Blue Mule resto in Malawi
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M5driver
MUD Addict (Ret.)
- Thread starter
- #103
The bottom obviously will have to be completely cleaned up and re-done. That's the part that was sprayed in the rain.
There are other spots that were just slightly oily/greasy but it was enough. On the top, two spots that were actually clean worked really well - they can't scrape or sand it off there. So at least they know what it SHOULD be like when properly done.
The owner of the shop wants to try again to see if we can convince the one guy that could sandblast this buggy to do it. The Nr. 2 at MacSteel just tells us "no". He says it's not worth starting up the blaster for a vehicle - not a big enough job. I have offered to pay whatever it costs him to start up and do the job, but he really doesn't want to do it. In any event, we are trying to contact the owner of MacSteel to see if I can convince him that he should do this job, and I'll make him famous in the internet
If we can't get it blasted (everything, not just the frame) then we'll have to redo this by hand - this will set me back by at least 1-2 weeks, maybe more.
There are other spots that were just slightly oily/greasy but it was enough. On the top, two spots that were actually clean worked really well - they can't scrape or sand it off there. So at least they know what it SHOULD be like when properly done.
The owner of the shop wants to try again to see if we can convince the one guy that could sandblast this buggy to do it. The Nr. 2 at MacSteel just tells us "no". He says it's not worth starting up the blaster for a vehicle - not a big enough job. I have offered to pay whatever it costs him to start up and do the job, but he really doesn't want to do it. In any event, we are trying to contact the owner of MacSteel to see if I can convince him that he should do this job, and I'll make him famous in the internet
If we can't get it blasted (everything, not just the frame) then we'll have to redo this by hand - this will set me back by at least 1-2 weeks, maybe more.
M5driver
MUD Addict (Ret.)
- Thread starter
- #104
So you know!
Here, they steal the parts off your car while you are shopping for bread, and an hour later some guy will spot you at another shop and sell the parts back to you. No one bothers the 40, cause they can't sell those parts to anyone BUT me - nothing else like it in all of Malawi 
OTOH, I've ransomed headlights, wipers, taillights, and the radio out of my Pajero several times in the last year. They don't go for the big stuff here usually, and they are a little more cautious with cars that have diplomatic number plates, but they also know we have money to buy the stuff back. You almost have to be sympathetic. I think most of them would work if they could, but there is an element that would rather just steal from you. We've probably had a hundred or more men by our house looking for work as gardeners, cooks, houseboys, etc. but you can't hire them all... I'm a little callous these days - fourth long tour in Africa (S Africa, Ghana, Kenya right after the bombing, and here), but it makes ya think.
M5driver
MUD Addict (Ret.)
- Thread starter
- #106
Well, sort of...
The owner of MacSteel basically told me to sod off. He said he doesn't need my money or my business and is not interested in doing "these f***ing little jobs". He also told me that if he were to do the blasting, he would charge me 50,000 Malawi Kwacha - about $350 - just to show up, plus time and materials.
So, based on that discouragement, we went back to scraping and sanding the badly done Rust Bullet off the frame.
Then, last Sunday, the owner of the panel beater shop went to lunch with someone from church who turned out to have a solution - we think. Chris is a local businessman, getting started in construction. It turns out Chris has a small sand blaster he imported from UK just a few months ago. He is willing to lend it to us at the panel beater's with three conditions:
1. His man operates the blaster;
2. I supply the sand;
3. He gets to talk to me about the project to supply advice and point him in the right direction for parts sources, and maybe some wrenching help when he starts the restoration of his 1980 BJ41!!!
So there is another 40-series fan here in Malawi, wanting to keep his 40 on the road! We can start a club!
Of course, I immediately pointed him to this forum, and hope to see Chris here real soon. We are going to meet at my place on Saturday to look at what I have stockpiled in the way of resto parts, and talk about sources. He has offered to help me with any wrenching I need help on and with shifting parts, moving the tub back on the frame, etc. I plan to visit his home on Sunday or Monday (4 day holiday weekend here) to see where he is on his project. He told me he has started his teardown, so I want to be sure we are getting plenty of photos to help with putting it back together. He was way too impressed with what he saw at the panel beater's yesterday - he didn't really realize how easy it can be to break a 40-series down. We'll see about putting it back together
Anyway, over the weekend, I'll be looking for sand fine enough and dry enough for us to use in the blaster. Turns out, the construction companies and others here consider sand sources to be some sort of trade secret and refuse to tell others where they get their stuff - even for mixing up concrete
If I don't find what I need, I'll see if I can get some of the folks I contract business with at the embassy to "leak". As usual, nothing is ever easy or straightforward. But, we
princess: and I) are encouraged. MAYBE we can actually get a better job done than originally anticipated.
for now.
The owner of MacSteel basically told me to sod off. He said he doesn't need my money or my business and is not interested in doing "these f***ing little jobs". He also told me that if he were to do the blasting, he would charge me 50,000 Malawi Kwacha - about $350 - just to show up, plus time and materials.
So, based on that discouragement, we went back to scraping and sanding the badly done Rust Bullet off the frame.
Then, last Sunday, the owner of the panel beater shop went to lunch with someone from church who turned out to have a solution - we think. Chris is a local businessman, getting started in construction. It turns out Chris has a small sand blaster he imported from UK just a few months ago. He is willing to lend it to us at the panel beater's with three conditions:
1. His man operates the blaster;
2. I supply the sand;
3. He gets to talk to me about the project to supply advice and point him in the right direction for parts sources, and maybe some wrenching help when he starts the restoration of his 1980 BJ41!!!
So there is another 40-series fan here in Malawi, wanting to keep his 40 on the road! We can start a club!
Of course, I immediately pointed him to this forum, and hope to see Chris here real soon. We are going to meet at my place on Saturday to look at what I have stockpiled in the way of resto parts, and talk about sources. He has offered to help me with any wrenching I need help on and with shifting parts, moving the tub back on the frame, etc. I plan to visit his home on Sunday or Monday (4 day holiday weekend here) to see where he is on his project. He told me he has started his teardown, so I want to be sure we are getting plenty of photos to help with putting it back together. He was way too impressed with what he saw at the panel beater's yesterday - he didn't really realize how easy it can be to break a 40-series down. We'll see about putting it back together
Anyway, over the weekend, I'll be looking for sand fine enough and dry enough for us to use in the blaster. Turns out, the construction companies and others here consider sand sources to be some sort of trade secret and refuse to tell others where they get their stuff - even for mixing up concrete
If I don't find what I need, I'll see if I can get some of the folks I contract business with at the embassy to "leak". As usual, nothing is ever easy or straightforward. But, we
princess: and I) are encouraged. MAYBE we can actually get a better job done than originally anticipated. for now.
My brother in law works for the foreign service down in Uruguay and before that in Mexico City. He has told me similar stories about getting jobs done both for the embassy and for himself and also of the sketchy work conditions the tradesmen work under.
I guess there are fundamental similarities between 3rd world countries, regardless of the cultural background they come from.
Good luck getting it worked out, and good job finding another Cruiserhead there, misery loves company!!
I guess there are fundamental similarities between 3rd world countries, regardless of the cultural background they come from.
Good luck getting it worked out, and good job finding another Cruiserhead there, misery loves company!!
WOW! great job mate! ... 
, 
,
M5driver
MUD Addict (Ret.)
- Thread starter
- #110
WOW! great job mate! ...
Gracias! By Tuesday afternoon, I should have some idea of how the blasting going to go. Then on Wednesday, I'll have to leave it for awhile, since I have to get to Lusaka on Thursday, back in Lilongwe on Monday. Hope to get time to go to Vic Falls while there, and maybe fly a microlight over the Falls.
Forget the microlight, rather take the yellow moth on the Zambian side "Bakota Sky" near Livingstone
Good read, did Maaco paint your engine blue also?The chassis. Not bad - no serious rust anywhere. A few more bits to take off, then I'll pressure wash the frame, engine, gearbox, and then send this to the panel beater. Progress!
M5driver
MUD Addict (Ret.)
- Thread starter
- #114
Nope. I did that myself while in Bulgaria. The road chemicals were getting to the engine as well, and the rust was starting to drive me nuts. The only hi-temp paint I could find at the time I decided to slow the rust down was that light (almost 854) blue. It won't be that color this time, when I'm done. t will either be factory black or a very dark blue - depends on what my contact in S Africa picked up. That should be here next week.
M5driver
MUD Addict (Ret.)
- Thread starter
- #115
Spent some time with Chris this afternoon. He came round to look over my work spaces and all the spare/replacement parts on my shelves, waiting for a vehicle to bolt them onto.
Then we went to his place to look at his rig. It's as torn down as mine right now. Nice mustard yellow factory soft top, 1980 BJ41 with the 2B engine and wrong hand, which is to say right hand, drive. Frame, tub, and body panels are in great shape. We will be encouraging each other on to get these rigs put right and back together.
When Chris found out I still need to scare up a source for sand, he just said not to worry about it. He offered to send a lorry load to the panel beater on Tuesday morning, so we're thinking that the blasting should be done by the time I am back from Lusaka. I will ask them to hold off any Rust Bullet-ing until I get back and can inspect, but I think we are about to make a leap forward. Here's hoping!
Then we went to his place to look at his rig. It's as torn down as mine right now. Nice mustard yellow factory soft top, 1980 BJ41 with the 2B engine and wrong hand, which is to say right hand, drive. Frame, tub, and body panels are in great shape. We will be encouraging each other on to get these rigs put right and back together.
When Chris found out I still need to scare up a source for sand, he just said not to worry about it. He offered to send a lorry load to the panel beater on Tuesday morning, so we're thinking that the blasting should be done by the time I am back from Lusaka. I will ask them to hold off any Rust Bullet-ing until I get back and can inspect, but I think we are about to make a leap forward. Here's hoping!
Great stuff, Dan.
I have been looking at this forum plenty of times, but this thread has finally made me register and write a post. I am driving a 1978 FJ40 in Addis Abeba, Ethiopia, and often tortured by the question whether I should just keep her on the road or do more to restore. Parts are usually available (you still see plenty of FJ/BJ40s being used as tow trucks around Addis), but as we can all read on this thread, it can be a challenge to find good expertise and supplies
I'm looking forward to reading more on your restore. I'll try to put up a few pics of my rig.
Cheers, Bart
I have been looking at this forum plenty of times, but this thread has finally made me register and write a post. I am driving a 1978 FJ40 in Addis Abeba, Ethiopia, and often tortured by the question whether I should just keep her on the road or do more to restore. Parts are usually available (you still see plenty of FJ/BJ40s being used as tow trucks around Addis), but as we can all read on this thread, it can be a challenge to find good expertise and supplies
I'm looking forward to reading more on your restore. I'll try to put up a few pics of my rig.
Cheers, Bart
M5driver
MUD Addict (Ret.)
- Thread starter
- #117
Bart, Welcome
This forum has been at least a sanity saver if not actual lifesaver for me.
I had been planning the restore for about 4-5 years, so when I got the Malawi assignment, I figured this would be a good time to do the work. The difficulties are frustrating, but not entirely unexpected.
Addis was on my bid list, but the job I was looking at was filled. I'm still checking on other possibilities there, but nothing so far. Bid on Gaborone, but that one went away fast, as did Pretoria. Still looking at Maseru. Ouagadougou wants me - the Amb there asked for me by name, but she will only be there about one more year, so that wouldn't really be of any advantage for either of us. There is a good chance we will end up back in DC. In any event, next tour is the tombstone tour - retirement beckons.
Cheers and again, welcome. I'd love to see a thread on your rig and some pix.
Dan
This forum has been at least a sanity saver
if not actual lifesaver for me.I had been planning the restore for about 4-5 years, so when I got the Malawi assignment, I figured this would be a good time to do the work. The difficulties are frustrating, but not entirely unexpected.
Addis was on my bid list, but the job I was looking at was filled. I'm still checking on other possibilities there, but nothing so far. Bid on Gaborone, but that one went away fast, as did Pretoria. Still looking at Maseru. Ouagadougou wants me - the Amb there asked for me by name, but she will only be there about one more year, so that wouldn't really be of any advantage for either of us. There is a good chance we will end up back in DC. In any event, next tour is the tombstone tour - retirement beckons.
Cheers and again, welcome. I'd love to see a thread on your rig and some pix.
Dan
M5driver
MUD Addict (Ret.)
- Thread starter
- #119
Getting Blasted
I held my breath all morning. Finally had a break for a late lunch and went to the panel beater.
The sand had been delivered. Some work had been accomplished before the usual power cut; power came back on just before I had to get back to work, so I didn't get to see any actual blasting. But...
Here's a photo of the blaster - it's a simple thick-walled cylinder with a couple of air fittings, a moisture filter, and a valve. Fill it up with fine sand, bolt the top down tightly, set the pressure to 8-9 bar, and blast away (Chris' man is using protective gear!)
I held my breath all morning. Finally had a break for a late lunch and went to the panel beater.
The sand had been delivered. Some work had been accomplished before the usual power cut; power came back on just before I had to get back to work, so I didn't get to see any actual blasting. But...
Here's a photo of the blaster - it's a simple thick-walled cylinder with a couple of air fittings, a moisture filter, and a valve. Fill it up with fine sand, bolt the top down tightly, set the pressure to 8-9 bar, and blast away (Chris' man is using protective gear!)
