THE ICEMAN restoration

With any luck it wont be long now before the Iceman will be back on his wheels! I spent the day rebuilding the passanger side front brakes, kingpin and stub axle as well as the steering relay and associated levers and rods. With that done its onto the last of the brake pipes and the flexies. Yesterday i finished off the exhaust hangers and got the last bit of fettling done on the exhaust so at least when he is started for the first time the fumes will have somewhere to go! I had a good go at undoing the pinion nut on the diff but no joy. I will have to wait until there is weight on the rear wheels again.
Effort is being focused towards getting the essential systems back in so he can be started and moved around. Apart from finishing the brakes all that has to be done is get the prop shortend and replace the diff oil seal which is totally stuffed. Cant wait to get him started, it will be a great boost! Will put up some pix tomorrow as too dark now.

Now with a bundle of joy - and a commer!
 
Just been looking through your restoration pics: Absolutely awesome - that's what you call a nut, bolt and splinter restoration! :p

The standard of your work looks to be absolutely first class and I look forward to seeing the finished article. I like the idea of a 'Bendy Commer' :D

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'I intend to live forever - so far, so good'
 
I was supposed to be getting a new concrete section of the driveway laid this weekend but the weather has been rubbish so had to fall back to plan 'B' working on the Commer... Oh well life is tough:D.
Started off by cleaning down, priming and painting the steering linkages and bars etc. ready to assemble on Sunday. You know all those socks that just vanish? well i found where they go! The same place as the vital bolt for the steering box mount[:0][:(!]Spent at least an hour turning the garage upside down looking for it but no luck[V]. In the end i had to go and get another fron the 'spare' front end i have stashed away for emergency bits. I cant understand it i always put bolts back where they came from but not this time it seems. Got the steering gear all done by lunch time and it is lovely and smooth. With any luck the van will now go roughly in the direction i want it to! With that all out of the way it was time to put on the passanger side front brake shoes and drum. At this point i discovered the drum has a nasty deep score all the way around from shoe rivits digging in[:(!][:(!] No problem i have a spare on that front end... Stepped out into the rain with a hammer and screwdriver to pop the drum off... A few quick whacks... a few more... nothing. Nada. No go... The drum was siezed sollid to the brake shoes. To help loosen it up i pried it out from the back plate with the screwdriver and hammered the wheel studs, which then dissapered into the drum. The rain had really begun to soak in now but it had become a battle of wills, a dual to the death. I decided to apply brain power and grabbed a wrench to undo the hub. After removing the rusty nail locking the nut in place[:0] it undid with surprising ease. It then became obvious that that the battle was far from over. The shoes are held in place by a retainer at the top of the backplate and this is what was now causing the hold up. No worries, more brian power... just undo the three bolts that hold it to the backplate. They turned easly, and turned, and turned[:(!][:(!]The heads of the bolts are inside the drum and free to turn[V] At this point there is about an inch gap between the drum and backplate and i can see the shoes well bonded to the inside of the drum. Then the rain got all the way through and i decided to give up and go back into the garage, then there it was. A six foot long, glinting problem solver. A demolition bar[:0][:0] Advanced on the drum with bar and wedged it in as far as it would go then with a mighty lever and 'POP' the drum sprang off and dropped with incredible precision onto my toe[B)] I was to elated to care about the pain or the rain[V]. But hang on whats this? the linings had parted company with the shoes ane were still well stuck on the inside of the drum! A little work with a hammer and chisel soon sorted that out. Once cleaned up the drum is perfect. Now all i need is a set of new shoes and it is done[^]
This week i hope to get the prop shalf shortend, i found a place that will do it and cert it as well. Then its time to get the wheels sand blasted and painted in readyness. Not to far away from a test start of the engine now. Perhaps three weeks. It would be two but have rellies comming over weekend after next. Will defo put up a video of the big moment.:)

Now with a bundle of joy - and a commer!
 
A mighty battle indeed - I hope you had your steel toe-cap flip flops on:I
Looking forward to the vid of the big moment:)

th_DCP_9918.jpg

Summer's here.....
Told you
 
If only Baz! There is still the entire interior to do. None of the original was saveable, it quite literaly fell to bits! I want to re create it as close to stock as possible but with a few modern touches for comfort. I got two small 12v electric fan heaters which will run great off a leisure setup for heating in the back so combined with proper lighting and a few toys should be better than new! If anyone has a scale drawing of the layout of the highwayman it would really help...........

Now with a bundle of joy - and a commer!
 
Deck shoes Panky[V] Steel caps got left out in the rain the day before - Doh. Toe is much better today:)

Now with a bundle of joy - and a commer!
 
Well not alot done this weekend. I put my back out on Monday and was out of action for most of the week :(
I did manage to spend some time on Saturday doing up a scale drawing of the interior layout as close as possible to the original but slightly adjusted to fit the appliences and modern living. New brake shoes and flexies are ordered and should be here tomorrow so with any luck might be able to get an evening to finish the brakes off.

Now with a bundle of joy - and a commer!
 
Spent the day pumping[:0] Bleeding the brakes! Because the whole system is new there was no fluid at all in there. It took quite a while to get it all the way through and get all the air locks out but got there in the end. It was a little more difficult as there is also a servo fitted which can be a pain to get all the air bubbles out of. But what a result:)[^] The pedal now has only about one inch travel before going solid. Also got the clutch sorted so inching closer to going for the big engine start!

Now with a bundle of joy - and a commer!
 
A bit of a frustrating day in the garage today. Started by checking the brake and clutch pedals which i am very pleased to say still had excellent firmness from yesterday so hopfully all the air is out of the system. Moved on by having a look at rhe rad. It had been installed some time ago but i then discovered it was blocked with lime scale. So today i pulled it back out and filled it up with caustic soda to clean it out. After a while it sprang a leak so will now have to go for repair. Carried on by installing the thermal switch and control for the electric fan. I decided to mount it to the top of the inner wing on the passanger side under the passanger seat. The relay was also mounted there. Next was the solinoid. It would not go in the original location as there is now a big carb in the way... I mounted it just beside the relay for the fan so had to get a longer cable to the starter and shorten the cables from the alternator but it is a much better location for access etc. The only issue now will be to find a small enough air filter to fit between the carb and the inner wing. Tommorrow i plan to get alot of the wiring into shape and tidy up the engine bay in general. With any luck the rad will be fixed for next weekend and once installed we could be near the big start!

Now with a bundle of joy - and a commer!
 
A good day in the garage today. Took another look at the hole in the rad and decided to have a go at fixing it myself. Got the trusty blow torch out and some plumbing solder i had stashed away for just such an ocasion. It took a surprising amount of heat to get the thin metal up to a high enough temperature to let the solder flow. I cant pressure test it but it looks hopeful. Even if it does still leak a bit it will be good enough for the first few test runs.
Once that was done the rad went back in no problem. Next was the electric fan on the outside (front) of the rad. Not as efficient but much easier to fit and should be well up to the job. The adjustable thermo switch was wired in with its fuse and relay. I then spent quite a while sorting the rest of the engine criticl wiring. Most of the wires were ok and just needed a tidy up and re terminating. All terminations have been crimped and soldered. After that was done the adapter for the oil pressure switch was fitted to allow a capillary tube for the oil gauge to go in. For the moment the heater feeds from the engine will be blanked off for testing. No need for a heater here really. Its 20+ degrees here in The winter so wont miss it for now. The heater itself is in mint condition but the airbox was beyond repair. I will just use it as a recirculating heater later on.
Once all that was sorted i did a general tidy and fettle of the engine bay. Just got to fit the starter moter and its cable, fill up the rad and gear box and put some oil in and we should be just about ready to go for a test start.

Now with a bundle of joy - and a commer!
 
Got all excited at the prospect of a test start and rushed off out this morning to pick up a new battery, 10 way blade type fuse box, load of 20/50 oil, diff oil, carb daspot oil and a brand new shiny rad cap to finish off with. Started off by plumbing in the heater to complete the cooling system. Once that was done a good look over to see if anything had been missed and then it was time to fill up with water. All seemed well but then i spotted a dribble from the heater hose on the water pump outlet. A quick tighten of the clamp soon sorted it. There was a small leak from the rad as i had expected. Seems my repair wasnt as good as i thought, it will do for the first tests and then i will whip it out and get it recored. After a little while a small pool of water gathered in the top of the thermostat housing and it became clear that there was a leak from the join between the housing and block. Drain everything and pull of the housing to find the engine reconditioners had not used any sealing compound, only the gasket[:(!] This might be ok on a modern motor but the faces on older motors are rarely smooth enough to do without it. GGrrrr. Any way put it all back together with cereal packet gasket and loads of sealer. After a refill all is well and the Iceman can now hold his water:I
Just as i was about to bolt on the starter something made me double check the engagement mechanism. NNNNooooooooo[:(!][:(!] The spring is broken and on taking it apart every part of it is either damaged or broken[V] Makes me wonder how it ever worked - Oh wait it didnt[B)]
As luck would have it i had a spare starter in the BOTG so after a quick clean up on it went. I even remembered to test it on a battery first[^] Next on the list i hooked up the capillary pipe from the oil gauge. At that moment the bulb in my worklight decided it had had enough of this life and expired leaving me in pitch darkness[xx(]
Cant do anythin untill tomorrow but i hope to get him started then fingers crossed:p

Now with a bundle of joy - and a commer!
 
This is it! the big day!! Going for a engine start!!!
This is the first time the engine willl have run in the last seven and a half years[:0]
The first taks of the day was to make sure iceman has all the food he needs so went in search of the funnel to get some petrol in the tank. Gave up after half an hour and made up this...[^] Worked a treat too...
2011-06-12110118.jpg


Twenty liters had the tank well over half full[:0]

In order to get the petrol through i took out the spark plugs and spun the motor over on the starter. I was surprised how quick the pump drew the petrol through. My attention was drawn to the sound of dripping from under the van. A quick look revealed the hose connection onto the carb was leaking. Easy fixed with a new jubilee clip.[^]
Next task was to top up the oil and water. The starter was sounding a bit lazy but with any luck it would have enough grunt to get things under way. Once that was all sorted i set up the dristubitor and ignition timing.
With a brand new battery in and no further excuses it was time to go for it[:0]
http://s928.photobucket.com/albums/ad125/claron/?action=view&current=P1000667.mp4
Quite promising:)
Then the starter gave up completely[:(!][V]
I decided to pull it out to see if anything could be done. One opening it up i could see the outer coils and the carbon brushes were in a poor state so i pulled the body off the original starter and inserted the shaft from the current one. Confused? Well anyway it worked and the starter now whizzez the engine over whith great gusto.
Then after a few more tweaks including resetting the timing this happend....
http://s928.photobucket.com/albums/ad125/claron/?action=view&current=video-2011-06-12-17-23-49.mp4

The grin just wont go away[^][^][^][^]:D:D:D[8D][8D][8D]

Now with a bundle of joy - and a commer!
 
As has already been said - well done that man[8D]
A quick dusting off and you'll be ready for a trip out next weekend:D

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Summer's here.....
Told you
 
Nice! 20+ in the winter? Bliss.....

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Peggy is sold ...... boo hoo
If I told you I was a pathological liar, would you believe me?
 
Thanks guys. A very uplifting day all round. I plan to take a week off work soon and spend it working on the van. I know it looks a state but apart from putting back in the prop shaft and topping up the gearbox oil he is actually ready to drive! The first thing will be to get everything cleaned up and get him out of the garage so the garage can be cleaned out in preperation for the interior work and the painting. It will be brilliant to have him back on the road again.
I took advantage of the runnung engine to test out the new brake booster and i am pleased to say it seems to be working just as expected. The pedal is rock solid after only an inch or so of movement. I hope it improves the driveability.
After i bit of a faff the lecky fan is now cutting in and out right on cue which keeps the temp needle at about half way mark.

Excellent this is my 200th post!!!

Yes it is paradise Baz, can get a bit chilly at night but generally the winter is mild and wet here. We can often get 150mm of rain in one day. Summer is hot and Very humid as we get the tropical air off the Pacific to the north (off the equator area)
Baz i hope you get another Highwayman soon (and somewhere to store it) I would be gutted to part with Iceman as he seems almost one of the family and we have so much history.

Now with a bundle of joy - and a commer!
 
Thanks Mark. By the way the interior light arrived safely. It will be going in as soon as the cab is painted!

Now with a bundle of joy - and a commer!
 
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