Popular Post Flash Posted November 6, 2014 Popular Post Share Posted November 6, 2014 Well I've been lurking around the forum for a few months now and have really enjoyed trolling through the Projects and Build Ups section. I figured it was about time that I gave something back by sharing some of the history of my van build. First off a bit of background: In December 2009 I spotted a relatively unmolested Bedford CF230 panelvan on TradeMe. The van was located down south in Weston so too far away for me to view it personally, but I liked what I saw in the pictures. A quick online check listed 3 previous owners and at the asking price of $2,500 I figured it was worth a punt. A quick call to Captain Transporter and the van was on its way north. The timing really sucked as we were staying in a small studio apartment in the city and were just about to start building a new house, so the van went straight into storage where it languished for almost a year. Discuss here //oldschool.co.nz/index.php?/topic/45781-flashs-78-bedford-panelvan/#entry1413650 A few dodgy snaps of the van taken shortly after it came out of storage. 11 Quote Link to comment Share on other sites More sharing options...
Flash Posted November 7, 2014 Author Share Posted November 7, 2014 So firstly a little bit of the van's history. It was purchased new from Schofields in Newmarket in June 1978 by a gent who owned his own glazing business in Mount Eden. The van was immediately fitted with ply floor covering and was used as his daily work hack until he retired in 1998. The van was then sold to a chap from Temuka who owned the van for a further 11 years. During this time it was mainly used as an overnight camper by the then owner who was a keen fisherman. He moved over to Aus and the van was sold to a gent from Weston who only owned it a for a few months before selling it on to me. At that stage the van had covered just over 196,000 km. Apart from an aftermarket flip up glass sunroof and a sliding window fitted to the cargo door, the van was in stock standard condition complete with the original Vauxhall 2.3 litre motor, manual 4 speed box and a diff that limited top speed to 80k's per hour. Although it had an aerial fitted there was no evidence of a radio fitment, not even some stray wiring. My original plan was to give the body a quick tidy up and a lick of paint and to get it as reliable as possible. As you all know even the simplest of plans don't always work out that way and what follows is a diary of my journey with plenty of uphills and downhills along the way. 4 Quote Link to comment Share on other sites More sharing options...
Flash Posted November 7, 2014 Author Share Posted November 7, 2014 As previously mentioned I pulled the van out of storage towards the end of 2010. The first step was to chuck a WOF and a bit of REGO on it so that I could assess the overall mechanical condition. The first issue was a lack of charging which I traced to a broken alternator exciter wire. The only other items needing sorting for WOF were a new sealed beam up front and a replacement tail light globe. I'd also managed to score myself a sorry looking set of Cheviot Tridents off TradeMe. After a few hours with some 1200 grit water paper and a tube of Autosol, we were in business 3 Quote Link to comment Share on other sites More sharing options...
Flash Posted November 7, 2014 Author Share Posted November 7, 2014 The rest of the summer was spent generally hooning around ... well as much hooning as you can do with an awesome Vauxhall power package. The annual pilgrimage to Kumue in January 2011 nearly ended in tears when she started to overheat whilst we were sitting in the traffic. On pulling out the radiator I discovered that most of the fins had long gone and the inside looked pretty blocked. I splurged out on a re-core, new radiator hoses and a brand new water pump. Whilst I had it all in bits I replaced the cam belt and had the distributor reconditioned. New spark plugs, leads and a distributor cap completed the package. Although the cooling issue was a thing of the past, performance still left much to be desired. It seemed to have an unquenchable thirst for both fuel and oil and I soon realised that I was on a hiding to nowhere if I was going to try to make anything decent out of the original mechanicals. So I hatched a cunning plan which came in the form of a donor van fitted with a Chev 350 small block, TH350 auto and a Galaxy 9 inch rear. 7 Quote Link to comment Share on other sites More sharing options...
Flash Posted November 7, 2014 Author Share Posted November 7, 2014 The donor van looked like a bit of a swamp donkey with an awesome roller paint job, but it ran really well and I could see the value in the mechanical bits and pieces. The first thing that I did was flick on the Dragweld rims and tyres and immediatley managed to recoup a quarter of the cost of the complete van. I also removed the wheel arch extensions and running boards and then slapped on a set of Cheviot Tridents destined for my original van. As the donor still had a valid WOF and REGO my plan was to drive the donor van which would allow me to take my original van off the road to start sorting the bodywork. 1 Quote Link to comment Share on other sites More sharing options...
Flash Posted November 7, 2014 Author Share Posted November 7, 2014 By this time I'd realised that a windowless van was something of a rarity, so the quest was on to return the cargo door to its original factory condition by getting rid of the sliding window. After months of searching for a relatively rust free windowless door I gave up and compromised on a fibreglass replacement panel that I sourced from Aus. The plan being to graft this panel onto my relatively straight cargo door. After trimming and massaging the panel a bit it was epoxied in place and then reinforced from the back with chopped strand. 2 Quote Link to comment Share on other sites More sharing options...
Flash Posted November 7, 2014 Author Share Posted November 7, 2014 On close inspection of the rest of the body I could see signs of previous bog work and a number of rust patches. I'd used a bit of detective work to track down the original owner and discussions with him had revealed that the van had lived outdoors for the first 20 years of its life and over those years he had had a number of rust repairs done. I was faced with two options, first option being my original plan of a quick and nasty bog job on what was visible, the second option being to remove all of the paint and start from scratch. After much deliberation I decided to go for the second option. I purchased a sandblasting pot and proceeded to line our garage with sails to turn it into a blasting booth. We had a pretty good technique going. I'd blast as much of the paint off in one go as I could and then I'd mark the entire area with a black sharpie before going over it again. Its not easy to see in all that dust so any sharpie lines left give you a good idea of where you have missed the second time around. You can see the levels of air borne dust in one of the pictures of the bonnet. I was probably getting about 5 minutes of blasting out of a full pot. I'd then have to stop, sweep up the garnet into a red plastic bucket and take it outside where Mrs Flash would sieve the garnet with a flour sifter before filling up a green bucket for re-use. We had a chain of about half a dozen red and green buckets going. Each time you refill the pot you have to drop the pressure and then re-pressurise the filled pot afterwards so it was pretty time consuming. After two weekends of blasting all that I had managed to clean was the inner and outer bonnet, inner and outer grill and half of a back quarter panel. A quick calculation pointed towards about 4 months of weekends to complete the entire shell. Despite my best efforts at lining the garage our new house had turned into a dust bowl and even although we were using high quality dust masks I was starting to cough like a cowboy and had grit in places I didn't even know I had. I guess by now that you can tell how this is going to end. 1 Quote Link to comment Share on other sites More sharing options...
Flash Posted November 8, 2014 Author Share Posted November 8, 2014 So I took a trip over to The Shore for a quick chat with Dave from Autoblast and quickly realised that swapping some cash for a professional blast job sounded much more attractive than spending 4 months sucking in lung fulls of dust. Its only money after all. My plan was to strip it down to the basics at home and then drive across to Dave's shop where I would then strip off as much as possible before Dave worked his magic. 3 Quote Link to comment Share on other sites More sharing options...
Flash Posted November 8, 2014 Author Share Posted November 8, 2014 A week later I was back at Dave's shop to re-assemble the van and get it home. A few images of the overall result. 2 Quote Link to comment Share on other sites More sharing options...
Flash Posted November 8, 2014 Author Share Posted November 8, 2014 By now I was seriously committed. I've done a number of bog and fiberglass jobs in the past myself, but realised that this van deserved far more than that. My welding skills are close to non existent so I needed to find someone who would do the old girl justice without breaking the bank. After chatting to a number of folk and getting some ridiculous estimates that were literally pulled out of thin air I finally stumbled across a metal magician called Barry. I must have spent almost two hours at his place while he went over the bodywork with a fine tooth comb and we discussed various approaches. Barry's bread and butter is structural WOF repairs, but he offered to undertake the work on the van in between his regular customers at a very reasonable hourly rate. We agreed to an up front engagement of 20 hours and I could then assess how things were going and we could take things from there. It sounds crazy now that I should have taken such a blind leap of faith, but sometimes you can just read a person right and this was one of those cases. I'll try not to bore you to death with endless photos, but hopefully the ones that I post will give you an idea of the skills that Barry possesses and the amazing job that he did on the van. So firstly a few pics of the carnage. Lots of swiss cheese and lashings of dodgy repairs that were hidden under layers of luscious bog. Quote Link to comment Share on other sites More sharing options...
Flash Posted November 8, 2014 Author Share Posted November 8, 2014 And more Quote Link to comment Share on other sites More sharing options...
Flash Posted November 8, 2014 Author Share Posted November 8, 2014 And this beauty right in the center of one of the front doors. A classic knock it in and kiss it with a bit of bog routine. Quote Link to comment Share on other sites More sharing options...
Flash Posted November 8, 2014 Author Share Posted November 8, 2014 In my meanderings through everyone's build postings I've seen some amazing workmanship and have been blown away by the skills that some of you possess. Sadly I am not as gifted. At first I toyed with the idea of doing a welding course and buying my own kit, but soon realised that my quest to get the van on the road as quickly as possible meant outsourcing this work to someone who already possess the skills and time to get the thing done within an acceptable time frame. I'll now showcase some of Barry's workmanship. Quote Link to comment Share on other sites More sharing options...
Flash Posted November 8, 2014 Author Share Posted November 8, 2014 And more Quote Link to comment Share on other sites More sharing options...
Flash Posted November 9, 2014 Author Share Posted November 9, 2014 The leading edge of my left hand rear fender was probably the worst bit as both the inner and outer skins were badly ravaged. First step was to cut all of the rot out and then start building things up from the inside working outwards. Quote Link to comment Share on other sites More sharing options...
Flash Posted November 9, 2014 Author Share Posted November 9, 2014 More of the same. Quote Link to comment Share on other sites More sharing options...
Flash Posted November 9, 2014 Author Share Posted November 9, 2014 Some of you may be wondering why the epoxy primer has such a textured finish. The reason is that I took the plunge and had the body zinc metal sprayed before the temporary primer was applied. It results in the textured finish that you can see in the close up pictures. My daily is over 30 years old and was factory galvanised. It has held up well over the years so I'm a big fan of anything that could give the metal a fighting chance. Metal spraying is not as good as the factory dipped galvanising process, but it was an option that I thought was worth investing in. Quote Link to comment Share on other sites More sharing options...
Flash Posted November 9, 2014 Author Share Posted November 9, 2014 Bedford vans are notorious for rust in the roof gutters. By some small miracle the gutter rust on my van was limited to the gutter above the rear doors and a short section on the right hand side. Quote Link to comment Share on other sites More sharing options...
Flash Posted November 9, 2014 Author Share Posted November 9, 2014 By this stage I was visiting the van three times a week to review progress. Barry would cut open each section and we would then discuss the best approach to each repair before he continued any further. This door was a classic example. The outer skin looked good, but there were signs of pitting on the panels edges. We decided to separate the skins for a quick look see and boy was I glad we did. What lurked beneath was a ticking rust bomb. Apologies for the crap picture quality, but hopefully you get the idea. Quote Link to comment Share on other sites More sharing options...
Flash Posted November 9, 2014 Author Share Posted November 9, 2014 The back corner below the tail lights are where 3 pressed panels converge. Absolute carnage in this particular case. 3 Quote Link to comment Share on other sites More sharing options...
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