Removed the remains of the steel reinforcement plate at the top of the rearwards entrance pillar. Cut out the rotten wood which extended from the cantrail joint for about 12 inches down the pillar. I used the router for this, leaving one good edge intact in order to enable me to get the correct profile on the finished repair.
Cut some new ash to replace this section, drilled and screwed it to the pillar using PVA to add strength and structural sealer to ensure no gap between the remaining pillar edge. Drilled and pegged the repair using a pair of hardwood dowels.
I realised that it would be necessary to cut into the roof cladding in order to determine the full extent of the corrosion in the steel reinforcement over the door, so this was partially done yesterday and completed today. The plan is to repair this by letting in joggled replacement sections using structural seam sealer and countersink rivets then finish with a skim of filler.
Some sections of the the rotten steel were cut out today, primarily to allow access to the T-shaped steel flitch plate that reinforces the joint between the top of the door pillar and the cant rail. This is quite badly corroded so a new one will be made. With this out of the way the rotten wood can be cut out of the door pillar and repaired.
Repairs by welding will be made to the steel section over the door and window 1 by welding with 1.5mm ZIntec, ordered today for delivery on the 21st.
The previous two days I spent making the ash repair section for the entrance pillar. This is completed and fitted as shown in the picture:
Entrance pillar repair.
Other work done includes plugging more screw holes with hardwood dowels and sanding these off flush. Work is now concentrated at the top of the pillar where there is a steel plate and bracket under which the pillar has rotted. This requires the removal of the drip rail above the entrance and the wired-edge panel that finishes the top of the entrance, which is extensively corroded as can be seen in this picture:
Fairing above the entrance as found
New fairing for the entrance.
Restoration diary of a 70-year old AEC single-deck bus and the trials, tribulations and adventures of our 1966 Bristol bus.
