My 1967 Carawagon (no name yet!)

[RMS]

I assume you'll be swapping the front end back to the proper setup in time?

Yep, the guy I bought it from still had the front panel, grill & wings, so in time it should be back as a 'lights in grill', probably when they all come off for the 200TDi to go in

He also threw in the original S2 gearbox (it's got an S3 in now), but if I'm going for 200TDi and 3.54 diffs, I'll probably leave the S3 in (more changing down to 2nd with that setup ).

I've also scrounged enough hinges to replace the S3 ones, but again, as this is a rolling resto, my priority is really to get it on the road in time for this year's shows/camping weekends, and deal with the niceties as and when I've got time

Cheers,
Robin.

[RMS]

I had another 1/2 day to work on the 'wagon today and managed to patch both front chassis legs, between the front spring hanger and the bump stop.

I've finished the front brakes and the front is all back together. However, I was planning on popping on a couple of MAP hubs I had, but after I got it all together, I realised my front halfshafts are 24 spline ( ) and my MAP hubs are 10 spline

I happen to have another pair of front halfshafts, 10 spline, so might have to pull the hubs and brake backplates (again) and swap them out.

Oh, why didn't I check when the halfshafts were out yesterday

Anyway, rear brakes tomorrow, then fill, bleed & adjust.

Then there's just the steering joints to check, front seat runners to fit, lower seatbelt mounts to make & fit, lights/horn to check, then I hope it's MOT time

I'm getting there

Cheers,
Robin.

[RMS]

Well, I've had another couple of good days on my Carawagon - I got the rear brakes sorted, new cylinders, shoes, springs, pipes and freed off the adjusters, then bled the system through so it's all fresh fluid in the new cylinders
I've adjusted the brakes up and I'm happy they are fine now (no MOT/insurance/tax so can't road test yet!).

I also put on my spare set of 7.50 wheels/tyres rather than the cracked mis-match of 7.50/205s that were on!

Yesterday, I bolted in the seat box (it wasn't fixed in!), seat runners and fitted the seats - it looks a lot more like a roadworthy Carawagon now

I also topped up the gearbox & transfer box before I put the tunnel and floor plates in - and remembered to fill the front axle (after I replaced the diff a couple of days ago) while I had the EP90 out.

Patrick has set of for Cornwall today, in his Carawagon, for a month's holiday, so yesterday was the last chance to do 'two-man' jobs (without someone driving over to help, John ), so I checked the steering joints while Patrick moved the steering wheel.
All seem ok, but one TRE has a split rubber, and that's now an MOT failure, so that will have to be split for a new rubber.

I checked all the electricals out as well; found the original screen washer pump dead and parts missing (looks like the previous owner had a go!), so I've connected in another pump and wired that in.
All the rest were fine - lights, wipers, horn, apart from a missing brake light switch.

I just need a couple of bits to finish putting the inside front together (bulkhead to tunnel panel & lower seatbelt mounts) which I'm hoping to pick up today from a friend, then I think it's ready for MOT

Today looks like a bit of a bust for working though - it's raining and is forecast to rain most of the day, and as I'm going commando (ie. outside, not without underwear!!), I really don't fancy getting soaked

Note to self: must remember to take more pictures

Cheers,
Robin.

PS. I haven't started on the cabinets or roof yet - broken hinges, peeling ply, pulled screws) but that can all wait until after the MOT.

[AlexB]

Well done that man!



and you are absolutely right about the lack of pictures!

[RMS]

The problem is, when I think of taking pics, my hands aren't in a fit state to handle the camera. Then, later, by the time I've finished and got clean hands, I've forgotten all about taking them

Maybe I need an old, rough, camera that I don't mind getting greasy paw prints all over

[RMS]

Right, managed to snap some pics off today:


This shows the aluminium trim, riveted on from the outside (along the top of the windows), which prevent you getting to the roof bolts!



And the other side after the trim is removed:


Now got S2 hinges - I welded a piece of 6mm plate to the top hinge for the mirror arms, same as Military hinges:


and I made the lower seatbelt brackets from 3mm plate:


More pics to follow

Cheers,
Robin.

[AlexB]

You have been busy!

Have you got 6 pot brakes on it? and if so, where did you get the overhaul kits from and what were they like?

I need to do something on the chassis to prepare it for Dormobilisation and getting an overhaul kit might be a good way of starting!

[RMS]

Hi Alex,

No 6 pot brakes on this one, just standard LWB.

I got the kit from Paddocks - generic (some blue boxes!) - I think around £59 +VAT for the whole lot, cyls, shoes, springs, adjusters, though I did already have a roll of brake tubing, ends and a flaring kit - soooo much easier to cut pipes and remake them rather than struggling trying to undo them !

I did get a front overhaul set for Patrick's 6 pot brakes, from Island 4x4, again blue boxes, but for £38 + VAT, I thought I'd try them - can't be worse than the ones that were on!
They certainly seemed ok, and went through the MOT with really good balance, so hopefully the grabbing times have gone
Paddocks do a full 6 cyl kit, front and rear, for £79 + VAT, but I only needed the fronts for Patrick's.

If you do think about getting the Island 4x4 kit, they list them as 12" "Brake Kit Front 12" DA6045".

Hope that helps,
Robin.

[RMS]

Well, I took the Carawagon out for a spin yesterday, and what a disappointment

I don't know if it's a 'good' 2.25 Diesel or not, but what I do know is that I can't live with it as it is. 45mph flat out and 30mph up hills - that's no good for what I plan on using it for

So, as I happened to have a Disco in the garden, with a 200TDi engine, ready and waiting to go into the Carawagon I decided not to mess about with the current engine, but to go 200TDi
I had intended driving around with the 2.25D for a while to see if I could cope with it, but I just needed that 5 mile run to know I couldn't

So, started at 10:00 this morning, had a break of an hour to show Rex, my 109 with Prima TDi, to a prospective buyer (who has agreed to buy and left a deposit ), another break for lunch, and by 5:00 the engine was out, in the garage, ready for a new timing belt and rear crank seal
Just had a long soak in the bath to ease my back, and now catching up on the forums.

Here's the engine coming out:

Now, just how high does my engine crane go? Well, not quite high enough, so had to let some air out of the front tyres

The gerabox being lowered - now where have I seen that idea before - oh yes, all hail the removable crossmember


Those of you who are used to doing this sort of work will now notice a problem; no gearbox means no transmission brake, and the brakes on the Disco don't work!!!
So, I piled lumps of big timber a couple of feet in front of the ramps, and knocked the chocks away - that got the adrenalin going
It did the trick, then I used the front winch on Steptoe (another of my 109s), with a snatch block on a strop to a tree in the garden to move the Disco out of the way, so tomorrow I can start to pull the engine out of my Carawagon

Only 2 free full days this week, so I hope I can get it done ready for a planned camp on Friday night

[RMS]

2 1/4 D engine out this morning:


and the Disco engine going it this afternoon


I'm cheating a bit here as this was only a trial fit to see how the turbo fits in and to see the exhaust routing, so it wasn't actually bolted in place

Oh, and I had company and help this afternoon (thanks John ).