Build BJ42 Restoration

[Crescent Wrench]

Turned out better than I hoped, I’ll give it a final top coat of Cygnus White 033 and that’s done. I need a new head liner, so I ripped out the old one and then went shopping…$450 for a headliner is highway robbery, shoulda worked the old one over in hindsight.
On another note I’ve been waiting 3 years for a painter to finish painting the panels and line everything up, last month I found a guy that’s willing to do it for a price that I can live with. Hopefully you his overdue project will be moving along.

 

[Crescent Wrench]

Turned out better than I hoped, I’ll give it a final top coat of Cygnus White 033 and that’s done. I need a new head liner, so I ripped out the old one and then went shopping…$450 for a headliner is highway robbery, shoulda worked the old one over in hindsight.
On another note I’ve been waiting 3 years for a painter to finish painting the panels and line everything up, last month I found a guy that’s willing to do it for a price that I can live with. Hopefully you his overdue project will be moving along.

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Don’t judge the welds, it broke 3 times and I just kept welding over top, I was in too much of a hurry to put the welding lid on so I did it with my eyes close, and that’s exactly what it looks like haha!

 

[alberta mac]

Hi there Mr. Wrench, really glad to see your back at it. I don’t think it too serious. What I think might be happening is a build up of corrosion on the contacts in the EDIC relay box. as well as that possibility there are contacts in the EDIC gear box that may not be contacting well but I’d go for the relay box first. last thing is really good grounds.
cheers,
Rob

Edic relay and arm: if it's what i'm thinking then yank the arm right off, it can go on again easily. you will need to stall it to shut the motor off or put in pull cable to choke the fuel. Your diesel may also be starting to jell so pre heat a few times before starting then add some fresh diesel and some octane boost. Glad to see your back at it ! I'm in the process of reviewing my drawings for my second gen stainless tub but work has delayed the process. Keep at it you are motivating us all !

 

[Crescent Wrench]

Today’s project was it reinstall that front valance for the windshield to room interface. I made a post for backing the Aircraft Rivets and to hold them in place while I mushroomed the pin with a drift. I had to use pop rivets on the 2 very outside corners until my Sikaflex
Sealer cures and then I’ll drill them out and install the factory rivets. I also bought 2 very large C clamp style visegrips to push the metal down to squish the sealer and secure it until I could rivet it.

 

[bikersmurf]

Today’s project was it reinstall that front valance for the windshield to room interface. I made a post for backing the Aircraft Rivets and to hold them in place while I mushroomed the pin with a drift. I had to use pop rivets on the 2 very outside corners until my Sikaflex
Sealer cures and then I’ll drill them out and install the factory rivets. I also bought 2 very large C clamp style visegrips to push the metal down to squish the sealer and secure it until I could rivet it.

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In school, when we made a Dommer, we heated the end cherry red and then hammered down on a 1/4" bearing to round out the divot so that the end of the rivet will be smoother.

We also made a fetcher to help make sure the rivet is tight. With copper rivets we usually used a washer on the domer side.

 

[Crescent Wrench]

Well after around 3 years I have finally secured a spot at the paint shop. Today’s project is to strip down the body so they can edge the doors and hard sides.
Also I need to install the intake shroud for the blower fan motor.

 

[Crescent Wrench]

Blower Motor intake Shroud spot welded in and painted. Motor reinstalled. Hung the fender loosely and I’ll button that up up tomorrow.

 

[Crescent Wrench]

2 new running boards underside paint finished. These will get another top coat once they are installed and the final coat goes on. July 17th she goes into the shop. Not sure how long it’ll take but he’s pretty quick and extremely talented. I was fortunate to get the original shop that started the paint to finish it up.

 

[Crescent Wrench]

Stripped down and ready to go. I’m scrambling to finish up little things like installing the hood release latch that I hadn’t drilled and routed through the fire wall. I’m a bit afraid of the final bill but the paint finishing will be perfect. Tomorrow I might run the wires and mount the switches for the heated seats,
Finish hanging the fender and change out the front bumper mounting plates. If I get time I’ll strip the rear bumper too because I want to have it repainted in place. It’s taken some hits over the last few years and the shop that painted it didn’t do the best job. (Different shop)

 

[Crescent Wrench]

Today I installed the rad mesh, and badging. I can’t even explain how satisfying it is to put badging on a project like this. 27 days to go before she gets finishing paint and assembly. Then it’s glass installation, weatherstripping, badging, door handles and tail light wiring.

 

[alberta mac]

Nice to see your still at it, Hopefully on the road soon !

 

[Crescent Wrench]

At the body shop, the owner is allowing me to work on it and to use some of his tools.
One of those tools is a pneumatic rivet set tool,
I redid all my rivets for the windshield trim piece on the front of the roof and OMG where was that tool when I did the drip rail. I have to say it is actually worth buying the $40 attachment for the rivets, it just makes life easier. We did a mock up of the sheet metal, it fits ok but it’s not perfect.
This is as good as you get when using an aftermarket tub. Next up he will spray everything, and call me back to assist in lining everything up and then she’s coming home for glass and badging. That’ll be exciting

 

[Crescent Wrench]

Had to get creative for holding the nut in place for mounting the bumperettes. Once the cross stay brackets are in place it is almost impossible to hold the nuts in place while you fiddle with the bolts. The mechanics wire did the trick.

 

[Chamba]

You know the windshield brace on the roof is white from the factory, not body colour, yes? Now is the time to correct it, unless that's how you want it to be.

 

[Crescent Wrench]

My lovely assistant helping me with the new roof liner, FYI: I used 3M spray but only bought one can, it wasn’t enough adhesive. The next day the liner was hanging down in places.
So we gently pulled it off and used a pint of LePage glue, brushed it on and installed the head liner. This is where things went sideways, the fumes reacted to the headliner and while it started off nice and smooth it quickly started to react to the glue and bubble up something terrible. I was pretty upset, having sourced this brand new headliner directly from Japan and it wasn’t cheap. We smoothed it out as best as we could and left it in the sun all day. The next morning it actually looked much better, it had returned (mostly) to its original form, it’s not perfect by any means but it looks decent. One day when I’m bored over winter I will redo the liner, but that’s after I install a turbo down the road. I’m running 33” tires and I’m worried that I’ll lose 5th gear on the highways and hills.
The body shop is closed for summer break, but come Hell or High water it will be painted and sheet metal assembled by the end of August. Thanks for reading.

 

[Crescent Wrench]

You know the windshield brace on the roof is white from the factory, not body colour, yes? Now is the time to correct it, unless that's how you want it to be.

Shoot! I did not know that, I thought mine was blue, but I can’t actually remember because it’s been so long. I’ll look into that. Thanks for bringing ing that to my attention

 

[Crescent Wrench]

Final paint and assembly ongoing, body shop just reopened after being closed for summer holidays. Should be completed by the weekend…maybe. Really getting excited to get this done.

 

[Crescent Wrench]

Anyone know where to get a plastic insert for the rear ambulance door striker?

 

[Crescent Wrench]

Apparently industrial plastic has 3D printing and scanning abilities. I’ll find out Tuesday.

Today’s project is to pick a corner and finish it while working may way around the vehicle. There are some gaskets missing for the roof corners so I’ll have to source those or never drive it in the rain which is hard to do when you live on the West Coast.
I’ll finish all the little stuff before I tackle the glass.