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    #61
    Todays update with photo's

    I decided to remove the front bumper today because I'd spotted some rust just below the bumper area, took me ages to get those 2 screws out on the top but in the end I managed to get one and had to cut the plastic bumper where the screw fits on the second one, I wasn't bothered as I know I can repair it.

    I finally got the bumper off and I didn't know whether to laugh or cry, I was faced with a large amount of rust on what I would presume is called the cross member that holds the bumper on, (please feel free to correct me if I'm wrong) the only way to see the real extent of the damage was to remove this cross member as well, I removed it to be met by more rust on the chassis cross member, now I'm stood there thinking to myself do I beat chitty to a pulp with my sledge hammer or do I smile and say "You will not beat me Chitty" guess which one I chose?
    I sat down scratching my head and looking at this bumper cross member thinking, shall I repair or see if I can buy a new one, I went online but I can't track one down, so any help in doing this from you guy's and I will be so grateful.

    I put this bumper cross member to one side and took a look at the cross member that is welded to the camper, I set about with my tape measure, my sheet metal and my marker, I then cut out the shapes I needed and set them to one side while I took the wire wheel to the chassis, on top and below was cleaned of the rust, I then applied rust killer and did what it said on the bottle, did this twice to make sure I'd got everything.
    Took my one of my newly cut pieces and clamped it to the chassis and began to weld away, this done I ground down my welds checked it then applied 3 coats of red oxide, I'll prime it then re-spray to match the white of the camper. In the mean time I really need to source a bumper chassis if not I have an awful lot of fiddly welding to do and I have to guess the outer shape if this is what I end up having to do.

    Anyway this little job took me most of the day so see the photo's below and pass your judgement.
    WP_20160826_12_49_17_Pro__highres (Medium).jpgWP_20160826_13_59_32_Pro__highres (Medium).jpg



    Last edited by Jeff Brown; 03-09-2017, 23:41.
    "Take nothing but pictures. Leave nothing but footprints. Kill nothing but time"

    Comment


      #62
      I would take some careful measurements and plenty of pix, then spend a few hours looking around the scrap yard looking for something the same, or similar enough to be made to fit.

      You know you can do it.

      Comment


        #63
        Just spent some time on google trying to track one down but finding it elusive. I have at least found it's correct name, front bumper reinforcement.

        We have a couple of scrap yards around near me, so I'll be tracking one down and if I can't, then I will repair this one I have, she won't beat me.
        "Take nothing but pictures. Leave nothing but footprints. Kill nothing but time"

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          #64
          Spent the day hammering banging, cutting, grinding and welding and I actually repaired the front bumper re-enforcement bar, it was a lot of fiddly welding and I guessed the end shapes but they fitted and that's what counts I think but I'm well pleased with the result. Sorry, I forgot to take a picture before I put it all back together got home tonight at 8:30 so it's been a long day but happy once again with chitty's progress.
          front chassis cross member.jpgWP_20160826_17_46_18_Pro__highres (Medium).jpg
          Last edited by Jeff Brown; 03-09-2017, 23:43.
          "Take nothing but pictures. Leave nothing but footprints. Kill nothing but time"

          Comment


            #65
            Sacred Bleu! C'est encroyable monsieur. Brilliant, I wish I could do that. Well done that man
            Blessed are those who find wisdom, those who gain understanding. Proverbs 3

            Comment


              #66
              Originally posted by gasgas View Post
              Sacred Bleu! C'est encroyable monsieur. Brilliant, I wish I could do that. Well done that man
              She's getting there slowly but she's getting there.

              My granddaughter came out into the garage today and said would Caractacus Potts like a cup of tea?, who's that I asked and she replied, the man who converted chitty chitty bang bang lol I should have known who he was
              "Take nothing but pictures. Leave nothing but footprints. Kill nothing but time"

              Comment


                #67
                Raining pretty heavy yesterday so no welding on chitty was done but instead I decided to strip down the front brakes as she's been stood for around 3 years now. I found out from the previous owner that she had brand new disks and pads the day before her cam belt snapped and looking at the disk pads and disks I found this to be true, so a good clean up with brake cleaner made her disks and pads look pretty good again, also checked the movement of the callipers as those calliper pins have a tendency to seize but I had full movement on both sides, checked the pistons weren't seized and again full movement on them. It took me several hours to do just the front brakes and still have the back ones to do yet, I was told only the front disks had been changed so she may well need new shoes on the back. I'll also be checking the equaliser at the back too. Once all that is done I will be changing the brake fluid as the old fluid is pretty old.

                I wasn't happy with the gear selection on chitty, I have commented that she felt really sloppy and it was guesswork as to what gear she was in and to get it into reverse I had to force it pretty hard against the drivers seat and hope she would slip into reverse but yesterday while under the car trying to free the brake calliper bolts I noticed that one of the control arms had popped off, rolled under chitty and popped it back on, got into her and wow what a difference in the gear selection, more positive movement and you can now select reverse gear positively. Well pleased with that result.

                I have some more welding to do on the nearside and I'll have all that completed in a day. Then its a lot of little things to complete and tidy up as well as the rear brakes and fluid change. She needs a re-spray but I'm not even going there until she passes her MOT.
                "Take nothing but pictures. Leave nothing but footprints. Kill nothing but time"

                Comment


                  #68
                  I couldn't do my final welding today as another day of heavy rain. I wanted to finish the N/S sill off, the chassis is welded and complete and so is the front n/s wing. The n/s door pillar next to the accommodation was rusted badly for around 2 inches and nothing but a large hole, yesterday I got the tape measure and measured the damaged area, the sheet metal I had is ok for the chassis but not for this thin steel, rather than drive around trying to find somewhere to buy some as I was sat there having a cuppa staring at this damage the light in my head suddenly came on, I got my disk cutter and marked the size I required onto chitty's old door, cut out the piece and with only a pair of wide welding mole grips and a panel beating hammer I managed to bend it into the L shape I needed, punched a few holes into it with a jodder/hole punch I have and I spot welded it into place just enough to hold it so I could gently tap it so it fitted, completed it by spot welding through the holes I'd punched. The finished job will have a small lip on it but I can either use some body filler or just leave it because I bet no one will ever notice the patch..

                  I decided I'd take a look at the heater blower today as I already had the parcel shelves off. Remember that large hole I found in the bulkhead? well it was directly above the heater blower, so during rain or any washing it had the water would cascade over the motor, so I wasn't holding out much hope to rescue it...
                  Very easy to remove with just 2 nuts holding it in place, and the 3 cable power lead to unplug a little wobble and I got it out to be met by the image below and I'm thinking the blower was doomed.
                  I stripped it down by separating the 2 plastic halves that houses the motor and the fan, I was able to remove the motor with the fan still attached, gave it a good wire brushing with lashings of GT85 and I was finally able to freely spin the motor, continued cleaning with a brass wire brush until it spun with just the touch of my finger, I rigged up some jumper leads and connected chitty's battery to it and she tried to spin, gave it a little push and it burst into life all be it at a slow speed, I wobbled the 3 wires coming from the motor and it went up to full speed, when I let go of the wiring she slowed down again, I took each wire individually and gave it a little tug and on all 3 wires it would burst into full speed, I de-soldered the 3 wires and re-soldered them back on in case of any dry joints then connected it back to the battery only to be met by the same problem, in the end I solved the problem with a cable tie by hooking it around the 3 wires and onto one of the rails in the housing and tried it on and off a good dozen times to make sure it wasn't a fluke. I put it all back together again and re-installed the blower back into chitty, connected the wiring back into the loom and gave it a try only to be met with it working only on slow speed, I removed the switch and cutting a long story short, someone had wired it incorrectly and it only worked on one speed but after re-wiring the switch chitty now has a working 2 speed blower, took me around 2hrs but 2hrs well spent.
                  chittys heater blower (Medium).jpg
                  Last edited by Jeff Brown; 03-09-2017, 23:48.
                  "Take nothing but pictures. Leave nothing but footprints. Kill nothing but time"

                  Comment


                    #69
                    Brilliant. There is so much more satisfaction spending time doing that, than the worry and grief that giving the job to a garage produces. I recently spent three days trying to get rid of the ABS light on my car. I looked on the owners forum for possible causes. I swapped the ABS pump for another known working one, I swapped all the sensors for known working ones, cleaned all the notched drive shafts which operate the sensors, and changed the ABS relay for another one. Eventually I gave up and sent it to a competent garage. Although the brakes worked fine, the car would not pass the MOT with the ABS light on. You can't just remove the indicator bulb, the light has to come on when ignition is on, and it has to go out within 3 seconds of the engine starting.
                    The garage phoned to say it was now fixed, with a new MOT. I went to collect it and my heart went thump when they gave me the £340 bill. It was for four hours labour plus a cheap relay.I asked for more details but they just said the trouble was it took four hours to find the problem and was difficult to get at, inside the dashboard. I thought I knew the car, I have looked inside the speedo and behind the glove box before and never seen a relay and I thought I had worked out all the electronics of the ABS circuit. Anyway I paid, after all they had done what I asked and it passed the MOT.
                    Yesterday I was changing the speedo to see if the rev counter on a replacement one worked. It didn't, but I was a bit surprised to see a new small relay with lots of new wiring sitting behind the speedo, with a wire going to the ABS light. I began to wonder what it was for. Anyway the new speedo rev counter didn't work so that problem must be at the sensor end. I put everything back together and got on with the rest of the day, going to a Cruise Show. That was a bit of fun. . some cruises cost £350 per day per person. You get your own butler and constant champagne. I don't want a butler and I don't like champagne and more than that I don't pay £350 for each day of two weeks on a boat. Or £700 a day for me and The Fragrant One.
                    Blessed are those who find wisdom, those who gain understanding. Proverbs 3

                    Comment


                      #70
                      Originally posted by gasgas View Post
                      Brilliant. There is so much more satisfaction spending time doing that, than the worry and grief that giving the job to a garage produces. I recently spent three days trying to get rid of the ABS light on my car. I looked on the owners forum for possible causes. I swapped the ABS pump for another known working one, I swapped all the sensors for known working ones, cleaned all the notched drive shafts which operate the sensors, and changed the ABS relay for another one. Eventually I gave up and sent it to a competent garage. Although the brakes worked fine, the car would not pass the MOT with the ABS light on. You can't just remove the indicator bulb, the light has to come on when ignition is on, and it has to go out within 3 seconds of the engine starting.
                      The garage phoned to say it was now fixed, with a new MOT. I went to collect it and my heart went thump when they gave me the £340 bill. It was for four hours labour plus a cheap relay.I asked for more details but they just said the trouble was it took four hours to find the problem and was difficult to get at, inside the dashboard. I thought I knew the car, I have looked inside the speedo and behind the glove box before and never seen a relay and I thought I had worked out all the electronics of the ABS circuit. Anyway I paid, after all they had done what I asked and it passed the MOT.
                      Yesterday I was changing the speedo to see if the rev counter on a replacement one worked. It didn't, but I was a bit surprised to see a new small relay with lots of new wiring sitting behind the speedo, with a wire going to the ABS light. I began to wonder what it was for. Anyway the new speedo rev counter didn't work so that problem must be at the sensor end. I put everything back together and got on with the rest of the day, going to a Cruise Show. That was a bit of fun. . some cruises cost £350 per day per person. You get your own butler and constant champagne. I don't want a butler and I don't like champagne and more than that I don't pay £350 for each day of two weeks on a boat. Or £700 a day for me and The Fragrant One.
                      WOW!! £350 and the majority of that was labour for a couple of pounds relay and I can probably vouch for the length of time it takes to trace a fault as I've done it a few times on chitty trying to trace wiring problems and I have a problem with the wiring on the left hand indicators now, so no doubt that will take me a couple of hours to trace. I found chitty's heater blower was probably the easiest job of all the jobs I've done even though it did take me 2hrs to complete. I would have during chitty's restoration a welder and a mechanic on stand by to help but labour costs just make me sit back and think "Can I do this myself" take the welding, they wanted £200 just to remove the old sill and weld on a new one, so I bought my own welder and just as well I did with all the rust I eventually found, I think the welding alone could have cost me well up to a grand, so I'm well pleased in saving myself around £800 and I've really enjoyed doing it myself. The only time I called on the experts was to have the cam shaft and head machined but even on that I saved £90 Just got to finish off this last sill and then chitty goes back together, just a few more wiring jobs to do and then chitty should be ready for her MOT once she gets that then chitty will be cruising the motorways or side roads because that is the only cruise we'll be going on, I spent enough time out at sea but happily I was getting paid for it, sadly we had no butler on hand and no Champaign either lol
                      "Take nothing but pictures. Leave nothing but footprints. Kill nothing but time"

                      Comment


                        #71
                        Originally posted by gasgas View Post
                        Brilliant. There is so much more satisfaction spending time doing that, than the worry and grief that giving the job to a garage produces. I recently spent three days trying to get rid of the ABS light on my car. I looked on the owners forum for possible causes. I swapped the ABS pump for another known working one, I swapped all the sensors for known working ones, cleaned all the notched drive shafts which operate the sensors, and changed the ABS relay for another one. Eventually I gave up and sent it to a competent garage. Although the brakes worked fine, the car would not pass the MOT with the ABS light on. You can't just remove the indicator bulb, the light has to come on when ignition is on, and it has to go out within 3 seconds of the engine starting.
                        The garage phoned to say it was now fixed, with a new MOT. I went to collect it and my heart went thump when they gave me the £340 bill. It was for four hours labour plus a cheap relay.I asked for more details but they just said the trouble was it took four hours to find the problem and was difficult to get at, inside the dashboard. I thought I knew the car, I have looked inside the speedo and behind the glove box before and never seen a relay and I thought I had worked out all the electronics of the ABS circuit. Anyway I paid, after all they had done what I asked and it passed the MOT.
                        Yesterday I was changing the speedo to see if the rev counter on a replacement one worked. It didn't, but I was a bit surprised to see a new small relay with lots of new wiring sitting behind the speedo, with a wire going to the ABS light. I began to wonder what it was for. Anyway the new speedo rev counter didn't work so that problem must be at the sensor end. I put everything back together and got on with the rest of the day, going to a Cruise Show. That was a bit of fun. . some cruises cost £350 per day per person. You get your own butler and constant champagne. I don't want a butler and I don't like champagne and more than that I don't pay £350 for each day of two weeks on a boat. Or £700 a day for me and The Fragrant One.
                        Mmm, I hate to say it, but it crosses my mind they have wired a relay to the light, so it simply comes on with the ignition, then goes off when it times out, rather than fix the ABS?

                        Comment


                          #72
                          I must admit that the same thought crossed my mind, the relay could be a 3 second delayed timer.
                          I'm not asking. The car works fine and the brakes work fine. They don't lock up on emergency braking and the braking effort far exceeds the MOT requirement.
                          Blessed are those who find wisdom, those who gain understanding. Proverbs 3

                          Comment


                            #73
                            Worrying isn't it? although we trust a certain garage and they seem to cure a problem that we have on our vehicles, how do we know they did the job correctly? truth is, we don't.
                            I once put my old Vauxhall Vectra in for a new cam-belt and new tyre and MOT the mechanic working on it used tipex to mark the timing but during his instalment of the new belt he moved the crankshaft and rubbed off the tipex, they ended up having my car for a week and transporting it to a Lucas specialist because of damage they did, that must have been one very expensive mistake and to top it all the same guy changed my tyre and bent the steel rim, I heard my car wasn't the first he messed up and I do believe he got fired for it but it was no consolation to me not having a car for a week. I had the MOT done at the same time and I did wonder if they actually did do the MOT or just gave it to me to get rid of me.

                            From now on if chitty needs to be repaired I'll do it myself unlike my car a Vauxhall insignia 2015 if anything goes wrong with it then this will have to go into a garage because everything is operated by a computer, so pleased to have chitty going back in time to when I could work on them.
                            Last edited by Jeff Brown; 05-09-2016, 00:02.
                            "Take nothing but pictures. Leave nothing but footprints. Kill nothing but time"

                            Comment


                              #74

                              Final bit of welding finally done.
                              Chitty's second sill welded on now, ready for grinding and treatment then painting.
                              You can also see the small plate on the pillar that I fabricated and tac welded on this also needs grinding before painting.

                              A few more fiddly jobs to complete and to get my N/S indicator working and then chitty needs a good wash before I take her for her MOT. Then I'm thinking of giving her a complete re-spray and new decals, I think I'm looking at a couple of weeks before we get to that stage because of the distance I have to travel to work on her, so who knows if she passes her MOT then I may even be going away in her pretty soon ,so fingers crossed.
                              WP_20160905_16_35_51_Pro[1] (Medium).jpg
                              Last edited by Jeff Brown; 03-09-2017, 23:52.
                              "Take nothing but pictures. Leave nothing but footprints. Kill nothing but time"

                              Comment


                                #75
                                Is that a continuous weld on the bottom of the sill?

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