Episode 2 - Checker Plate Front - Rust Removal | Caravan Build Series | 1978 Millard Mini Pop Top
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- čas přidán 30. 06. 2022
- Welcome back to our Caravan Build Series!
In this episode we replace the old pitted and broken cladding off the front of the van with a new piece of aluminium checker plate. We discover a couple of rust holes in the chassis, cut them out and weld in some new bits. While the front of the van was off we also repaired some water damage we found in the floor, repair the two front windows and front window shade.
Stay tuned for Episode 3 coming soon where we rip out the old broken plastic wheel tubs and make some brand new galvanised ones.
Any questions regarding this project, drop them in the comments below, or, reach us on our socials @jossandell.
Cheers!
Joss + Ell
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License code: EJ1ZAYYFXWM6A5N6 - Auta a dopravní prostředky
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Thank you for the wood hardner tip, worked really well
So glad that it helped you out! It worked well for us too 👍
Yeah real good product
Awesome episode. We're doing the same thing for a 2024 trip. Enjoying watching the build.
That’s awesome Luke, look forward to seeing your adventures next year. What will you be traveling in in 2024? 😀
THANK YOU FOR GREAT VIDEO
Thank you! It’s our pleasure 😀
Dont worry about the dodgie bend on the plate because we all know if you were an American and not an Aussie you would have cut the plate on your CNC laser cutter then rolled it in the plate roller and then put it into the pan break to get the final bend. Great to see someone having a go with what they have at hand. Cheers mate.
Hi mate, don’t need to be an American to do that. I would have done the exact same if I had access to a pan brake. But that’s it, had to use what I had at my disposal to get the job done. Thanks heaps, all the best.
Joss + Ell
Nice job
Thanks heaps 👍
Really good videos you two! Really helpful and lije the detail givdn! Thx and looking forward to watching some of your trios when its fone! Keep em comin, phil
Thanks so much Phil! Glad they’ve been helpful and in enough detail for you. We’ve got a few more coming so stay tuned 👍
Cheers,
Joss and Ell
Amazing guys! You are so handy! Can’t wait to see it all finished. You guys will have so much fun making memories in Sunny the van 😍
Thanks so much guys!! We can't wait to finish it off and start travelling in it! Looking forward to touring with you guys when it's done 🙌🏼🔥
Just watched this one again as I've taken off the front and replacing the front section of floor then adding checker plate. So good to see how this was done by you, makes me feel more confident about doing it myself....with a bit of help from OH ;)
Thank you! Glad this gave you a bit of confidence to tackle it yourself 🙂 what is OH? Haha
@@jossandell other half, he who must listen and obey haha 😉
bravo
Thank you 😁
Probably a good idea to put that bitumin everywhere under the Caravan, as they say in your part of the world 🌎, good on you Mate 😂
Haha don’t worry mate we have done the whole underside of the van in it since and repainted the chassis as well which we’ll show in another episode 😁
These videos are very helpful! Hope you keep them coming. I’ve got a 26ft van of same era and hitting some of the same problems.
Glad to know they're helping mate! We've got lots of content ready to make more episodes which we'll post soon. Goodluck with your van! It's a lot of work but hopefully worth it in the end. Cheers
Great work mate just currently looking at my first van and rebuilding my myself this was a massive help keep up the good stuff 👍 🤙
Thanks heaps mate! That's exciting stuff, it can be a big task to tackle but we're hoping it'll be worth it! We'll bring out some more videos of the build soon 👍 all the best 🤙
Hi, great video, where did you find the rubber seals for the glass and the top of the window
Hi Katie, we bought all the rubbers for the windows from Vintage Caravan Spares online 🙂
Great video. I thought you might put alcor or snakeskin in the corners.🤔
Wouldn't have been a bad idea actually!
Hi there! Great video... I have just purchased one of these as a project build, and wondered if you know the tare, and gross weights on this model. Cheers...Al
Hi Al, how exciting congrats on the purchase. On my rego papers it had the original tare as 820kgs but no GVM. When I got it blue slipped by the mechanics they updated the rego papers with the GVM as 1680kg which I have no idea where he got that figure from and it seems a little high but we’ll take it! Not too sure what the original GVM is though sorry.
Cheers,
Joss and Ell
@@jossandell thank you for that... awesome help there!! Cheers..al
Love your videos. Joss you are so imformative and explain things so well. I hope you get some cool sponsors from these videos. Question did you pain the window frames or just cjean them up ive spent days on our windows and they still look pitted but hey it is a 1978 van
Thanks so much Brooke! No sponsors at the moment but we’re happy if our videos help others out doing a similar thing 🙂 No I didn’t paint the windows, just spent many hours with the wire wheel in the drill going over them along with replacing rivets, rubbers and seals etc. It was a very time consuming job given there is 9 windows in it but they came out pretty well considering the age!
I'm not sure if you are aware but cutting out the rust spot the way you did was actually the better engineered way, since its not box frame having that small 90degree angle has given the two metals a bridge (kinda like sistering a joist when building) and more surface area for the welds to penetrate the metal and bond rather than chop the whole thing off, hope the welds were zinc sprayed.
Hi mate, thanks for the comment. That's a really good point and yes, definitely more surface area. Hopefully it'll be okay. And yep, the welds have been taken care of 👍🏼
@@jossandell I'd say the welds took great, I'd be happy with the job you did. We cut the metal out of chassis's to weld extensions onto their frames and we cut the metal very similarly for things like longer ute trays or turning a wagon into a dual cab ute.
@@tomhalf3018 That sounds really good thanks Tom 👍🏼 I'll be getting rid of the current draw bar and making a longer one and stronger one. Any tips/advice for doing so?
@@jossandell most drawbars for 16ft caravans are extended to around 1800mm using galvanized RHS (rectangle hollow structure ) steel to suit what thickness is used already by manufacturer but inspect the chassis by tapping with a hammer for anymore rust everywhere, sand and then coat in a 2 in 1 rust converter + primer(super cheap has a good sca brand one) as cutting and extending it will put a tonnes of more stress on any compromised areas.
Most people can get away with extending the drawbar just infront of where the caravan ends (closer to car) without getting it checked out just grind the slag down a little and don't do anything super long e.g 2200mm
When welding i suggest making two 90degree angles opposite facing so that they fit into eachother like tetris to reform the original box shap, i can find a video and like you an example if you like
@@tomhalf3018 thanks for the informative reply mate. I won't be cutting and extending the existing drawbar. I was thinking of making a brand new one. Won't be super long just a bit longer than the original with a little more room to fit a toolbox. I've been using that exact rust converter from Supercheap on the chassis, been wire wheeling off the surface rust and spraying on the rust converter/primer. But all of that makes sense, thanks heaps mate!
Can I ask what a etch ? Cut is in the j rail when u have to run around a curve
I just had to cut a small wedge shape out of the j rail so that I could bend it up without it squashing out of shape 🙂
Hi guys, curious what size the plate was and where you got it from? I assume its 3mm?
Hi mate, sorry for the late reply I must have missed your comment. The checker plate was 2400mm x 1200mm x 1.6mm thick. I got it from Steel Supplies 👍 4:11
@@jossandell No problem at all. Happy travels!
@@andrewmadge thanks heaps mate all the best!
How much does it cost to replace the walls in a caravan
It really just depends on how much you need to replace. For the polyester ply wall skins, I bought 7 sheets and that many delivered was around $430. That’s not including the bendy ply I used for the two ceiling ends. You could do it a bit cheaper and go with a cheaper 3mm from Bunnings. We got ours from Plyco 🙂
12:05 where did you get the weather seal from?
Hi, we bought all of our glass rubbers and weather seals from vintage caravan spares. You can buy them by the metre 🙂
vintagecaravanspares.com.au/product-details/596
@@jossandell oh excellent thank you 👍 just bought myself a 77' Millard last weekend. Couple of fixes to be done and I love the bed frame idea with the slide out very clever. Awesome job you guys done I've been watching this video's over and over just learning!
These videos*
Slide out kitchen*
@@Tigerlillyxo12 that’s so cool! Overall is it in fairly good condition? I’m glad you’ve been enjoying these videos and hopefully they’ve been a help in working out what needs to be done with yours 🙂
Just about to finish my 1979 Modern done much the same. Are you finding that nothing is square and very poorly manufactured so much for saying they don't build them like they used to.
That’s awesome mate hope it’s turning out well for you. A few things I think were done poorly from factory but mostly not too bad for being made 45 years ago. The floor wasn’t very flat and was a bit tricky to try and get the cabinetry to sit square.
Where’s the rest of the videos?
Got some more episodes coming soon, in the middle of editing them up 👍
no need for the uptempo loud music..
Just need to turn your volume down or mute it 👍
Boo, the music is fun and upbeat, and the vids are awesome!