The start of my van's body build

[Bruce Nicholls]

Van build looking good and very interesting. Miss my Lotus, a red pre airflow S£ Coupe which I sold when we went to sea 15 years ago, I decided I could only aford to store one car and the Austin won. Back ashore now though.

[Steve Bryant]

Well the build has raised more questions which might be considered as being fussy but that's just me.

The screen rail is on the screen pillars and raises the question of a seal between the screen rail and the windscreen frame.... Is there  one fitted here normally ?

   

I resolved my issue of the tank flange to dash and steering column with a purpose made clamp which has a pin in the center to locate the tank flange to the dash  and a hole either side for the bolts that hold the steering column bracket  to the dash.

   
   

It looks like I'm going to have to make up two new wheel arches as one is badly warped / twisted and both are a different radius to the rear wings.

   
   

Some things seem to be a case of one step forward two steps back . So far the build is giving me pleasure as well as a few head scratchers.

Cheers,
Stephen

[Steve Bryant]

The wheel arch laminates look like they are going to be an issue to resolve. They are laminated from ten thin laminates to make a 3/4" thick piece.

I have two problems with these as you can see from the previous pics. The radius of the inside edge is smaller than the rear wings outside radius which means that the wings don't fit properly. The other problem is one of the arches is twisted so as to be unusable in my opinion.

SO: Can I salvage these arches or should I make new ones ?  Will these arches respond to soaking and clamping until dry to fix the issues ?

I'm thinking they may not so I am currently looking for suitable wood to turn into laminate strips to glue and laminate around a proper form.

Any wise words from our wood fabricating specialists would be appreciated.
Thanks in advance,
Stephen

[Peter Naulls]

I wouldn't bother trying to rescue that one. 

If it were me I would make up a rigid former the size of the wing and laminate new strips around it. It is very wasteful on wood (cutting into thin strips) but you'll end up with a piece that stays exactly the right shape. Turn every other piece upside down to eliminate any natural warping of the grain. Hold it all together with ratchet straps while it dries.

[Henry Harris]

I wouldn't be checking the radius of the wheel arch with a repro mudguard.

[stuartroach]

Hi Stephen

Are you sure that there should be a piece of wood that goes around the wheel arches?

We have never fitted anything on our C Cab Chummy van bodies, see the photos

Cheers

Stuart

[Steve Bryant]

Hello guys
Peter: I'll am pretty much committed to making new arches. Seems to be the best option.

Henry : the rear wings are restored originals.

Stuart : John Heath's van kit uses wooden laminated arches :
   

   

So I'll try to keep with his original build method.
Thank you for the lovely pics.
 Cheers,
Stephen

[Steve Bryant]

Hi all, today being a provincial holiday I was able to use the time to work on the van at work. A number of little things were done but the big step forward is that the B pillars are now installed to my satisfaction. It took ages to get the dimensions for the door opening the same at the top for both. Three countersunk stainless bolts were put through the outer steel sides and washers and nuts tightened up on the inside. I wanted them to be as strong as possible as they will have to take a beating from the door slamming.

I am also currently making the bending form for new wheel arch laminates to replace the two supplied that aren't usable.
Cheers,
Stephen

[AllAlloyCup]

Brilliant build … I look forward to this long thread!

Bill G

[Howard Wright]

Hi Stephen

Regarding your post asking for info on sealing the top of the windscreen.  I’m not sure if Austin ever provided a seal as the peak over the screen does tend to stop rain coming in.

However on my RK I screwed an aluminium half round section trapping a butchered rubber section I just happened to have lying around.


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Hope this gives you food for thought?

Cheers

Howard