OK time for pics!!................................
StereoSonic Music festival was a great weekend, but the weather was more like a UK festival than an Aussie one! Very different to last years perfect weather!
I'm sure this was lost on most people at the festival, but I can still remember that screen channel 4 used to display when there were no programs on!
Was an awesome weekend but I hit it a bit too hard and was sick for a few days afterwards!
OK back to 4x4's!
I had to do a load of work on a customers rare Suzuki.
The guy had had it since new and it had spent the last 30 years working on his farm and sadly had been pretty abused.
We needed to replace the fuel tank which was rusted through, but we couldn't source a Sierra ute tank, so instead we chose to adapt a normal Sierra tank to fit.
The only difference is the position of the filler neck. The normal configuration is for it to come out the end, but on the ute version its in the middle.
Ute version.
Normal version.
I cut some tube and welded it together with my new TIG.
I could then weld this to the tank to change the direction. We would then use 2 rubber 90 degree hoses to connect it back up to the filler neck mounted on the car.
Cut the end off the pipe.
Pushed the new piece in position.
That all worked well and my next job was to repair the rear axle which was leaking.
One of the leaf spring perches had been badly welded back on to the axle tube, it had flexed and cracked the axle tube.
So I removed the perch and cleaned the tube up ready for welding. TIG was the only choice for this as I wanted it to be fully air/oil tight.
Love the new TIG.
100% fusion! Cant get that with MIG or ARC!
New spring perch which was slightly bigger than the old one.
That worked well and fixed the leak. I then did a complete front axle rebuild!
I had to make a tray to allow a battery box to be strapped in place in the back of another customers Triton ute.
I fitted a suspension lift kit to a customers Hi-Lux.
I had to fit an MSN drop fridge slide (the same as mine) to a customers Hi-Lux.
It was to be mounted under the canopy in the back.
I cut and carpeted some ply for it to mount on to save drilling loads and loads of holes through the floor of the canopy.
I had to put it together.
MSN have made a few improvements since I bought mine.
Firstly they now include bolt packs to fit most of the different fridges.
They have changed the design to how I modified mine, changing the bolts for countersunk headed ones so that they dont hit and damage the fridge bag.
They have lots more fridge mounting holes so you can bolt different fridges in place. Personally I dont like relying on the fridge tie down straps, I'd much rather have the fridge bolted in place through the feet!
They've also now got the factory check list/quality control printed in English (unlike when I bought mine and it was printed in Chinese).
So it will now be much easier for them to dupe the unsuspecting customer into thinking they are buying a quality Aussie made product, after all this isnt a cheap product!
Only real clue is the name.
But all in all its a good product which is now much better thanks to the changes!
I do wonder if they saw my review/rant in this thread regarding this product when I first fitted one to my truck and the modifications I had to make.
Anyway........................
All fitted to the vehicle.
We still have the Maruti for sale as were asking good money for it after the last one I built sold on the first day I told my boss to not let this one go too cheap!
We have had lots of interest in it though!
How NOT to build and connect a snorkel!
And how not to clamp a battery in place!
I did a bit more on the work bench.
I got both shelves fitted and its now in the auto electricians fitting bay, will get some pics next year. It looked good when it was finished.
TIG welding next............................
I broke up for Christmas on Friday but the company was open on Monday and Tuesday with limited staff. My boss kindly said I could go in and have a few days practicing with my new TIG.
I've got loads of pipe to practice on.
Now I've pretty much nailed it! Apart from the root run run which I'm still struggling with a bit.
With the root run your welding from the outside of the pipe but what it looks like on the outside doesn't matter, as it gets ground out and then has 3 more runs of weld over it.
Its the inside that needs to be perfect, and obviously you cant see it until its welded and removed from the jig!
So in affect your welding blind!
Trying to get the perfect amount of penetration, no undercut, no lumps or bumps is bloody difficult! It needs to be smooth and uniform as any lumps or bumps would cause issues, particularly when used in food industries etc. So it should have a nice neat 2-3mm seam of weld all the way around.
After beveling the pipes on the lathe or in this case the oxy flame beveler and cleaning them up with the grinder, they can be tacked together in 3 places.
I use a 2.5mm bent rod as my spacer, meaning the 2.4mm filler rod should fit in the gap easily when I come to weld them.
Tacked in 3 places and on the jig ready for the root run.
Root run.
Not perfect and certainly not a pass!
Hot pass next, meaning I can crank the amps up to 120.
First of the 2 capping runs next.
Final capping run, with smaller 1.6mm filler rod and trying to blend the 2 seams of weld into one.
One finished pipe joint!
This would have passed, had it not been for the in-perfect weld on the inside! The seam of weld around the outside is spot on!
I decided I really needed a proper clamp system like at TAFE, which would allow me to position the pipe at different heights and also in the other plane, which is part of the test.
I decided I would weld it all together using the TIG, I thought it might be a lot slower than the MIG (or glue gun as a lot of TIG welders refer to them as) But it didn't really seam any slower at all and its a thousand times neater than anything I could ever do with the MIG. This really is precision welding! I love it!
Anyway.......................
back to the build.
I cut some steel, 6mm plate for the base and 50mm box for the up right.
Welded the 2 together.
Cut and drilled some more steel.
Welded some M8 nuts on.
Cut some 25mm x 3mm flat.
Ground a groove in the bolt head.
Cut and drilled some angle and a piece of flat.
Welded the 2 together.
Both sides.
Welded the nut on.
Used a couple of off cuts of angle to help me position the tube onto the piece of box.
All welded!
The arm next.
Just needed to weld the clamp to the end.
Bolt for the clamp.
All done!!!
So I can clamp the pipe jig in this plane, at different heights.
And also this plane.
I did a root run and hot pass with the pipe on the jig and it went well! Usually I find it harder in this plane than the horizontal weld but it came out good enough to be a pass! Its just difficult when your welding over head as gravity wants to pull the weld metal down!
And that was my TIG welding practice!
I need a bit more practice before I can sit and pass the exam but I'm getting very close! So hopefully early next year I will get it!
I love the new machine, its awesome!
And I love the process of TIG welding. Theres no sparks or splatter (so I can wear shorts and dont need boot guards like when using MIG) and its so precise and neat!
I can see why its used so much in aerospace and food industries!
OK..................................
Last but by no means least the star of the thread LJ!
Remember back to my Simpson Desert trip and you may remember we started the trip with those 2 huge blue space cases on the roof as there simply wasnt enough room inside LJ for all the gear for such a big trip.
Well they made LJ very top heavy and horrible to drive. Hence why they ended up on the back of the Black Mav, after Ian kindly offered to take them for us.
While driving over endless sand dunes I came up with the idea of fitting a shelf above the fridge in the back which would allow me to stack all the light weight tent, sleeping bags, pillows, chairs, clothes etc. high up to the roof and allow me to really maximize space.
So Thursday night I got LJ in the workshop to start on the project.
But first I wanted to put her on the hoist for a quick post Simmo check over.
The oil seal behind the output flange on the front of the transfercase needs replacing as its weeping.
The rear trailing arm bushes are all completely shot at the axle end, I suspect because the panhard rod is too short and constantly trying to pull the axle over.
I want to fit some of the Superior Engineering adjustable panhard rods if my boss can get me a good price. Then I could change them, or if I convert the rear to 3 link I will cut the end mount off the trailing arms all together so will just have a bush on each to replace.
OK..............................
On with the cargo shelf build!
I took some measurements, did a rough drawing with a cutting list, cut some 25mm box section and laid it out on the floor.
*The cut out section is to allow the fridge to open.
Started tacking it all together.
Tried it in place.
Fridge still opened.
Decided to reduce the size of it slightly.
Welded it back together.
After checking it fitted OK and I was happy with it I measured how high I wanted the front section to be, measured, cut, and welded it together then tacked it on.
I decided the front section was too high.
So I cut it down.
Welded it back on.
Much better!
Brackets to suspend it from the roof next!
I cut, bent and drilled some 25mm x 5mm flat. It actually took a lot of trial and error to get the angle of the bends just right.
I wanted to pick up on the captive nuts used to hold the grab handles in place.
Tacked them on.
Bolted it in place.
Worked out where the rear mounts needed to be.
Welded them on and then fully welded the rest of it up.
Cut some weld mesh.
Welded it on.
My boss kindly said I could start later so I could spend half an hour finishing it off before work and then use the 60 to take it for powder coating.
Wanted to add a slight upstand around the fridge.
I cut a piece of 4mm rod.
I wanted to weld it along the front as I was concerned that the edge of the weld mesh might damage things like sleeping bags, tents etc. being pushed up over it.
Perfect!
It was then ready for powdercoating.
Borrowed the 60 and dropped it off at the powdercoaters and he told me it was the last day of the year for powder coating!
4pm that day it was done and I picked it up! He only wanted to charge me $30 (£15), but I gave him a bit extra so he could get himself a drink, it is Christmas after all!
I found opening the side sliding windows made it a lot easier to bolt in place.
The headlining has sagged a lot (common problem on UK 70's)
So it doesn't look like theres much storage space but theres a fair bit.
I'm actually trying to source a new one over here. From what I've seen the Bunders over here had vinyl headlinings that dont seem as prone to sagging as the UK spec cloth ones. I've found one in Brisbane that a guy said I can have, but I'm hoping I might find one a bit closer.
Plenty of room for opening the fridge.
So you may be thinking why is opening the fridge so important, hes got a drop slide??
Well...........................
Because I can open the little rear door, reach in and grab a cold beer super quick!
Certainly a lot quicker than opening the swing away wheel carrier, opening both rear doors, pulling the fridge slide out and down!
I was a bit concerned that my LED strip lighting might no longer be as effective at lighting up the rear cargo area with the rack/shelf in place.
Certainly loaded up with stuff its not going to be as bright in there.
The auto electrician has said we could peal it off, move it down and stick it back on with silicon but I think I'd rather just add more LED strip along the bottom of the rack/shelf.
View from the cabin.
Has given me a useful place to mount the first aid kit, nice and high up so should stay dry, yet quick and easy to get to.
Started looking at what gear would go where.
With the sagging headlining pushed back up theres quite a bit of room.
Little spare tent first.
Then I had to go and do another job for my South African friend, the one I did all the deck and planter boxes for.
Having the shelf in certainly limits the amount of tools I can get in but I managed.
He wanted 3 steps leading down to his lower deck filling in with decking, first job was to construct a frame to take the boards.
Then decked and stained.
OK back to packing LJ..............
The double, self inflating mattress was too big to fit.
But I did manage to get both tents up there, fold up alluminium table, 2 chairs, double sleeping bag and a tarp. Should also be able to squeeze the pillows up there.
I knew LJ's radiator had been leaking a little bit since the Simpson trip.
Not much, but something that needed fixing before my week away 4wding at the start of January.
First job was to remove the rad.
Now unlike my last radiator that had a very convenient drain plug on the bottom this rad doesn't have one. Not a problem I thought, position a bucket underneath, remove the bottom rad hose and collect all the coolant. I was hoping to reuse the coolant as its expensive 5 year long life stuff!
Well it went totally to shit!
Pushed LJ outside and ended up having to hose and sweep all the sticky coolant off the garage floor.
Rad out.
Dropped it off to the rad guy in the morning and picked it up in the afternoon. It had split the solder around where the bottom hose mount, exactly where it had gone last time. So this time hes added a load of brass to reinforce it.
Repaired rad and new coolant.
Re-fitted.
I pulled the air filter out to check it and was amazed at how little dust was in there.
I blew the filter out with compressed air and virtually nothing came out!
The uni filter I had on my snorkel head did an awesome job on all the dusty roads and tracks we drove!
I'd definitely recommend one!
Happy Christmas guys.
Oh almost forgot.....................
I'm in my old local paper tonight!
They wanted to do a feature on Shropshire expats who have moved abroad, so I emailed them.
http://www.shropshirestar.com/news/2014/12/23/expats-abroad-ben-cook-in-melbourne/
