Boris

Since moving down to Dorset Boris has been hibernating in the workshop, a shed on a dairy farm with some little ratty friends. Since I've settled in and made a nice little nest in the corner for the workbench, boxes of parts I thought it was about time to get the tools out and get started on the little resto project I'd always been planning but never got round to. Think music festivals, holidays and life in general got in the way most of the time. Now, I'm just working about 5 mins away from the workshop, the weather is nice and I have a lot more space to work in than ever before! No excuses now...so I thought I could start on this thread to show you what Im up to and hopefully get some motivation too.

This is where Boris is right now:

IMG_9926 by Aussiboris, on Flickr
IMG_9900 by Aussiboris, on Flickr
IMG_9894 by Aussiboris, on Flickr

And this is the corner of the workshop that I've made my own

IMG_9927 by Aussiboris, on Flickr
Painted the walls white in the area, hung a strip light and some shelving up with help from Andy the guy I share the place with. Thought it has all come up real nice
IMG_9899 by Aussiboris, on Flickr

Zoe and I bought Boris from a nurse near to Sydney a few weeks after we arrived in Oz. He had no interior inside but only cost us AUS$3600. That's about £1800. We immediately went about converting the van loosely based on the Devon interior of my previous bay which I sold to fund my travelling back in 2007. Thought I had finished with veedubs at that time! Little did I know that about a year later we were going to be arranging the shipping of Boris back to the UK after driving around Australia and arriving back in Sydney!

I shall try and dig out some old pics as I put more stuff on this thread.

For now, what I've been up to this week has mostly involved the use of this
IMG_9911 by Aussiboris, on Flickr
Removing the interior was so much easier than building and fitting it by hand
IMG_9903 by Aussiboris, on Flickr
IMG_9909 by Aussiboris, on Flickr
IMG_9913 by Aussiboris, on Flickr
IMG_9912 by Aussiboris, on Flickr
The wardrobe came out and revealed some confetti from Andrew and Christine's wedding in the corner. That stuff gets everywhere!
Plenty of other nostalge in the back and cab including fridge magnets from various places, stickers, plastic whale sharks, strange stringy hippy tat and carved wooden trinkets.
IMG_9904 by Aussiboris, on Flickr
When we bought Boris there was evidence of a forced entry on the driver's door. Looked like a crow bar or some thing. With help from Iain who used to be an old skool panel beater and sprayer, we started to get the door back into shape.

IMG_9895 by Aussiboris, on Flickr

IMG_9896 by Aussiboris, on Flickr
Grinded a hole, levered the dent out as much as poss then went over with some filler. Will get the rest of it sorted later on I guess...the door will be coming off soon anyhoo,

With the plywood out the back, I started looking at what could be removed from the front:

IMG_9902 by Aussiboris, on Flickr

IMG_9930 by Aussiboris, on Flickr

IMG_9933 by Aussiboris, on Flickr
There's a lot of dirt under those seats. I think most of it from Vanfest 2009.

Popped the sliding door window out and checked where the corrosion was coming from

IMG_9921 by Aussiboris, on Flickr
Appeared to be all from the frame of the 1/4 light window which was good. The lip in the door was solid. Hope the rest is all okay too.

IMG_9915 by Aussiboris, on Flickr

IMG_9917 by Aussiboris, on Flickr
Did notice a very crusty bit on the roof which I stuck my phalanges into

IMG_9918 by Aussiboris, on Flickr
In parallel to all this I've also been cleaning up an old head and valves etc

IMG_9932 by Aussiboris, on Flickr
Come pretty clean with some gunk
IMG_9901 by Aussiboris, on Flickr

Got the folks visiting tomorrow so what I get done this weekend will be limited. Going to be back on Sunday I hope. Think I'll get all the underside cleaned up with Meredith (the Kercher jet washer) and pop more windows out perhaps.

See ya

Bit of a long job you've got there, but you've got the know how. BTW we have still got your carb conch.
Helen

looks like a good project, have you still got the Bug?

Still got the bug but had to get it welded for its MOT. Not looking forward to picking it up again as I think it may be pricey work. Thinking of selling it to focus on the bus right now.

Well done Rob get cracking and save Boris

What plans have you got for boris, hopefully taken it down abit more and more. David

Well Dave, Im gonna get a couple beam adjusters and drop the beam soon. Check it over and get the adjusters welded on. May change all the ball joints and bearings at the same time. Still working out the order of things but I think the beam can be looked at early on. A short arse like me could benefit from a dropped bus, would help getting access to the roof!!

Not got a great deal done today. Mostly tidying and going to the tip.
I sorted out a tea and microwave meal station

IMG_9952 by Aussiboris, on Flickr
Cleaned this block up

IMG_9953 by Aussiboris, on Flickr
...and got cleaning all the debris from under the cab seats

IMG_9954 by Aussiboris, on Flickr

Noticed this behind the passenger seat which was pretty interesting. Hadn't seen it before. Seems Dulux were supplying the paints after the vehicles were assembled near Melbourne.
IMG_9955 by Aussiboris, on Flickr
I really want to get the Volkswagen in Australia book now.

Got one of these and did some sorting out.
IMG_9956 by Aussiboris, on Flickr
Im not always this organised but I get really annoyed spending 20mins or more trying to find a simple nut or bolt.
IMG_9961 by Aussiboris, on Flickr
Im not sure how long this level of organisation will last

Stripped all of this out and checked out the floor

IMG_9965 by Aussiboris, on Flickr

IMG_9970 by Aussiboris, on Flickr

IMG_9964 by Aussiboris, on Flickr

IMG_9963 by Aussiboris, on Flickr
There was only a couple extra holes that I didn't expect and these were perfectly round rather than an irregular iron oxide type hole. Quality!

The soundtrack to todays effort consisted of James Lavelle, Alice in Chains, Beck and 2 many djs. The best thing that happened at Wimborne Recycling Centre was finding this vinyl

Vienna by Aussiboris, on Flickr
...Oooooooh Vienna.
The guy in high viz wanted 50p but all I had on me was 3. What a steal. I shall be looking out for other 12 inch singles down the tip from now on

excellent work rob! Boris looks pretty solid! gimmie a shout if you need any help i feel a boris bashing and clubbing weekend coming on!
i think he would lookgood with drop spindals and a 2 inch narrow beam and the gasburners that were on the beige bitch!

Pretty solid. Just very dirty. Theres dust everywhere. I think I will be spending some time with the compressor. Not sure about narrowed beam. I want to just mod the one thats on there already. Thinking of getting steering pin kit and beam adjusters soon.

Just let me know when you want to come and play in Bournemouth. No illuminous tutus allowed mind. How about the week after Stonor? Im available a lot more now since starting this. I eat pot noodles for tea and dont get home til 10pm in the week so would be up for some weekend fun too

Well done Rob. If your organiser isn't working in the workshop then it's the right colour to put in the bus isn't it? Just rewrite the labels, tea, coffee, aspirin, sugar........................

Tone

lol thats a great idea Tone

I've been fairly busy at work but that hasn't stopped me getting down the workshop most evenings. It's been hard to figure out what to do and in what order.
Some of my progress has been hampered by stuck fasteners too. Just trying to keep meticulous about the strip down has been a bit tricky. Just have to remember to bag and label up the stuff I take off as I go.
Here's what I've been up to since the last post.

Taken the swage line / track cover thing off. That was a bit of a git as it was corroded tight on. Took a combination of rubber camping mallet, stanley knife and soaking oil to get it free after a couple hours.
[img] IMG_0127 by Aussiboris, on Flickr[/img]

Been popping out more glass and generally scraping / tapping suspect areas to assess what needs to be done down the line. A guy called Ian who works on the farm has been helping me out. He's an old skool panel beater so has been able to give me some advice on how to tackle things.

IMG_0128 by Aussiboris, on Flickr


IMG_0131 by Aussiboris, on Flickr


IMG_0132 by Aussiboris, on Flickr


IMG_0133 by Aussiboris, on Flickr

Around the windscreen area...

IMG_0134 by Aussiboris, on Flickr


IMG_0135 by Aussiboris, on Flickr


IMG_0137 by Aussiboris, on Flickr

Rear nearside window...

IMG_0138 by Aussiboris, on Flickr


IMG_0139 by Aussiboris, on Flickr

Took some filler off the rear arch here to reveal a bit of a hole. Took it back with the Dremmel a bit and slapped on new fill.

IMG_0140 by Aussiboris, on Flickr

Rear openings off with the help of some easy-outs.

IMG_0142 by Aussiboris, on Flickr


IMG_0145 by Aussiboris, on Flickr

Noticed this behind a rear arch.

IMG_0143 by Aussiboris, on Flickr

Started prising the headliner off. Potentially I can use it again if Im careful. I did notice that there's a loftfull of fibreglass behind it though. Gonna get that lot removed I reckon, dont fancy it so close to where I sleep. What alternative insulation can I use when I come to refit? I think I've seen silvery adhesive stuff somewhere.

IMG_0148 by Aussiboris, on Flickr

Wipers off...

iphone_pic by Aussiboris, on Flickr


This weekend my attention turned to getting the motor out. As you may know it's greasiness has got a little out of hand lately and I hadn't had the opportunity to remove it until now. My last garage had low beams so couldn't jack the bus up.

iphone_pic by Aussiboris, on Flickr

Having the use of 3 jacks was amazing

iphone_pic by Aussiboris, on Flickr


iphone_pic by Aussiboris, on Flickr


iphone_pic by Aussiboris, on Flickr

Then strip down...

iphone_pic by Aussiboris, on Flickr


iphone_pic by Aussiboris, on Flickr

Asked the farmer to use the uber diesel steam pressure washer (aka Super Meredith) on the block and tinware. Tinware mostly flew across the yard when sprayed but got the block spangly clean with a little help from Ian. Later on I found the oil cooler bracket was cracked. Probably the source (or one of the sources) of oil leak.

iphone_pic by Aussiboris, on Flickr

Got plenty more dismantling on the inside to get on with over the next couple weeks but I've also been out and bought a load of filler, primer and wet and dry so will start properly on the body repairs and keying paint.

If anyone fancies a wet and dry holiday in Bournemouth (and I don't mean swimming in the sea and sunbathing) just give me a shout. You're still welcome to join the tutu and L-plate wearers in the evening if you like!

Looking good dude your going great guns with that! I will come down after europe for a wet & dry party!

Liam wrote:Looking good dude your going great guns with that! I will come down after europe for a wet & dry party!

Cheers mate. Gonna get the roadtrippin tunes finished for you lot this week.

Aussiboris wrote:

Liam wrote:Looking good dude your going great guns with that! I will come down after europe for a wet & dry party!

Cheers mate. Gonna get the roadtrippin tunes finished for you lot this week.

Wicked nice one dude cant wait to hear it!

Been taking the cab doors off this evening and listening to some ninja tunes albums.

[img] iphone_pic by Aussiboris, on Flickr[/img]


iphone_pic by Aussiboris, on Flickr


iphone_pic by Aussiboris, on Flickr

Had some hassle with the hex screw / bolts. So I got the easy-outs on the job again.
I can't recommend these enough. Got them off of Amazon for £9


easy outs by Aussiboris, on Flickr

Spent a couple more hours stripping the doors down. I managed to remove the aluminium blade frames without damage too so happy about that. I do have tinitus from driving the hinge centres out with a hammer though.
I've been given a massive squeejie. Who's up for a wet and dry party then?

iphone_pic by Aussiboris, on Flickr

How big is this massive squeggie then rob? Have you orderd a narrowed beam yet ;-). Theres not enough late bays dropped right down!

It's a beast. I think it came from the Dairy but it was very clean.

Started taking out the wiring this evening. Now I'm getting slightly nervous.

Not ordered a narrowed beam. Decided to get on with the bodywork before I start on the beam. There's so many things to think about

I know what you mean! Im finding it really hard to resist the narrowd beam temptation or new wheels haha!

Rob, hope you're also wearing those ultra long gloves up to your armpits from the dairy too...

mmmooooOOOOOOOOoooooo

ha ha. I have no gloves. Wish I had as Boris' behind is far dirtier than any of the cows there!

Tonight I've mostly been getting greasy in the engine bay removing the old loom. I've worked out what the pipe that runs to the inlet manifold does. Up until now I have had no idea what this was for...
[img] IMG_0159 by Aussiboris, on Flickr[/img]
This pipe was connected to a one-way valve then to the inlet manifold just below the carb. Being the simpleton that I am I assumed that it was just another air intake and was expecting to find some kind of filter on the other end. But following the tube took me to the servo in front of the master brake cylinder.

IMG_0161 by Aussiboris, on Flickr



IMG_0163 by Aussiboris, on Flickr
IMG_0162 by Aussiboris, on Flickr

As you can see in the last picture, the tube connects to the front of the brake servo behind the brake linkage connecting rod. I got home and did some reading of the old Haynes. It turns out that the servo is designed to utilise the vacuum from the induction at the manifold to increase the total pressure at the master cylinder thereby making the brakes easier to apply. I noticed when removing the engine that this servo tubing wasn't connected up very tightly to the inlet. Certainly wasn't vacuum tight though I haven't had any issues with applying the brakes.

So I have a question... I would like to make use of the servo (I expect I will remove this and the master cylinder to inspect and clean up) but how can I provide a vacuum with the use of a twin carb setup? Could I modify the manifold on one side? Or is it too much hassle and recommended to stick to the manifold I have and run the single stock carb? Hope someone understands what Im on about and can help me on this. Laters

Another pic of the servo thing
[img] IMG_0164 by Aussiboris, on Flickr[/img]

£15 plus postage
[img] IMG_0154 by Aussiboris, on Flickr[/img]


IMG_0156 by Aussiboris, on Flickr

Anyone zeroized clocks before? Is it a case of connecting a drill to the speedo cable and sticking it in a clamp?