Aaron's 90 rebuild (round 3)

chassis looks far better than mine, shame you're so far away lol

Could you do me a favour, Aaron? Could you taker a close up picture of the rear tub to van side fixings. I've bought new bolts with the built in washer with the three cut out bits, new rubber spacers, big washers and nylock nuts. But I don't know what order they go in. If you could post the pic on here mate that would be great.

Form your first picture of the engine bay I can tell that my new bulkhead is a 200TDi instead of a 300TDi I've got two threaded holes on the back of the engine bay and didn't know what they were for. I can see on yours it's where the fuel filter bolts to on the 200TDI.
Ashtree assure me all the major parts like windscreen, doors, tunnel etc will fit. It's the annoying little things like the lugs that electrical connectors slide on to are way wider and there are threaded holes missing that you really need to bolts ancillaries on to andother threaded holes that you don't need.

Anyway, cracking pace you're setting. Unbelievable. You'll probably still get your finished before mine, but I'm going to race you from now. I think it's only fair that I get this massive head start!

I told you round 3 was coming cracking work so far mate. Can't wait to see it progress.

Round 4 needs to be a 110 I think!!

subscribed!! roll on!

At up cocker, yo don't let the grass grow lol.
Is this one gonna be a fully galved build lol. Got more of your bits galved mate. There just some brackets left to do.
I'll pop em over in a couple of weeks.

JohnM70 said:

@aaronmorris it's not broken as such - just un-loved! Just picked up a set of alloys for not much money in an aim to try and gain the enthusiasm to do something.
It needs:
New drivers door in total
Lots of welding on the bulkhead
New dash in total
Electrics need looking at and sorting - fed up with having to wiggle stuff to get it to work
Rear wheel bearings
Interior sorting
Many other things I haven't found yet!

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Doesn't sound too bad, but I understand the lack of enthusiasm thing, it can be hard at times when their seems mountains to do.
Just got to stick at it, one job at a time.

cowasaki said:

If I remember rightly it was shot blasted, dipped and then modified before being galvanised.

What are you looking at for a new chassis? How much for blasting, dipping and galvanising? Clearly would be less hassle for new galvanised one. Same with bulkhead. I'm looking at the cost of both myself at the moment although there is probably a good few years left in this one.

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Yes it needs some thought before I make a decision.
I'm sure someone on here said they paid £150 to have their chassis blasted. Galv about the same?
Still it does make it significantly cheaper as it's £1400 for a new one from Richards' or the like.
My problem more than anything is transporting stuff.

JohnM70 said:

I need to clear the garage before I even think of starting to do anything on mine!

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You're not the only one, the other 2 sheds are just as bad

mick the builder said:

You might want to change that fence post before you end up moving in with the fav. neighbors ;-)

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Yes. They love me really

Bennehboy said:

Wahey! They're bloody brilliant aint they.

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Yep. Seems good so far, well better than the old snap on one I've got. Although the towbar bolts have already defeated it.

daddy2coull said:

chassis looks far better than mine, shame you're so far away lol

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It is actually very good. Time will tell as to what will happen, but it would be a shame if it went for scrap.

Al2O3 said:

Could you do me a favour, Aaron? Could you taker a close up picture of the rear tub to van side fixings. I've bought new bolts with the built in washer with the three cut out bits, new rubber spacers, big washers and nylock nuts. But I don't know what order they go in. If you could post the pic on here mate that would be great.

Form your first picture of the engine bay I can tell that my new bulkhead is a 200TDi instead of a 300TDi I've got two threaded holes on the back of the engine bay and didn't know what they were for. I can see on yours it's where the fuel filter bolts to on the 200TDI.
Ashtree assure me all the major parts like windscreen, doors, tunnel etc will fit. It's the annoying little things like the lugs that electrical connectors slide on to are way wider and there are threaded holes missing that you really need to bolts ancillaries on to andother threaded holes that you don't need.

Anyway, cracking pace you're setting. Unbelievable. You'll probably still get your finished before mine, but I'm going to race you from now. I think it's only fair that I get this massive head start!

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Cheers mate I doubt I'll be anywhere near finished by the time yours is. This build is going to take a long time I recon.
Bad news about the bulkhead Even worse that it has now been painted and is a little late to go back.
Hopefully it all works as they say it will bud
Oh and I will try and get a picture in the week, although non of mine have ever had a rubber spacer?

James_mac said:

I told you round 3 was coming cracking work so far mate. Can't wait to see it progress.

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Cheers mate I wasn't going too but when you mentioned round 3 I thought, 'ho-hum I might as well'

James_mac said:

Round 4 needs to be a 110 I think!!

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I want to build a 130 double cab pickup
Unfortunately nothing other than a 90 will fit in the garage or out of the way (in front of the garage) during the build process

IamRobbie said:

subscribed!! roll on!

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No free time like last year, so you'll have to be patient this time around.

XRIZLAX said:

At up cocker, yo don't let the grass grow lol.
Is this one gonna be a fully galved build lol. Got more of your bits galved mate. There just some brackets left to do.
I'll pop em over in a couple of weeks.

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Now then, aye the grass has been growing long enough Just been waiting for something to come up for reasonable money.
I'm hoping for a fully galved build, but something in the back of my head is already telling me it probably ain't going to happen.
Need to get cracking with lots of different thing if I am going to do it though. It'll be a challenge to say the least.
Oh and cheers again for the bits Had I thought about it, I could'a popped over when I collected this.

aaronmorris said:

Yes it needs some thought before I make a decision.
I'm sure someone on here said they paid £150 to have their chassis blasted. Galv about the same?
Still it does make it significantly cheaper as it's £1400 for a new one from Richards' or the like.
My problem more than anything is transporting stuff.

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You could buy the equipment to blast it yourself for less then the cost and then have it for as many jobs as you like

OR

You could buy a trailer

I'm not sure which option I'm going to go for but you can also add the cost of dunking it to get rid of the rest of the crap.

Is that not a rubber spacer where the arrow is pointing?

Or is it just the metal tube upstand?

where did you pick her up from aaron

aaronmorris said:

Yes it needs some thought before I make a decision.
I'm sure someone on here said they paid £150 to have their chassis blasted. Galv about the same?
Still it does make it significantly cheaper as it's £1400 for a new one from Richards' or the like.
My problem more than anything is transporting stuff.

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As I already owned a compressor I purchased a sand blasting pot and gun for £70 on ebay and intend to blast my own chassis. I found a place not far from me that will galvanise the chassis based on weight 126Kg-175Kg = £137.50 + VAT. I believe a 90 chassis is about 150Kg.

Similar to you transport is my issue, I think I will end up hiring a trailer for £40 a day. Will just have to factor this in to my cost But as you mention, all these things together are a lot cheaper than a new galv chassis.

cube1729 said:

As I already owned a compressor I purchased a sand blasting pot and gun for £70 on ebay and intend to blast my own chassis. I found a place not far from me that will galvanise the chassis based on weight 126Kg-175Kg = £137.50 + VAT. I believe a 90 chassis is about 150Kg.

Similar to you transport is my issue, I think I will end up hiring a trailer for £40 a day. Will just have to factor this in to my cost But as you mention, all these things together are a lot cheaper than a new galv chassis.

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I think you need to get them chemically dipped too. This removed the iron oxide from all of the inside sections you can't get to with the blaster.

You also need to make sure it's super clean, not just a light dusting.

cowasaki said:

You could buy the equipment to blast it yourself for less then the cost and then have it for as many jobs as you like

OR

You could buy a trailer

I'm not sure which option I'm going to go for but you can also add the cost of dunking it to get rid of the rest of the crap.

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Yes, theirs lots of if's, buts and maybe's at the moment, hopefully all will become clear withing the next few weeks.

Al2O3 said:

Is that not a rubber spacer where the arrow is pointing?

Or is it just the metal tube upstand?

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Pretty sure that is just the metal upstand mate.

cube1729 said:

As I already owned a compressor I purchased a sand blasting pot and gun for £70 on ebay and intend to blast my own chassis. I found a place not far from me that will galvanise the chassis based on weight 126Kg-175Kg = £137.50 + VAT. I believe a 90 chassis is about 150Kg.

Similar to you transport is my issue, I think I will end up hiring a trailer for £40 a day. Will just have to factor this in to my cost But as you mention, all these things together are a lot cheaper than a new galv chassis.

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Yes it needs some careful thought, although I do still think a new chassis is the best way to go.
I do like the thought of blasting myself, but my worry is that it will be painfully slow without professional equipment.
How have you found yours?
Oh and the last 90 chassis I took for scrap was 120kg.

Al2O3 said:

I think you need to get them chemically dipped too. This removed the iron oxide from all of the inside sections you can't get to with the blaster.

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This is true, although I personally don't see it all coming out, especially on the double skinned sections, so that's a worry.
But I believe the galv company acid dip prior to the galv anyhow.

aaronmorris said:

Yes, theirs lots of if's, buts and maybe's at the moment, hopefully all will become clear withing the next few weeks.



Pretty sure that is just the metal upstand mate.



Yes it needs some careful thought, although I do still think a new chassis is the best way to go.
I do like the thought of blasting myself, but my worry is that it will be painfully slow without professional equipment.
How have you found yours?
Oh and the last 90 chassis I took for scrap was 120kg.



This is true, although I personally don't see it all coming out, especially on the double skinned sections, so that's a worry.
But I believe the galv company acid dip prior to the galv anyhow.

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If you get it dipped you don't need to get it blasted as it will remove everything blasting will AND MORE

B

Jam1 said:

If you get it dipped you don't need to get it blasted as it will remove everything blasting will AND MORE

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But there might then be further damage appear that you couldn't see prior to the dipping. I agree though that if you have a decentish chassis it would be nice to save it.

You could always sell the existing chassis to help fund the cost of a shiny galvanised one. I like the thought of not having to worry about the tinworm, and a rebuild on a new chassis is much cleaner work.

aaronmorris said:

Doesn't sound too bad, but I understand the lack of enthusiasm thing, it can be hard at times when their seems mountains to do.
Just got to stick at it, one job at a time.
.

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I did pick a set of alloys up over the weekend for very little and knew someone else who has a new set of tyres for sale - BFG's - Turns out the tyres were 285's so these got turned down as I thought they were way too large for the vehicle - I actually saw them and even a 110 would have looked stupid on them!

damn you, can't get good big tyres round this way unless you're buying new

Jam1 said:

If you get it dipped you don't need to get it blasted as it will remove everything blasting will AND MORE

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Not nececerily, galv needs clean rust free steel to chemicly adhere to. Acid does remove rust if left in long enough but doesn't remove grease oil and paint, OK you can dip twice, this burns off the oil etc but then need re dipping in the acid to remove any galv first time round.
Galv plants arnt really keen to do this as it is time consuming and ****s up both galv bath and acid.
All planst will pickle in acid before dipping.