spunkymonkey
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Post by spunkymonkey on Mar 28, 2012 18:13:22 GMT
Bit of a mojo boost today. I remembered last night that, as well as the MIG he has in for repair, the workshop owner had an old VERY heavy SIP arc welder shoved away in a corner. So I decided to drag it out and see if it was any more stable than my little Clarke buzz-box: i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/properArc.jpg[/IMG] Apart from a little work needed on it's connections, it seemed to switch on and not blow any fuses so I connected up and gave it a test-drive. Not quite as smooth as Farmer George's 3 phase monster but so much better than mine to work with! Who says you can't arc weld on bodywork thickness? The end result was that Boris now has nice new metal where people's feet should be: i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/newFloor.jpg[/IMG] and most of the sill is re-attached: i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/sillJoint.jpg[/IMG] with just the jacking point and front closure to do: i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/jackingPointToDo.jpg[/IMG] It's so stable I might even go back and really seam that driver's sill if I can get the sealant off
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Post by Nick the man with a daf.... on Mar 28, 2012 18:36:01 GMT
good effort for a sparky stick dude ! ! as you seen on the other thread, Reenie kicked me there today as well. although not quite as bad as Boris
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spunkymonkey
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Post by spunkymonkey on Mar 28, 2012 18:44:51 GMT
There's some blobbiness about, but only 4 (small) blow drain holes, and I can jack the car wheel-clear by it so it's not going anywhere. One of the bits I like about arc is you can be a LOT less fussy about cleaning old sealant beforehand because (within reason) it burns off as you go - safes a lot of prep time Saw Reenie's woes - at least once it's done you'll know it's done
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spunkymonkey
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Post by spunkymonkey on Apr 7, 2012 22:37:35 GMT
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33grinder
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Post by 33grinder on Apr 7, 2012 23:19:54 GMT
Good progress Joe! I can't help but feel guilty that Martin and I stopped you getting more done although we did appreciate your help earlier. Shame you are not closer as you've earnt sone ramp time at IL which would make all that underside welding a lot more comfortable.
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spunkymonkey
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Post by spunkymonkey on Apr 8, 2012 19:51:22 GMT
Ahh, the best laid plans & all that : Got down today full of hope to complete the welding and started by priming and painting the front bit: i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/nsfWheelArchDone.jpg[/IMG] i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/frontDone.jpg[/IMG] So far so good. So I went on to make a start on the back corner. A little reminder, it looked like this: i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/neRearSillEnd.jpg[/IMG] Nothing too bad there - cut out the end and a nice little patch panel to finish, right?. Wrong!, When I started cleaning up the inside edge ready for welding, I found this: i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/fibreglass.jpg[/IMG] An old patch with a worrying coating of fibreglass! A bit of heat and some digging revealed why: i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/underGlass.jpg[/IMG] Whoever fitted it hadn't gone high enough and had basically nothing to weld the top edge to. Rather than extending it to sound metal, they just fibreglassed over the whole lot, rust, holes and all - not even an attempt to weld the top edge! That's a good lesson in what "nice example" can mean if you dig too far - by all accounts this was a well looked after example and I've no doubt its previous owners wouldn't have condoned that sort of work, but some mechanic somewhere had obviously decided it was easier to paint on some resin than melt in some metal. Just hope it wasn't charged out as welding at the time!!! Lots of cursing, cleaning and metal bending later and there was a new piece tacked in place ready to finish the welding: i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/plateTacked.jpg[/IMG] Only, at that point I smelt something worrying and pulled myself out to find the car completely full of smoke. A bit of frantic water flinging later and the fire was out, revealing this under the back seat: i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/fireDamage.jpg[/IMG] Oops! So at that point I decided to stop for the day while there's still a car to work on tomorrow!!!
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spunkymonkey
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Post by spunkymonkey on Apr 12, 2012 18:34:05 GMT
Well, the fibreglass is gone and there's metal where metal's meant to be: i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/nsRearSillEndDone.jpg[/IMG] Why do these "easy little corners" always take 5 times as long as you expect? It'll all have to be done again at some point because it really is a "patch up for a couple of MOTs" job but hopefully we'll have the 2 poster and decent mig welder back in action at some point, both of which make proper rebuilding a whole lot easier! There's now just this patch to the rear floor to complete, and a similar but smaller one on the other side, and (as far as I can see) the welding will be complete other than running round a couple of spot-welded patches to make them look nicer i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/nsRearFloorPatch.jpg[/IMG] Meanwhile, I couldn't resist fitting the new light, so he now has a full complement of eyes: i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/fourLights.jpg[/IMG] And, while I was at it I had a quick look at the important bit, only to find that it was made for Ford! i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/fordAerial.jpg[/IMG] Still, couldn't let that put me off so tried a bit of wire-fiddling and: How 70s-bling is that? ;D eta: In other news, have 2x new brake cylinders on the way courtesy of EBay. They're still available for about £8 each (+ VAT & post) from mainstream suppliers, or £33 a pair from our local factors, but £17 delivered for the pair was just too good to miss! And finally, got back to a message from the windscreen place that our new windscreen is ready for delivery, if we'd like to phone with card details tomorrow it'll be here on Monday ;D
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Post by Nick the man with a daf.... on Apr 12, 2012 21:04:56 GMT
great stuff... reenie has two holes at teh back there so can only presume she ran twin aerials at some point.. (and probably will again)
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spunkymonkey
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Post by spunkymonkey on Apr 13, 2012 17:00:15 GMT
The ns is now officially done, with the exception of underseal over the seam sealer when it's set: i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/nsSillEndComplete.jpg[/IMG] i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/nsFloorComplete.jpg[/IMG] i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/nsWheelarchRear.jpg[/IMG] I think that just leaves one small patch to the rear floor on the driver's side and some tidying / sealing to do and I can finally crawl out from underneath him and start putting everything back together. Ok, so the first bits of that involve crawling back underneath to refit the driveshafts and fuel tank but at least it won't be rust-related crawling underneath! Hopefully back on track towards having him back on road by mid May.......
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spunkymonkey
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Post by spunkymonkey on Apr 15, 2012 18:21:54 GMT
Don't EVER let me say "think there's jut one small hole left" again!!!! Went down today to tackle the small patch to the driver's side and the wire brush revealed this: i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/osFloorToSill.jpg[/IMG] That's not too bad really, but at the back of it there was an old patch which turned into this: i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/patchCleaned.jpg[/IMG] If you look closely you'll see that one side of that was never welded, despite being right next to a spring mount: i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/unweldedFrontEdgejp.jpg[/IMG] Not only that, neither had the back edge: i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/unweldedEdge.jpg[/IMG] The remaining sides had 3 or 4 spot welds each, which was all that was holding it in place. Didn't even need a grinder to start removing it! i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/noCuttingNeeded.jpg[/IMG] Did a bit of cutting back, hoping desperately that the spring mount wouldn't collapse as I did - the only place I could get the stands stable was under the axle so the mount still has weight on it! Luckily, Daf knew how to build cars and there's still decent structure above it to bear weight. The end result was this, before I decided I really couldn't be bothered and did a few electrical bits instead: i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/osRearPatchRemoved.jpg[/IMG] At least I know the extent of what needs dealing with next visit, but I'd love to know: (a) who thinks it's ok to spot weld a clearly structural patch on 2 (adjacent) sides only - and not even the side that the sping should be attached to??? (b) where the hell did it get its last MOT??? I know it was a long time ago but the welds that aren't there haven't just disappeared since! Good lesson here that pretty doesn't matter (that patch looked very neat until I disturbed it), sound metal does!
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spunkymonkey
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Post by spunkymonkey on Apr 18, 2012 11:25:57 GMT
Oh bother! We had a delivery today: i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/IMG_0849.jpg[/IMG] Inside was that bit of glass we'd been waiting for (and had paid £230 for!): i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/IMG_0853.jpg[/IMG] Only, as it was VERY carefully unpacked, this was revealed: i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/IMG_0855.jpg[/IMG] No sign of damage on the packing but clearly something went wrong somewhere To be fair to the guys at Uroglas, they've reordered without question and no charge but it means a delay until the end of May until it's available. That kinda screws up his planned first show at Henblas for him unless I can come up with something really creative in the next 3 weeks or so........
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mattsdafs
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Post by mattsdafs on Apr 18, 2012 11:51:24 GMT
Joe...that is a shame and not good another will take so long to re-order The only thing i can think of,is that 66 coupe Ken tryed to enquire about in his neck of the woods and got a very sweet welcome ;D...or have a word with Derek Reynolds
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spunkymonkey
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Post by spunkymonkey on Apr 18, 2012 16:56:20 GMT
It is a shame, Matt, but dealt with brilliantly by Uroglas ordering another without question - once signed for they could easily have said tough luck even though the courier was NOT going to wait while I unpacked it! As for the delay getting him road legal, seems there may be way round that
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v8gasser
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Post by v8gasser on Apr 20, 2012 18:21:15 GMT
1000 views ! ....8=)
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Post by Nick the man with a daf.... on Apr 23, 2012 18:54:27 GMT
ok make it 1001
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spunkymonkey
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Post by spunkymonkey on May 8, 2012 13:07:42 GMT
Well, that's the welding finished (until Mr MOT decides it's not up to standard!) so I'm heading down in a bit to get the underseal on. The replacement screen has also arrived today (safely this time ). So it's now reassembly, tidy up, and get a test booked - hope to have news by the start of next week.....
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spunkymonkey
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Post by spunkymonkey on May 9, 2012 13:13:32 GMT
Just got the old boy insured from tomorrow morning, so there's no excuse to dawdle any more. We had an online quote from Lancaster for £124 but decided to phone because they wouldn't allow the car to be a 1971 1300 Coupe (as the DVLA insist it is). So they ran the details again, final cost??? £68.90!!!!!
Thank you again Lancaster Insurance!!!
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33grinder
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Post by 33grinder on May 9, 2012 17:16:23 GMT
RESULT!!!
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kenr
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Post by kenr on May 9, 2012 21:39:07 GMT
Nice one Joe. Glad that it is all coming together mate but be VERY careful with that windscreen ok.
Ken
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spunkymonkey
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Post by spunkymonkey on May 9, 2012 22:36:37 GMT
Don't remind me - I'm trying hard not to think about the fitting part.....
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spunkymonkey
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Post by spunkymonkey on May 11, 2012 20:53:30 GMT
Finally couldn't put it off any longer. The old screen came out today: with only a few more cracks than it started with i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/brokenOldScreen.jpg[/IMG] Needless to say, I wasn't too careful removing it because it wasn't going back in. Good job really because the seal was seriously stuck down! The aperture was nice and clean so, with quite a bit of trepidation (£230 a pop and a month + to supply can have that effect!) in went the brand new Triplex made on the Isle of Sheppey especially for us: i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/newScreenFitted.jpg[/IMG] Having got that out of the way, his exhaust was re-hung with new rubbers and a rope loop (can't seem to get suitable size exhaust "donuts" for one mount so splices a rope loop instead - it's supported, so it's legal ) and his fuel tank refitted for the second time - the first time I failed to replace the rubber pipe on the outlet, which Judge Sod promptly declared to be porous. And you can't get to it with the tank in place. Then it was finally time for him to go back on his wheels: i113.photobucket.com/albums/n228/Charlie_D_Brown/Boris the%20Daf%2066%20Marathon%20Coupe/backOnWheels.jpg[/IMG] Doing that I noticed some pretty serious cracking on one tyre so will have to see if the spare will hold air for the test next week. He'll be getting a full new set before going into real use but it's an expense we could really do without until then. He also went out in the sun for a quick test round the yard and seems to drive very nicely indeed, although not 100% sure that he's changing up as quickly as he should - but that may just be a case of getting used to the different car and the limits of an 80 foot square yard. We positively did NOT take him for a quick blast down the small lane to the beach car-park but, if we had, we might have discovered a few minor snags like the speedo not working, a very slight hesitancy on snap throttle opening, and just how SLUGGISH our other Dafs are Guess we'll have to wait until Wednesday and the trip for his MOT test to discover things like that....
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Post by dafdaffer on May 11, 2012 23:13:02 GMT
have you done the old blow test Joe?.... also the 66 is quite a revvy car compared to the others.
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spunkymonkey
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Post by spunkymonkey on May 11, 2012 23:25:21 GMT
Think I did before I put the engine back in but may be worth repeating. Part of the problem was the lack of speedo - in an unfamiliar car it's quite difficult to judge speed but I would think we didn't get above about 25 - 30 round that, errr, 80 foot yard. Whatever speed we were getting to, he only just showed signs of dropping into a higher gear as I lifted off. Betty and Matilda will both do that anywhere above about 20mph but I've set them up to keep revs down. Guess we'll get a better picture when we can take him out on a proper run - 4 miles to the MOT will be the first of those
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Post by dafdaffer on May 12, 2012 8:18:14 GMT
i believe that they are set not to change up before 30 on the micro-switch as default, you can adjust it to make it change up earlier.
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spunkymonkey
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Post by spunkymonkey on May 12, 2012 21:03:46 GMT
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spunkymonkey
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Post by spunkymonkey on May 13, 2012 15:48:16 GMT
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33grinder
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Post by 33grinder on May 13, 2012 18:01:32 GMT
Looking very nice indeed Joe.
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spunkymonkey
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Post by spunkymonkey on May 13, 2012 21:53:10 GMT
Thanks Pete, I'm pleased with it even if it has ended up as another slight rush for Henblas. Seems we're getting into a tradition of trying to return a new one to the road each year for that ;D
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mattsdafs
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Post by mattsdafs on May 14, 2012 15:37:04 GMT
Very very nice Joe ..you have done well with him...let me know if you need another speedo cable sent
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spunkymonkey
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Post by spunkymonkey on May 16, 2012 14:28:11 GMT
Fail. One hole missed (between the flanges of the o/s/r jacking point - solid all round) O/S headlight signaling to space-ships Both front brakes binding (was a little worried about them but hoped they'd free up enough in use - obviously not!) The nut holding the steering wheel. Plonker here fitted the wheel temporarily about 3 months ago to push him round the workshop and completely forgot to do the nut up. My bad 1x exhaust mounting not secure (can't find rubber loops suitable so used a rope one and he didn't like it). Oh, he also decided to give the tester a shower when his heater tap started to blow all his water out. Small list, expect retest tomorrow, although he didn't want to book it in cos he wasn't convinced I could finish by then so need to call him in the morning
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