The last few days have been taken up with preparing the new steel stress panel for the boot front. This included painting the external surface of the timber frame with aluminium paint where it abuts the stress panel, marking out the steel for cutting using the hardboard template, cutting the panel and trial fitting. The trial fitting needed to be repeated a couple of times but finally today I was able to start drilling the holes for the screws and coach bolts that will attach it it to the frame.
Steel stress panel being prepared for fitting to the boot front. The large cut-out accomodates the central gangway.
Yesterday was spent completing and painting the new gusset plates and the two extra brackets for the replacement OS upright (no.3 in the boot counting from the back). I also cut a piece of hardboard to exactly half the length of the boot steel closing panel so I can use it as a template.
Today the two for upright no.3 were installed. I also cleaned and primed the outer faces of timber that form the frame the boot closing panel is mounted on. Once this is dry they can be painted with aluminium paint then the closing panel can be cut and fitted with screws and coach bolts.
A lot of grey paint was applied today to the frame along the back of the bus and down the offside towards the emergency door, including the pillar repaired yesterday.
Whilst the grey paint dried I drilled the cross bearers and pillars for new bolts to fix the gusset plates, adding a few extra bolt holes to increase the strength of the joints. Next I cut out and drilled the rest of the gusset plates. These need deburring and painting then they can be fitted.
The next major task will be fitting the new steel bulkhead to the front of the boot.
Restoration diary of a 70-year old AEC single-deck bus and the trials, tribulations and adventures of our 1966 Bristol bus.
