd a new tailgate there, as rust is coming from inside out.

you could really do with getting the seems blasted, then get some rust converter on there.

something like por 15 metal ready.

clean and strip wheels are very good for rust as well.

http://www.rightlines.ltd.uk/Stripping-Discs.aspx

andy

The problem is good tail gate without rust are like hens teeth.

I am replacing the panels and putting in new metal, I was then going to use hamerites crustoff to prevent further rust.
put I will Change that to the POR 15 as I have heard and read lots of people use it.

Thanks for the email gonna order a couple wen I order me cutting discs as the ones I have are to thick.

The G wrote:

joker 67 wrote:

you are going to needd a new tailgate there, as rust is coming from inside out.

you could really do with getting the seems blasted, then get some rust converter on there.

something like por 15 metal ready.

clean and strip wheels are very good for rust as well.

http://www.rightlines.ltd.uk/Stripping-Discs.aspx

andy

The problem is good tail gate without rust are like hens teeth.

I am replacing the panels and putting in new metal, I was then going to use hamerites crustoff to prevent further rust.
put I will Change that to the POR 15 as I have heard and read lots of people use it.

Thanks for the email gonna order a couple wen I order me cutting discs as the ones I have are to thick.

And Toolstation do the wheels to

joker 67 wrote:

you are going to needd a new tailgate there, as rust is coming from inside out.

you could really do with getting the seems blasted, then get some rust converter on there.

something like por 15 metal ready.

clean and strip wheels are very good for rust as well.

http://www.rightlines.ltd.uk/Stripping-Discs.aspx

andy

Would you use a ZINK primer after Andy ?

The G wrote:

joker 67 wrote:

you are going to needd a new tailgate there, as rust is coming from inside out.

you could really do with getting the seems blasted, then get some rust converter on there.

something like por 15 metal ready.

clean and strip wheels are very good for rust as well.

http://www.rightlines.ltd.uk/Stripping-Discs.aspx

andy

Would you use a ZINK primer after Andy ?

i would probably use an acid etch primer, to be honest, as you will need to fill over the rust pits, then filler prime it and last seal joints after flatting down with a good quality sealer, using a cloth and sprit wipe to clean the excess away.

THE VOLKSWORLD KEEPING YOUR BUS ALIVE MAG HAS A (fucking caps lock, the password for our pc is in capitals and i can't type and look at the screen at the same time) feature on repairing the front panel.

joker 67 wrote:

The G wrote:

joker 67 wrote:

you are going to needd a new tailgate there, as rust is coming from inside out.

you could really do with getting the seems blasted, then get some rust converter on there.

something like por 15 metal ready.

clean and strip wheels are very good for rust as well.

http://www.rightlines.ltd.uk/Stripping-Discs.aspx

andy

Would you use a ZINK primer after Andy ?

i would probably use an acid etch primer, to be honest, as you will need to fill over the rust pits, then filler prime it and last seal joints after flatting down with a good quality sealer, using a cloth and sprit wipe to clean the excess away.

Thanks Andy,