Post Hurricane IRMA brake and body work!

If it doesn't fit in the others but is 60 series related, post it up.

Postby richw » Wed Aug 07, 2019 9:37 pm

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They say any good paint job is all about the preparation!
I spent $800 on sand blasting but it was money well spent.
Paint stripper works well but it is really time consuming and very messy.
The wings, inner wings, wheel carrier, doors, air cleaner...all came back naked and perfect.

Overall the job is going well but the devil is in the detail.
For example the front wings are amazingly rust free but there are two areas of concern.
One is easy to fix, that's the doubled up reinforcing plates that live under the wing mirror attachment points.
There is some rust bubbling up there, the correct fix would be to cut out that zone and weld in fresh material.
Back in the UK with my industrial mig welder this would have been a doddle.
Here in the BVI it's not so easy. The rust was really minor so that will wait for another day.
Just ospho and sealant to stop it in its tracks for now.

The other 'problem' are the seams between the panels that make up the front wings.
The 43 year old caulking is done, it shrinks, water gets in there and you have a rust sandwich!
Again, it's really minor rust that I'm looking at.
I have raked out the old caulking and have ospho'ed the seams.
Question is what product is best to use to replace the original caulking?

OK, here's an odd one.
Why on earth is there a castellated pinned nut and bolt both sides on the inner wings that attaches to the frame with a small bracket?
Seems strange to go to those lengths for a bit of bodywork that is well attached anyhow!?

Last coats of primer on tomorrow and then it's a day of sanding.
Then a day of painting.
No nasty surprises yet, I continue to be amazed how well preserved 'old blue' is.
Nothing sheared during the disassembly, nothing.
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Postby RiverPatrol » Thu Aug 08, 2019 10:29 am

You're going to amazing detail, the result will be well worth it. This Patrol will last forever!

I know the little brackets to the frame you're talking about. It always was a head scratcher. Apparently the fender needs some extra support right there. :think:
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Postby richw » Sat Aug 10, 2019 7:57 pm

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So, I only have 5 days left before heading off to Blighty for a 2 week holiday with the family to see the fossils.
All the bare metal got 3 full coats of 2 pack primer followed by 2/3 coats of 'tops' and a clear coat.
The POR 15 seam sealer pictured here worked well in the end.
It bubbled up a bit whilst curing but that may be due to our tropical conditions.
Normally I would have used a west system marine epoxy with low density filler for this job, a whole lot cheaper than POR.
Once cured the product was easy to sand, hopefully, along with the Ospho these seams will be inert for many years to come!
I do like the POR 15 products but their applications have to be understood.
The paint works great on treated rusted surfaces BUT it's crap once it hits sound coatings.
It's also crap on bare non-rusted steel, a guy on u tube showed this and I concur.
If you have gone to all the trouble of getting back to bare metal and have oshpo'ed the surface a 2 pack primer is the way to go, keep the PUR for heavily rusted bits that need saving. It works great for that.

I have some very necessary parts headed my way.
The Datsun 120 dual circuit master cylinder just got to Miami via Aussie post, the exhaust system has been shipped in bits for home assembly, new rubber boots, lights, bonnet rubbers in hand from Colombia, a 5 pack of oil filters from e bay US, if anyone needs details just ask.

Tomorrow I'll be re-assembling the soft top frame which has been sprayed in original drab green.
Anand, my Guyanese paint expert maintains it is the exact colour of all military vehicles back in Guyana!
By the way, he and a couple of his mates have been instrumental in the paint job, they love their classic vehicles!
(and they all seem to have ridiculously good skills)

I'll do my best to post the finishing strokes.
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Postby RiverPatrol » Sun Aug 11, 2019 8:03 am

Amazing work.
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Postby richw » Mon Aug 12, 2019 5:52 am

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4 days left.
I'm glad I labelled every nut washer and grommet!
There is enough of the original soft top left to use as a pattern, I also have the heavy military canvas in hand.
Checking the valve clearances was never going to be easier, it's hard to believe but they were perfect, I checked twice before I believed it.
Just a new rocker gasket required.
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Postby Esteban » Mon Aug 12, 2019 7:28 am

You've done a fantastic job, congratulations. :clap: :clap: :clap: Great tips also!
Owner of the same Patrol since 1967
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Postby richw » Thu Aug 15, 2019 8:46 pm

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Hey ho, time ran out.
Off to the UK tomorrow so I'll finish up in a couple of weeks.
The paint job is 90% completed, while I am away Anand will be spraying doors and wings, maybe fitting them too.
More to follow!
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Postby richw » Mon Sep 09, 2019 9:34 pm

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So, the job is nearly done.
Just the exhaust to finish up tomorrow and that's it.
It's all gone really well and I'm now happy that I have done all I can to preserve the vehicle without taking the body off.
That would have been nice, maybe one day I'll do it, but for now I know the tin worms are firmly 'at bay' after 6 weeks of hard work and a lot of paint.
I have to say I really don't get the current trend of enthusiasts (mainly in the VW world) who spray a clear coat over generations of old finishes, fillers and rust and call it 'patina'. In my case the 43yr old coating had failed and it all needed to go to literally stop the rot.
Maybe you get away with it in low humidity environments, that's NOT here!

I've learnt a lot about this patrol during the process and am willing to share, ask away if there's anything you see that needs an explanation.

For example, the exhaust I'm fitting came from 'Blackhorse Racing' on Amazon.
A 2" SS kit including 2 4' lengths, 2 elbows, 2 U's and 2 30 degree bends.
Couple that with a SS muffler and a modified bracket and you have a really cheap easy to fit SS exhaust system.

For chassis and box section preservation surely nothing beats injected 'Waxoyl', a hammerite product.
'Molyslip' for the gearbox and differentials, 'Lancote' or 'Copper Slip' for nuts and bolts...the list goes on.

Here's a bunch of pictures!
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Postby richw » Mon Sep 09, 2019 10:06 pm

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Irma day after.JPG
Irma day one.JPG
house gone!.JPG
2 years ago!
Notice the bark has been stripped off the trees, that was done by approx. 280mph winds mixed with sand and debris.
We feel for the Bahamas right now and have a pretty good idea what they are going through.
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Postby RiverPatrol » Tue Sep 10, 2019 9:09 am

With all the work you've done, your grandkids will still be enjoying that Patrol. :D
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Postby richw » Wed Sep 11, 2019 10:27 pm

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Finally, back on all 4's, licensed and insured.
I had the great pleasure of driving up the mountain to collect my biggest fan, daughter Rosie from school and drive home to Brewer's Bay.
The house is sorted, the patrol is sorted, just my boat to fix now!

For the technically and practically minded.
The final exhaust job resulted in 4x elbows plus a few adapters to create a single welded assembly that can drop out as one piece.
Just one chassis mounting mid silencer.

It sounds great and I have no backfiring on the overrun, just a manly gurgle.
All in all a very good day!
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Postby L60Boerne » Thu Sep 12, 2019 6:26 am

Well done. Glad to see you are recovering.
63 Soft Top
65 No Top
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Postby RiverPatrol » Thu Sep 12, 2019 8:58 am

Very awesome! This makes me want to take a trip to BVI just to see the Patrol there. 8-)
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Postby richw » Thu Sep 12, 2019 8:30 pm

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Teething problems.
The brake servo failed today.
It's not a show stopper, just back to the old Patrol days I remember that requires standing on the pedal!
If anyone has any leads on a replacement or spare parts please let me know.
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Postby richw » Thu Sep 12, 2019 9:17 pm

OK, it looks like a Datsun 240Z unit from the mid seventies.
I've found a few options on good old E bay, repair kit or adapted new unit? what a conundrum!
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