“Spring has sprung!” as progress for April has been good.
Our new front leaf springs have arrived replacing the old ones which
were in a poor condition. Unfortunately, immediate fitting wasn’t
possible due to the discovery of a badly worn front hanger bracket (the
‘eye’ is egg shaped!) – this will have to be sent away to be
repaired. This explains why the shackle pin had been welded into
position! Four new shackle pins will have to be sourced before we can
hang the springs too – we might as well fit new ones, as we definitely
won’t want to have to replace them at a later date with all the work
that would entail!
The axle beam and track rod have received
their topcoats of paint and await the return of all the constituent
parts which make up the front axle and suspension. Two new King Pin kits
have been purchased and are ready to be added to the Stub axles which
Stephen finished stripping and refurbishing last month.
He continues to
for-go his lunch breaks at work and has now rebuilt the offside front
break assembly (with the assistance & guidance of Pete) complete with
new break shoes. The nearside one should be complete this week if he can
find the energy.
Rebuilt offside brake assembly with new brake shoes
The floor traps have been disassembled and all the aluminium edgings
have been reshaped and tidied up to remove the score marks and ‘dings’.
supplier of suitable floor coverings has been located and hopefully,
once we receive some samples, the lino can be ordered and then the traps
can be covered.
The repaired plastic dashboard moulding has been refitted and now awaits
the next visit of electrical magician Mr Sharpe so that the actual dash
itself can be reinstated.
With Stephen in demand elsewhere on a couple of days, I’ve taken the
opportunity to take control of the workshop space and had the front
fibreglass moulding up on the work bench to continue its’ repair and
preparation. Next weekend it will get its first light coat of primer to
check how successful I have been!
Saturday the 18th was a landmark day for us – after a couple
of false starts the rear fibreglass moulding was permanently
complete and glue in place
Finally the rear moulding is permanently fitted - time for a brew and
weekend we had made up the last fillets of woodwork to support the rear
name glass which now fits perfectly in the aperture.
We are extremely pleased to have achieved this as we have replaced /
rebuilt virtually the whole of the back end of CDK (new boot walls,
floor, framework, seat box and of course all the supporting, shaped
woodwork). Not to mention the hours put in repairing the fibreglass
All that remains now is to re-hang the boot doors and
make up two galvanised steel panels which mount from inside the boot
behind the rear light clusters. This will also allow the new wiring to
be trimmed to the correct lengths in preparation for the re-instatement
of the rear light units. A bonus is that we now have a very handy place
to store away all the bits and pieces that have been scattered around
the workshop for the last 4 years!
During a check to see if the rear screen window rubbers had enough
clearance around the new back shelf it was discovered that over the
years vibration of the screens in the rubbers had worn away the
fibreglass around the upper edge of the window aperture – so much so
that in some places it was non existent. A liberal coating of ‘instant
bus’ (glass fibre resin filler) quickly solved this! Not a great deal
remains to be done at the back now - time to start moving our way down
Final nearside panel being attached
Late April - The lino samples have
arrived and we have settled on a suitable colour for the recovering of
the centre aisle and floor traps. Also in the sample pack was a grey
coloured lino which will be suitable for the area of floor around the
driver's seat and up to the front wheel arch - unfortunately it is only
(allegedly) available in tiles. As we need several meters of it we will
have to contact the manufacturer to see if they can supply in roll form.
It is a very close colour match to the original.
Also sourced have been the required shackle
pins to enable the springs to be hung. The damaged hanger bracket has
gone away to a local firm to be reamed out and have a steel collar
inserted - once this is returned the springs, axle & radiator can be
refitted. Then perhaps, our pockets can stop sweating for a while!
The front fibre glass moulding is now
looking good after many hours of attention. This was in just as bad a
condition as the rear one following numerous minor collisions over the
years. This will have to await the completion of the electrics before it
can be refitted.
The air filter oil bath tray has been
removed from WEB, repaired, painted and fitted to CDK along with the air
intake 'mushroom'. We'll have to find replacements for WEB at a later
At long last we feel we are getting
somewhere with more bits going back on than are being taken off!