p.s.....thanks "insideout" for the recommendation for lift off, i saw it at WalMart then the gel....if you let the gel sit for 10 min then scrub it all into a paint "soup" with the spray, then you can spray it down with water and get 90% off, then rinse/dry/repeat....once the paint is removed, whatever "patina" is left is staying, my arm is numb from scrubbing!
it was a great weekend for the AS... We were able to get the frame into the shop and strip it down... It was better than I was expecting for the most part. I will be ordering the parts to rebuild the step brackets and the surrounding outriggers. The two out riggers that were under the tub (curbside) will be replaced as well. I did find something that will be another "cha-ching" item to the pile. The black-water tank exit flange is cracked about half way round. I don't think that it can be repaired. I didnt like what I was seeing with the angle iron that hold the water tank up so I cut loose the welds so that I can treat the rust that was traped between the frame and the iron... I will feel much better about putting it back...
the axles are definetly going to need replacing. They are really bad. That will be the first "big ticket" item that we order in the very near future. We are deep into it now...
made more progress on the frame resto... got a lot of the welding done as well as treating about 90% of the frame with POR 15. The rest will come next weekend. All the parts to completely rebuild the step outrigger section should be here on Tuesday. I plan on getting all the metal work knocked out then as well and finish off the rust treatment. I was able to source the 18mm Hydrotech MGP for the subfloor for 76.00 a sheet. WAAAHOOO! I will end up gettin 8 sheets in order to have one for under the water tank. anybody see any reason why I shouldnt use contact cement to hold the aluminum to the bottom of that piece o that it will slide in and out easier?
After the frame, floor and belly pan are back together the new axles will be installed. I just hope I ca get them befor the body goes back on, but it may not happen that way.
I God be willing I will be setting the body back on in 3 weeks...
the section marked in the red boxes will be replace next weekend. I also plan on working on the fram to take out the rear sag and box in the rear of the frame.
Any idea on how much time you have in the project to date?
If I had to guess, I would say that it has been about 50 hours spread over 4 weekends so far... I would like to think that when I get it back together, structurally, it will be better than new.
On that note, I have an idea that I would like to throw out. I was thinking that I will put jack stands under the front and rear of the frame, then I will "load" the center of the frame. Using a string line, I will load it to where there is about 1/2" of curve in the frame from front to rear, after which I will box in the rear half of the frame. When the "loading" is removed, the frame will straighten out to a great degree, but leaving the rear with a very slight upward curve. I would suspect that when I bolt the body back down, it will be flat and give me some future insurance against rear end sag.
Thoughts?
another small step forward for the Overlander...the outriggers and step pieces arrived today. I am very impressed with the quality of the items we received from Out-of-Doors mart. I was contemplating trying to fab this stuff myself, but decided to buy them because the prices were so reasonable.
I am also going to order the blackwater tank from INCA next week. they have the exact replacement and will install the necessary fittings... I received a quote of $240.00 for the H4 holding tank...
I also found a local source for elevator bolts. I can get them zinc coated so they should last a little longer. the plan is to use nyloc nuts as well as bending the bolts.
We also brought the windows home with us so we can start cleaning them up. I want to replace the scrathed up plexy. I will do some searching for window R&R threads...
You are making great progress. You might want to consider throwing a couple of straps over the shell to keep it down in the event of a high wind. There are a couple of stories of shells becoming crumpled scrap at this stage. Could be urban myth, but then again, maybe not.
We are in hurricane season around here. I just hope that we are able to get the shell put back down before anything like that might happen. But then again, if a storm comes in and winds are that high where we are doing the work, then I have bigger things to worry about at the house...
Hope all of you had a great weekend... it was a very busy weekend and at the moment I am fully wiped out. I pushed through and with the help of the wife making runs to different stores, the metal work is done!!! all the outriggers are replaced, the frame is as close to 100% as I am going to get it, and the step area is rebuilt and "It Works"!!!
The whole thing is coated with POR15 and top coated where anything is exposed to light. Plus it will just look better in the "Aluminum" paint we used. Next weekend the decking goes on...
Thank You. I wish I had access during the week to work, but I just have weekends. I could get so much more done. I will be picking up the plywood and the elevator bolts this week. This coming weekend will be a big step forward in the big picture. I ordered 150 bolts/nuts/washers all zinc coated, so they should hold up a little better in the long run. I will coat the bottom of the plywood with water sealer before installing it. Then when all the decking is down seal the whole thing. I cant wait to get the shell back on and move forward on the interior. The next "Big" purchase will be the AC unit. that way we can crank it up and work in a more comfortable area... it has been fun so far...
And I will say we are going to be pushing on that $10K envelope even with doing all the work ourselves...
Great job! It's also the dirtiest part of the whole project. Wish I had thought about laying a tarp on the floor. I'm not sure the floor of my shop will ever be the same again. Know what you mean about trips to the store. Its killer losing 45 minutes of project time every time the welder run out of wire or you can't find the right bolt and nut in inventory. I bet I've been through my miscellaneous coffee cans a hundred times in an effort to avoid those trips. The day the plywood was down and the bolt heads covered with Bondo and smoothed was a VERY exciting day. Looks like it'll be righ taround the corner. Good luck.
Looks like you're making great progress, certainly moving faster than I am! It looks like your frame was in better shape than the one for our '74 Sovereign which I am currently working on. I'm doing mine without removing the shell as space would have been an issue.
There is great satisfaction in standing back and looking at a repaired and painted frame.
Grant
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Grant Davidson
Milton, ON
1964 Overlander
1974 Sovereign
2005 F-350 SRW 4x4 crew cab long box
1965 Avion C-10 Truck Camper
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