This week’s work summary is once again focused on the offside frame. The panel to the immediate rear of the front wheelarch was removed to enable frame repairs to continue; this included the step ironwork for the cab entry. All the side-rod lower extensions have been removed, a small amount of heat being required to release the the through bolts that pass through the ends of the floor bearers. Exposed metalwork above the floor line had been treated with Vactan. A removable section of the frame around the fuel tank filler has been unbolted to allow access to other parts that needed to be replaced and to allow easier removal of the fuel tank.
All of the window verticals and the waist rail have now been dowelled and all rust screws and nails hopefully removed. The horizontal rail above the windows remains to be finished and painted. The new woodwork of the wheelarch frame has been painted, along the with the sections of the frame joints that are awaiting new flitch plates. The remaining flitch plates, including the wheelarch reinforcement have been made this week and are in the process of being painted ready for fitting. I also removed the beading above the (incorrect) cab mudwing. I had hoped to save this and reuse it but at first sight it appears too far gone.
I can’t believe it’s a month since I last recorded any progress. However, there has been progress; lots of rusty screws have been winkled out of the offside framing, several rust-eaten flitch plates have been removed and the first three replacements manufactured. The emergency door hinges have been freed up, de-rusted and prepared for painting. The frame around the emergency door opening has had all the rusty screw and nail remains removed and the holes dowelled. A new steel plate for the top right corner of the door opening has been manufactured and is ready for installation.
More lower side panels have been removed and the fuel tank exposed, this will need to be dropped and cleaned ready for treating any rust and repainting.
Most recent work (today and yesterday) has been cutting out rotten timber framing above windows 3 and 4 apertures. I cut some Iroko this afternoon in preparation for repairing this section.
Heavily-corroded flitch plate at joint between wast rail and cab door frame vertical.
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.
Restoration diary of a 70-year old AEC single-deck bus and the trials, tribulations and adventures of our 1966 Bristol bus.
