Here is the start of the list for getting it ready to MOT First is the brake calipers needed some attention, they worked fine but a bit crusty and the air lines needed replacing so a good opportunity to rebuild them. Not a bad call since the diaphragm spring was broken in one side and the other was looking pretty rough too, We sources 2 new housings
Blasted and powder coated
While we had them off and the wagon up in the air we also new one of the king pins was getting a bit worn and had to be greased for the past few years to pass the MOT. So bought a pair of new ones. This job that should have been fairly simple started a long cascade of events.
So how do you remove king pins? Normally remove the circlip and drift them out. Not too difficult to do. Now these ones have to be drifted upwards so short of removing the axle a logical solution was to put a jack under the king pin and then hit the hub down. Well that totally failed even after bringing out the BIG sledge (14lbs) nothing was moving so we stopped before anything sustained irreparable damage. We had a choice at that point either we had to make a press frame that would fit on the axle with it still on the truck or take it off and put it in my workshop press. We decided to remove it.
Its not a light lump to move but we got it up and onto the bench
Well it wouldnt move. The press is rated to 20 ton and i suspect we had it well and truly at its limit. The top frame bent and the pin still wouldn't move. The only heating source we have is a bottle fed blowtorch which is good but you can't get enough heat into something this size for it to make a difference. We tried anyway to no avail.
Next option we sent it up the road to a garage with a supposedly better press and an oxy torch. They got the pins out with plenty of heat around the casting. What they couldnt do was get the new ones in. And they busted both new pin kits trying.
Speaking to the garage we normally take the wagon to for its mot’s we decided to take it up there. Its a bit further but they have done them before so shouldn't have a problem. Another trip to collect the axle from the first garage and take it up to the next one and ask them to source a couple more king pin kits for it… A few days later we get a call. The axle is busted, warped. Sounds like too much heat had been used getting it apart and it has warped the hole the pins go through.
Ok, so thats several journeys, one axle and 2 new king pins trashed so far and nothing to show for it. A bit of calling around and we managed to find a breaker with the right model truck which had a decent front axle on it. Pennies changed hands and he shipped the replacement one up to us.
It not in bad condition and he left a few other unneeded bits on it too so we have some spares including front calipers. After a bit of debating we decided to put it on as it is and see if it needs anything changing later. It got descaled, before fitting
Then rust converter and paint. We did swap the discs and bearings over from our old one once we got them back as we knew they were good.
Along with new lines for the calipers as we refitted them.
Next up we had some wiring to do and make a start on a bit of bodywork.
Post by grumpynorthener on Aug 13, 2021 19:49:37 GMT
Reminds me of the many vehicles that enter my workshop for a few bits that need to be undertaken whereby the few bits very quickly becomes a very long list
Reminds me of the many vehicles that enter my workshop for a few bits that need to be undertaken whereby the few bits very quickly becomes a very long list
Yep this started as a just needs a bit of replacement floor.
I have turned away a few jobs from other people for that exact reason.
"oh it just needs a bit of welding" very quickly escalates if the job is to be done properly and anyone who just wants a patch slapped over the hole can find someone else to do it.
Now that the wagon can move again we need to finish up the side skirts. On the rear corners we decided the easiest thing to do was weld in some extensions that were chopped off the old box.
Then cleaned back
Staying at the rear end i fixed the wiring for the rear lights as it had been badly repaired previously. Chopped out the scabby bits
Repaired
And fitted new connectors that match the lights we will be fitting
Which are these, nothing fancy so they might get changed in the future if something better comes up.
We mostly reused the original side skirts and just modified to fit. A couple of areas had to have new ones made which we did using some of the aluminium that came off the old ramp.
We also needed new front corners that blend the front arches into the skirts. So a bit of aluminium was folded up.
Not the best but they will do the job. The sides got sprayed in etch primer just to make it all one colour and help protect the bare sections a bit.
The old frame from the steps was a bit rotten and had some flaws that needed correcting. So i made up a new one
And fitted
While we had some grey primer left and we had a nice still day we decided to do the ears and cab aswell. The poly mask makes short work of sheeting the cab up
Sprayed up.
It came up well and gives it a slightly different look.
Rear bumper We wanted something a bit different to last time so i made up a profile and took it to the local fabricators to get it bent up since i dont have a 8ft press brake.
A bit of work and we had the lights fitted.
But we needed a cover for the wiring so i bashed a few out.
And powder coated
Some fettling done and then the panel got removed and given a coat of primer
We had a few repairs to make to the front steps and we also gave the front bumper and steps a fresh coat of silver before refitting
Front bulkhead got fitted and the cutout made
I made up a battery tray as well complete with straps. Originally the batteries were hidden under the floor but they were rather difficult to get to so this time they will be getting boxed in by the benches and I plan on fitting a set of remote jump posts that can be accessed from the outside. Just in case.
We are going to need side lights if we are to pass any MOT First off side repeaters need fitting, the old ones are very battered and wont be going back on. The new ones arnt the same as originals but they looked like the best option given the constraints we had.
Of course the connector was wrong. So i soldered a fly lead on and potted it with sealer.
I then replaced both sides of the connector with generic 2 pin jobbies. Next i lifted the floor back up and made a start making up the looms which will feed the side marker lights.
I sat down and fitted all the connectors for the side markers.
Then they got fitted. You can also see here the start of making a hole for the fuel filler.
We also took one of the old locker doors, dismantled it and remade it to the new size.
The rear bumper got finished with new number plate lights and a new plate.
The propshaft got a new center bearing since it was shot. And thats about when we started having a few issues. We took it for a quick drive to find that we had a very nasty vibration coming from the drive train at about 40mph.
After a bit of work we decided the prop must have not gone back together in the same orientation since it wasnt marked when it was disassembled to change the center bearing. We took a bit of time and a few test drives to get it clocked back in correctly. It still had a vibration but it was good enough to drive it to the MOT station and the garage we take it to said he could re-align it properly.
A few small jobs got finished
Then off it went up to the garage who does the Pre-MOT checks and then takes it to the MOT center.
A week later we had it back with a fresh ticket. The only mark was that we are a little light on the rear axle, not enough to fail though. Since it all needs kitting out i think we can live with that.
It is old, we originally looked at replacing it with an replacement ex-fleet vehicle as they were showing as fairly cheap but having spoken to our tame MOT garage and hearing the amount of issues he has had with some of them and seing the cost to repair the faults that its almost gaurenteed to have it just wasnt worth it. Better to stick to the devil you know sometimes. After cleanup i was quite surprised just how solid the chassis was, have since seen issues on horseboxes on newer trucks with the chassis folding up due to corrosion.
Nice job, it should last years now! wouldnt mind betting it will hold its value as horse boxes seem to command good money
Mind you horses/ponies seem to be commanding good money at the moment as well
The boxes are holding a decent value. with all the work into this one so far we dont plan on selling it but if we were offered a decent price then we would let it go and would probably end up building another.
So then Prop shafts The one thats on the truck still isnt right so we decided to take it up for balancing. The guy got it on his machine and span it up to speed where it promptly tried to run across the workshop. Something definitely not right then. He tried balancing it but at the end of the day it turns out to be bent. As it happens they are pretty much made of tin foil and standing on it will have caused it to buckle which i think just about everyone had done at some point while we had the truck in pieces. A replacement would be £1.5k from MAN or we can have a custom one made for a lump less than that and we can have it made a bit more substantial than an original one.
A few days later the new one arrived and we fitted it, problem solved and wallets considerably lightened.
Whats next then? Well the forecast was looking particularly good so i took a long weekend off work and we got busy. Its paint time.
A couple of parts to fix before we start Holes in the back steel work where the old door hinges mounted need welding up
Welded up and cleaned back.
Remaining prep is to clean back the excess sealer around the doors and windows.
Bolted up the center wall fully now we had the correct bolts.
We made up some screens to protect from any wind there was.
The box started getting prepped
It got rather hot out in the sun
Plenty of masking and sanding
Followed by panel wipe over the whole thing
By the time we were ready to apply the etch primer it was around 9:00 and getting a bit dark But we started painting anyway and got 2 coats on, by 11:30 it was a late finish so slurped down a cold one and called it a night.
In the daylight you can see it came out pretty well.
Sheeted up again
We had a few areas to touch up but mostly it looked good.
Rubbed the flies off and cleaned back and then we got a couple of coats of heavy primer onto it.
Followed by the silver on the skirts and some extra at the back so some detail can be added
We also lacquered the silver as its a bit dull and stains easily without it.
Cab went back up
And we began stripping it back
Turns out the truck has a cabin filter we weren't aware of and since we have had it for over 10 years its not been changed for a long long time. Its a bit grim
Post by grumpynorthener on Aug 24, 2021 20:02:37 GMT
Exactly how I used to paint my old race car transporters (converted coaches) - due to the size of them - outside in decent weather and hope for the best
Exactly how I used to paint my old race car transporters (converted coaches) - due to the size of them - outside in decent weather and hope for the best
It would have been nice to borrow a barn big enough for it but it was getting quite a bit more difficult to do that. At the end of the day it doesnt have to be a showroom finish.
The next morning we got right back on with prepping the cab, it needed quite a bit of sanding back, the windscreen removed and masking up.
That took most of the day all on its own.
But all done and ready
We rejigged the sheeting
And got the etch primer down.
Followed by primer, there was a slight concern that we wernt going to have enough so we used some older stuff on the luton just in case.
Then while waiting for all that to dry we masked up the box where we wanted the silver to stay silver. So a steady hand and thin tape got the profile.
And some more masking tape did the rest.
A rescuff with scotchbrite and panelwipe there was nothing stopping the final colour going on.
The first coat went on rather well.
And by the time we had finished the second coat it was getting late again
Not wanting to leave it we unmasked it that night and left to cure.
Small things but i was rather impressed with the curve.
The finish came out well and i was happy to call it a night. The next morning a good look over it showed up a few areas that we could have done better but my holiday from work was over and we decided it was good enough for what it is. There may be some touch ups later.
