'71 Moonraker "The Rustmaker"

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Htotheunit

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Hello everyone!

I’ll start off with a brief history of my van up until now. As you can see, I have a LOT of documentation from a receipts for chewing gum to full blown restoration details and pretty much anything in-between.



Born on Monday 12th October 1970 as a Sierra Yellow Microbus she was brought by a Mr Roberts from Llangefni, Wales. I don’t have much in the way of history from 1971 to 1984. However I do have a receipt for a new engine dated 1984 which went into storage with her.



In 1986 she was stored somewhere (presumably) in Wales until 1998 when she was wheeled out from her nap and restored by the A41 Mini Centre in Birkinhead. According to a vehicle report written by the restorer, the bus had only covered 3,000 miles before it was stored, I presume that when the new motor was put in there in 1984 the clock was would back.. or maybe not who knows!

1998 Restoration work included:

Replace both main chassis rails
All outriggers and jacking points
Both Inner and outer sills
Both Wheel Arches
Inner and outer front valance
Outer front panel
New engine brace
New Petrol Tank
Sliding door inner and outer (bottom)
Resprayed in original colours
Mechanical bits (the usual)



Anyway, more on some of these ‘repairs’ later :roll:

Here are some pics from 1998 post restoration (notice the no longer flat arches :x )



After restoration the bus was sold to a a bloke called Mr Brown of Wallasey on 17/12/98. He kept every invoice for every piece of work carried out between 98 and 2001 from services to rear corner repairs. She was resprayed in 2001 by a place called AMS Motorsport in North Wales before he sold it to a Mr Mayman, Tamworth with around 100,000 miles on the clock some time around 2002/2003.

Here are pictures of the respray (you can see some of the previous repairs/filler)




Fast forward to 2006 when I brought the van and used her as a daily driver until 2011. Since then she has been in and out of use, had a crash (sorry!) which required another front panel but since 2014 she has sat patiently waiting to go on another adventure.

Shes currently under a van cover looking a little under the weather. Some of her old ‘repairs’ (panels on top of panels as I’ve found out) have crumbled to dust. It’s time to get her back on the road, and this time with no bodge jobs!

I’ll try and photograph everything that I do as it comes along rather than bombard you all with photographs of sections before I start but I think I have a fairly good idea of what needs doing (There will be surprises I dare say) and I have a loft full of panels I’ve slowly accumulated over the past couple of years. Hopefully the Fletcher Gillett Restoration Manual will guide me through my first restoration attempt.

First thing is first though, better practice some welding!

Wish me luck!
 

gninnam

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Nice bit of history and good luck with the resto - looking forward to seeing her (and your) journey :)
 

Htotheunit

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So it's been a very long time since my first post.

The story goes that the bus was still sat there come September 2019 and my lack of knowledge and experience cutting and welding was holding me back. I looked up welding courses nearby and there was nothing so I enlisted the help of a local chap called Karl to kick things off and teach me the basics of car restoration (when I wasn't at work) so I could eventually take over once I built up a bit of confidence.

First off, we took tabs on what we have to deal with on the drivers side. Let's just say it isn't pretty but looking at the piles of rust some of you crazy b***ards turn into beautiful bays, I think I can turn this around :lol:





With the arch and the cab floor/seat tub out we could assess the state of the front end of the chassis, the central part is OK but the Y section, not so good so I immediately ordered one. The panel with the bulge was a bit worse for wear, as was the B pillar. I already suspected this and had the parts ready to go in storage (i've been hoarding parts for years waiting to get started)









The sill was pretty much made of filler (no surprise there) and as suspected ALL the jacking points and outriggers were in very bad shape.





I'll be splitting these long overdue updates into several posts to save them getting too long!
 

Htotheunit

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fallingoffalot said:
Good luck, looks like you've got your work cut out there!

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Yep! There's plenty to get on with!

Thankfully we've tackled a lot already, I'm just spacing out the posts so I don't run out before I make any more progress :lol:

No so many surprises just shocked at the amount of previous bodge jobs and how thick the filler is in places. It's all getting cut out and replaced with fresh metal though :)
 

matty74

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Looking forward to the updates on this ... it’s exciting when a new restoration pops up.

Good luck with the work [emoji106]


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Htotheunit

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So I'm about to go back out and do some more work, but I thought I'd post some of the first progress pics.

Karl who helped me start the project (by start, I mean he did all the work whilst teaching me along the way) took photos as he went along, some things I was there for, some things unfortunately I wasn't but I'll do my best to explain what was going on!

The first thing we did was to take out the B pillar and sills that were very badly rusted, some parts appeared to be made out of old signage!

With all that junk out of the way, we discovered that the top hat was made out of a badly bent piece of metal, so we cut a small part of the cab floor out to access the top and replace as much as we needed.

I'm going to try and keep as much of the floor intact as it is in pretty good condition and doesn't need to be replaced.







We cleaned up the sill area and removed more rust (no surprise there) to get the new panels lined up ready for the B pillar and rear whee arch repairs





All protected ready to go, It's nice knowing theres a strong layer of anti rust primer in there, I'll cover it in waxoil or anchorwax once it's all done



Clamped in place

 

gninnam

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Welcome back and the work required looks familiar!
Good luck and will keep an eye out for further updates.
 

Htotheunit

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Another beautiful day outside but before I go out there and get covered in metal shavings i'll give you an update!

Jut a reminder that these pics are from september (ish) last year, once i've caught up on the pics I'll post recent updates rather than old ones!

With the top hat now fixed and the sills held in place it was time to fix the underside ready for the outer sill and posts.

As with most vans, we had to patch up some chassis sections to provide a good, strong place for the jacking points and outriggers



https://postimg.cc/jnRWYYCb

On goes the freshies...





Protected with some bonda. We removed the strengthener on the front jacking point temporarily as we discovered that the crossmember will need to be replaced, we'll get it back on when theres some nice fresh metal to weld it onto



With that all done and dusted, it was time to repair the C pillar which had disintegrated with the sills.





I'll put together another post in a couple of days, got to really stretch out the backlog :lol:
 

Htotheunit

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Well we’ll a couple of weeks has turned into almost two years. How time flies!

just a quick disclaimer before we jump back in, these pictures are now a year old (in some cases even older) I’m working through a backlog. The may also be in slightly the wrong order, we had quite a lot going on at the same time so some bits may appear then disappear haha!

I also didn’t do all this welding myself as I mentioned in one of my previous posts. In this section I did plug welding on the inner sill and a couple of the hidden seam welds on the inner and middle sill. I’ll pop those pictures in first.



Pretty neat for a beginner if I do say so myself!

I’m jumping back on this project once the weather eases up so I thought I’d post another bunch of photos from the project.



With the C pillar patched up it was time to tackle the lower B pillar that had rotted along with the section by the hump.











there is a line left over from a previous weld which I’ll either tidy up later on or just leave as it’s not really an area you see.

Up next we tackled the outer sill



looking more like a van we patched up the remainder of the b pillar and repelled the floor back in that we had to cut to access the top hat



 

Htotheunit

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Glad its still on the go :)
It sure has been a slow burner, I certainly could have done a lot more during lockdown but I found myself with some other projects that seemed to have sucked all my time!

I’m so desperate to get it back on the road, I managed to grab a few bargains (£500 brand new front panel) so even though work hasn’t progressed I’m in a better position to move forward :)
 

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