Cunning Bus Project

[Buss69]

Parts drop!

The custom-made headlining arrived from MegaVanMats too, but I didn't take a picture of it. :roll:

BOOM!

 

[cunning plan]

Finally completed the headlining, it was an epic mini-project!

I now just need to work my way down the sides and around the windows with the same material, then find a nice and tidy way to join sections together.

Hopefully, my choice of custom material will be worth it in terms of insulation and sound-proofing as it is quite thick, yet still a material as opposed to a vinyl.

Started to install the adjustable rear spring-plates.

In the Bentley manual, it states a measurement of 23° + 50' is the stock / default setting of the spring plates for a 'Station Wagon' Bay. So I went for that:

A snap shot of the build so far:

 

[gninnam]

Roof lining looks good

Bus is coming along nicely :mrgreen:

 

[aogrady]

A snap shot of the build so far:

Love this shot, headliner looks very smart!

Nice work!

Alistair

 

[cunning plan]

Working on the wiring diagram when I can! :roll:

It's starting to get messy! That is just the front lights and spotlight! :shock: :satanlook:

But I WILL have my toggle switches!!!!! :evil:

 

[Buss69]

But I WILL have my toggle switches!!!!! :evil:

Illuminated toggles? (I hope! )

 

[cunning plan]

Not illuminated as such, I am thinking of either using the toggle switches with LEDs in which show you that they are on or if I cannot get a matching set of them, I will add some 'status' LEDs to the dash.

Regarding lighting them up at night, I have a plan taken from BMWs! They (the 530D) has a set of lights above the console near the rear-view mirror which light up the gear-stick area with a non-intrusive 'glow'.

Recognise the diagram components? :tongue0013:

 

[cunning plan]

Lots of parts on order!

Starting to put things together now, which is always nice.

Had to modify the spacer-plates for the adjustable spring plates as the holes were not exactly in the correct position. :?
Used my new favourite tool with a grinding attachment - Dremmel!

Zinc prepared, primed and painted.

Fitted and bolts torqued. I need to do the other side to push the torsion bars through properly.

Found a replacement sliding door middle hinge on VZi for a reasonable price. Started to take it apart to clean it up.

Replaced the bushes with some special copper ones I bought a while ago, which are supposed to greatly improve the mechanism operation.

Pulling the rear hubs apart.

Cleaning up.

Zinc prepped, primed and ready for paint.


Here is what was on the work list:

[*] Sliding Door Hinge - Find a replacement or fix the original - In Progress (Waiting for the new parts for the hinge to arrive so I can finish reconditioning it).
[/] Buy components for headlining along with the actual headlining - Complete
[/] Fit Headlining - Complete
[*] Wiring Loom diagram
[*] Wiring Loom component purchase
[*] Wiring Loom fabricate
[*] Fit Rear Adjustable Lowering Spring Plates from TransporterHaus - In progress

 

[cunning plan]

Completed the reconditioning and rebuild of the sliding door middle-hinge, all greased up and ready to be refitted (quite proud of this):

Fitted the second spring-plate (this is mid-way through as I was applying rubber grease on the arm end ready for the bush):

Rebuilding the OS/Right rear hub with new bearings and fresh grease etc:

Even a reconditioned stud-axle which was very expensive (and I needed both )

Then I made myself comfortable and took the Diagonal / A-Arms off to replace the bushes:

Old bush out:

Red-Rubber grease:

New one pressed in with the assistance of Record.

All done, ready for the arm to be repainted (yes, I know I could / should have repainted the arm first before fitting the bush, but I knew I would need to be quite rough with it to get the old one out and the new one in and I did not want chipped paint, so I did it this way around):

[/] Sliding Door Hinge - Find a replacement or fix the original - Complete!
[*] Fit Headlining extra material around windows
[*] Wiring Loom diagram
[*] Wiring Loom component purchase
[*] Wiring Loom fabricate
[/] Fit Rear Adjustable Lowering Spring Plates from TransporterHaus - Complete!
[*] Replace A-Arm / Diagonal-Arm bushes, repaint and refit - 50% done
[*] Rebuild rear hubs - 50 % done
[*] Rebuild rear brake drums - 25% done

 

[subheatadey]

hmm, been playing with it and it just will not idle... Anyone got anymore ideas of what to try or is it a compressionless engine that needs to be rebult?

:?:

As aogrady says probably grit in the idle circuit 'cos mine did it replaced the carb runs fine all I need to find out is how to clean grit out of the fekkin idle circuit!

 

[Buss69]

Top work buddy, looking good 8) .
Wish I'd done something to mine, no chance

 

[cunning plan]

hmm, been playing with it and it just will not idle... Anyone got anymore ideas of what to try or is it a compressionless engine that needs to be rebult?

:?:

As aogrady says probably grit in the idle circuit 'cos mine did it replaced the carb runs fine all I need to find out is how to clean grit out of the fekkin idle circuit!

Thanks dude, but you're a little behind with the thread as that was a long time ago, unfortunately, the engine hasn't been anywhere near the bus in years :sad0049:

Top work buddy, looking good 8) .
Wish I'd done something to mine, no chance

What is taking up your time right now buddy? Not work still?

 

[cunning plan]

Shiny new stuff!

So, here we have LateBay backing plates (as you cannot buy EarlyBay backing plates) with standard EarlyBay '68>'70 cylinders, shoes, hand-brake cable and arm and the fitting kit. However, the shoes have been modified to allow them to sit in the angled adjusters.

 

[Resto-raider]

That's looking good. Nice work and better than new.

 

[cunning plan]

Thanks for the kind words Resto-raider :mrgreen:

 

[aogrady]

Shiny new stuff!

So, here we have LateBay backing plates (as you cannot buy EarlyBay backing plates) with standard EarlyBay '68>'70 cylinders, shoes, hand-brake cable and arm and the fitting kit. However, the shoes have been modified to allow them to sit in the angled adjusters.

Hi

Interested in this, i need new backing plates! So I use late bay plates and adjusters, and then just grind the shoes to fit? Seems simple enough, any thing else I need?

Great way by the way!

Cheers,

Alistair

 

[cunning plan]

Hi

Interested in this, i need new backing plates! So I use late bay plates and adjusters, and then just grind the shoes to fit? Seems simple enough, any thing else I need?

Great way by the way!

Cheers,

Alistair

Sorry for the slow reply buddy, but yes, they *seem* to work OK, although I have not actually used them yet (as you can tell, the bus is not ready for the road yet).

This thread might help you (this conversion idea came from OzzieDog, although he changed the cylinder as well. I looked at it and decided that modifying the shoe should also work):

http://forum.earlybay.com/viewtopic.php?f=4&t=30814&start=20" onclick="window.open(this.href);return false;

Parts-wise, essentially, everything is EarlyBay, apart from the backing-plate. The only parts that you have to modify are the shoes. However, as I said, they have not been tested yet, but there is no reason that it should not work. I have also ensured that there is enough adjustment.

*Note: I am not liable for any damage or worse that comes from copying this idea. This is for educational purposes only. :msn4:

 

[cunning plan]

Continued work on the Headlining around the windows in preperation to install windows.

Protection paint

Insulation

MegaVan Mats have been amazing for the supply of material, adhesive and answering my trimming-related questions!

The longer side without the slider. I did not want a break or joins, so I have had to use a really long piece of continuous material.

Measure, cut, glue, stretch, press. Repeat

Completed fitting the rear left brake-drum shoes and hand-brake parts

[*] Fit Headlining extra material around windows - 60% done.
[*] Wiring Loom diagram
[*] Wiring Loom component purchase
[*] Wiring Loom fabricate
[/] Replace A-Arm / Diagonal-Arm bushes, repaint and refit - Complete!
[/] Rebuild rear hubs - Complete!
[/] Rebuild rear brake drums - Complete!

New tasks:
[*] Paint rear drums
They are new, but I want a different finish as I don't want to have hub-caps / domes. I am going for the black, white and chrome look with original steelies.
[*] Fit rear drums
[*] Plan and purchase complete Hydraulic braking system
[*] Fit Complete Hydraulic braking system
[*] Fit Accelerator Cable

 

[gninnam]

Looks like hard work but should make the interior a lot more plush 8)

Nice work :mrgreen:

 

[cunning plan]

It was starting to get a bit messy during the headlining side-install. :shock:

Now mostly complete apart from some tidying of edges, installing the hinge covers for the tail-gate and hiding the join between the top headlining and the side.

The list now looks like this:

[90%] Fit Headlining extra material around windows (Need to tidy / Hinge covers / Cover joins)
[0%] Wiring Loom diagram (This was 10%, but now back to 0% for a change in direction.
[0%] Wiring Loom component purchase
[0%] Wiring Loom fabricate
[0%] Paint rear drums
[0%] Fit rear drums
[0%] Plan and purchase complete Hydraulic braking system
[0%] Fit Complete Hydraulic braking system
[0%] Fit Accelerator Cable
[0%] Rear Windows Tints
[0%] Rear Windows Install
[0%] Revise Front Axle / Brake Drums / Track-Rods / Re Torque all

:character0036:

arty0021: