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Lockdown labours...water pump and rear door body pegs

20 May 2020

Water pump...had ordered a water pump as was getting some slight water drops from somewhere...but not sure where. Just thought I would change it out to be sure.

Removed grille and radiator and started to undo bolts holding water pump on, only for two of the four bolts to shear off just below the head! But the pump would still not come loose. So after a far amount of heat from a blowlamp and thumps from a lump hammer I did get it off. The bolts/aluminium body had corroded together as one. Fortunately the remaining shafts of the bolts did unscrew from the main block without any damage.

The old pump was also badly corroded at the outlet pipe with some of it missing.

Replaced bolts and fitted the new steel pump without further trouble. Gave whole area a coat of green engine paint plus yellow fan and put it all back together. See photos below.

Old Pump

Pump Removed

New Pump in place

Belt & fan added

Radiator back in place and all done.

Rear Door Body Pegs

Bought 2 of these 3D printed pegs from Chris in Tasmania.
They are a good quality plastic 3D part that are supplied grey in colour.
I did a small amount of light sanding to remove some minor printing marks on the main barrel before painting. Then grey primed and black gloss. They look just like the metal ones, don't you think.
Mine are not functional as the doors do not fold back as I have then on check straps.
Fitted with 6mm bolts.


Too much time on our hands..........

5 April 2020

Does Coronavirus cause insanity?

Asked my wife to make covers for the headlamps, so as they don't get damaged while I work in the garage.

Should have know better!

Covers bearly fit!

Interior Additions

9th March 2020

Slightly changed the load area arrangement of items and added a large British Railways First Aid Box and Capstan packaging box.  Period (1960's) donations for the First Aid Box most welcome. Capstan box has spare cigarette & tobacco items from my collection. Hope to sell these as time permits. see for my current collection.

First Aid Box

Capstan Box

Changed layout

Winter Work 2

20 December 2019

More messing about!

1. Fashioned an instrument top cowl from brass sheet, similar to those seen fitted to GPO vans.

2. Filled in passenger footwell to make better flooring for passenger.

From This

To this

Winter Work 1

12 December 2012

Here are a few additions/changes I have made since displaying my van at the November NEC Classic Car Show.

In no particular order

1. Rear door handle.

Was fortunate to pick up a second hand rear door handle at the NEC. It did have a longer shaft than I needed but after a little bit of tweaking it fits fine. Chrome work is in very good order. Now fitted.

2. Gear Lever Bush

Had a lot of slop in gear lever movement making gear changing very vague so decided to investigate.
Bought a nylon bush from Moss, part number 22H15, fits MGA/MGB also.
Removed gear lever by removing large circlip, cover and spring, slackened off 2 side pegs by unscrewing them a few turns and lifted gear lever out. 
Had no trouble removing the existing bush, as there wasn't one! No wonder changing gear was a bit vague!
Fitted bush to ball on gear lever, it just snaps on, and re-inserted lever and bush into selector with a small amount of grease applied.

Reassembled spring, cover and circlip, best need 2 persons for this, one to hold done the cover against the spring and the second to locate the circlip.

Much less slop in gear lever movement now! 

3. Sliding Door Stops

Other vans at the NEC had positive door stop brackets where my catches just clashed with the door arch.

So I made some stop brackets from 25 x 2mm mild steel strip. There were a bit tricky to get in the correct position but do now stop on the catches.

4. New Headlamps

Replaced both headlamps with new from SVC. These are closer to the originals than those I had fitted previously.

5. Fitted interior light

GPO type, kindly supplied by GaryS. Fitted over back doors with a small switch on a bracket next to it and wired to a second battery. Already had a spare 12v battery so used this as the power supply rather than drain the main battery. Disguised this battery as a fake parcel.

Battery is securely fixed to the van side stay and can be recharged by lifting the fake parcel off. Uses 36w large bulb and illuminates the inside nicely.

6. New Ignition/light switch

This is not something I intended to do but after wrongly connecting the headlamps and creating smoke and smell of melting plastic I had to rewire some of the side light harness.
While doing this I decided to replace the old switch and add inline fuses to both the sidelight and headlight circuits.  

Sliding Door Wheels

Nov 2019 -Update of my sliding door changes (previously mentioned in June 2015)

Having fitted both sliding doors with some near identical sized acetal (plastic) wheels some time ago here is more information on them. They have been fitted for 4 years now and seem to be holding up well. (First fitted in June 2015).
Certainly others have commented on the smooth running of my van doors.

The wheels are supplied by Versatile Marine,(  based in Penryn, Cornwall. They are now selling on eBay also as supplier 'versatilemarine 2010'.

They supply a number of different sizes. The ones I used are very close to the metal ones fitted originally.

The size I used was: - Diameter = 36mm, Width = 12mm, Hole Size = 10mm

This compares with the original worn metal wheels, I have of : - Diameter = approx. 36mm, Width  = approx. 13mm, Hole Size = approx. 10 mm (suspect hole was 3/8 inch (9.525mm) originally but has worn)

The one dimension not quoted is the inner diameter, where the wheel would sit on the bottom runner.

For the metal wheel this is 1.0 inch diameter, (25.4mm) and for the plastic wheel this is  31mm diameter, (1.220 inch).
So in effect there is a radial height of half the wheel inner diameter difference. That is .110 inch (2.80mm). The door wheel holder spring easily accommodates this additional compression and the wheel stays on the runner okay despite it being a shallower profile..

To fit the plastic wheels I opened up the carrier fork holes to 10mm and fitted a piece of 10mm stainless tube as an axle. Flaring the tube at each end to hold it in place.

Additionally I added extra 5/16 ball bearings to the top door rails, filling each spare space.

For those with the means the plastic wheels could be machined to reduce the internal diameter down to 1.00 inch. (25.4mm) and making the profile closer to the original.

Calling these Acetal wheels 'plastic' is probably doing them an injustice. They are for a marine use and are intended for sheaves pulley wheels for blocks, masts, yachts, boats, dinghies etc. So they are intended for a pretty tough environment.

Quote "Acetal provides high strength and stiffness coupled with enhanced dimensional stability and ease of machining. As a semi-crystalline material, acetal is also characterised by a low coefficient of friction and good wear properties, especially in wet environments."

Sounds an idea material for driving in the UK!

See the photos below: -

 Acetal wheels fitted to holder

 Obviously metal on the left, Acetal on the right


13 Nov 2019

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