After a long month, the roll bar is finally installed.
231 DAYS TO GO !
|Picking up Gidget from JH Restoration|
|Unloading before the rain arrives|
|The new roll bar|
to pick up Gidget, and we pushed her on the trailer (the battery was out of the car due to the welding), and I tied her down while Brett and Peter vacuumed out some of the dust and swarf that had accumulated while the car had been in the workshop for the past month, and as soon as both were finished, I headed home. Just as I finshed unloading the car, and as I was pushing her into the garage, the heavens opened and we had a torrential downpour. Perfect timing 😀
I also took out the fire extinguishers and other items, all of which were completely covered in red dust. Everything has to be cleaned !
|Tent wedged in the roll bar|
An issue mentioned before is the severe lack of space in the car, especially for things like drinks, sunglasses, sun cream, etc etc. I had built an armrest pocket previously, and this worked well in Alice, but is quite small. The door panels have a stretchy cover over the single large pocket, but this really didn't work too well as it was just so big and so deep that stuff got lost in there and fell to the bottom and was not easily accessible. If you are going to spend 36 days in a car crossing half the globe, one needs to have a place for everything, and be able eo easily access anything needed quickly and easily while driving. The original door panel needed some improvement. First I went and purchased an offcut sheet of advertising sign board for $16 - This is the same material I used to build the armrest pocket and also the spare wheel cover - It is two thin layers of aluminium sandwiching a 2 mm thick layer of plastic - And is easily cut, worked, and bent, light, and also relatively strong. I also bought a can of glue and a metre of black vinyl. The thin foam, small L angle bar, and pop rivets I already had on the shelf, and set to work.
|Ashton's lost sunglasses|
down in the bottom - One of which was a sunglasses case belonging to Ashton - Covered in red dust, of course ! I let him know I had found them and he said he had been wondering where they had gone to !! I rest my case abut the door pocket being too large and deep to be easily accessible !
Having removed the original trim and panel, I unstitched the elasticated panel which ran the width of the panel, and then used the original panel as a template to trace the outline on to the alloy
|Cutting with the jog saw|
I cut out the centre section with my jigsaw, leaving a temporary solid panel (for strength) in the rear upper section. I then cut and bent into shape a 3 inch deep box section that would fit between the front and back of the panels, and used alloy L shaped bar to attach it to the main panel using pop rivets. I then cut out the hole in the panel I had left for strength, and fitted the box section in place. Trial fittings in the door showed it all seemed to work as planned.
I then took some thin foam and glued that to the outside of the panel to provide a "soft" finish, and
|Meauring the vinyl covering|
|Door panel in place|
|Upper storage pocket|
Once finished to my satisfaction, I trial fitted it all to the door - Perfect ! Now I just need to make an upper panel of vinyl that glues to the top of the door and holds everything in place.
|Bump stop full of red dirt|
|Sealed bump stop|
red dust while out in Alice ? As planned, I made up a small alloy
panel to fit over the top of the box section, then painted it, and the strengthening concertina inside, with POR15 so they wouldn't ever rust again. Once dry, I fitted the panel over the box section and used a bead of silicone to seal it in place. No dust or moisture is ever going to get into that bump stop again. I wonder why they don't make them like this in the first place ?
Next job is to move into the boot, syphon all the fuel out of the tank and then remove it so I can seal under and around the tank so we can be sure no more dust can come in. While working on the roll bar Brett noticed that the rear chassis extension bars were still slightly unsealed where they passed through the floor of the boot - This could be the major point of dust entry that we were looking for.
Rest of the photos are here :- https://photos.app.goo.gl/V9Lk1ry89cwj1teV9