Sept '67 (1968 MY) deluxe, another Blakes Bus

[sparkywig]

Steering column with ignition block reinstalled.

Steering box, coupler and horn wire connection.

Horn wire pulled through inner column.

[sparkywig]

June 2023
Fuel tank, sender, filler neck and breather install.
Tank fitted with AN-6 outlet and new filter sock.

New sender gasket.

Tank installed with silicone rubber tank strap pads, and silicone ethanol proof filler hose.
NOS sender unit, I've had this for years stored in a drawer for this very moment.

Filler neck fitted with new gaskets.

And while we're round the back, a cleaned up gearshift rod with new greased bushes and rubbers is going in.

[sparkywig]

Handbrake lever and pivot next.
I had to cut the old one off with a recip saw a while back, as the pin was seized into the lever.

Handbrake bracket and pull arm

[sparkywig]

Mid July 2023
Front beam removal and replacement with 4.5" king and linkpin beam from a previous bus.

The old one came off after a bit of persuasion.

Check the chassis, clean, remove the old brake lines and paint.

I've got a selection of new brake pipes to replace all the existing ones.

I reused the existing pipe clips and positions, but as you can see when I offer the replacement beam up, the beam plates hit the pipe clips.So they were removed.

Beam bolted in place.

The next job is to swap the RHD steering idler for a Split Screen LHD idler.

You can just see the difference in size between the Split idler on the left and the Bay idler on the right.

[sparkywig]

I was previously running a Futbus twin PCD (205/130) front disc brake conversion with this beam, but I'm now swapping to Porsche 944 hubs, 996 calipers with a custom bracket and 1980's Carrera discs.

The bearings are exactly the same as stock Bus ones, apart from you need a Split bus inner grease seal.

[sparkywig]

Hubs fitted

[sparkywig]

I know I'm jumping around, but as I'm finding stuff in boxes I'm trying to fit them.
So walkthrough trims are next.
Gave them a good scrub and then a few coats of Diamondbrite Replenish. It's a rubber and pvc/vinyl cleaner and conditioner.

[sparkywig]

Before I can fit the rear hub carriers I'll swap out the trailing arm bushes.
Two large sockets, a short length of 10mm threaded bar and nuts and washers.

And repeat for the other side.

[sparkywig]

I took the rear hub carriers, brakes, etc off another bus as a complete unit.
They're a Creative Engineering twin PCD rear disc kit.
I wouldn't recommend it. The brakes are fine, it just took loads of modification to get them to fit and you had to supply loads of parts that weren't included.

The springplate adjusters had seized, so had to free them off. I'll replace them with new high tensile set screws and nuts at some point.

The assembly fitted with new rubber doughnuts. The good thing about these springplates is that you can can the ride height without stripping the rear hubs off the springplate.

With some wheels fitted to see how it looks. Plenty of room with the rear notches even allowing for the added weight of the transmission and engine.

[sparkywig]

September 2023
Scored a bargain on FB Marketplace, CSP lowered bus custom front shift rod for £50.

Such a shame it doesn't actually fit.

[sparkywig]

Back to the interior.
I have some '68 only(?) sunvisors, but the clips don't line up with the holes in the upper windscreen surround. They're way short.

However, if I fit some '69 onwards sunvisors, the clips line up perfectly.

Gave the gauge pod, glovebox cover and mirror a clean and a coat of the Replenish.

Then screwed the mirror in place.

[sparkywig]

October 2023
More interior, time to start fitting carpet and getting the seats in place for good.
I'm using automotive polyproplene "rot proof" carpet.

N/S tub carpeted

And seat fixed in place.

O/S tub

Having the seats installed gives me a little more room in the workshop.
Talking of room, I've had these bumpers in storage for a couple of years now so fitting the front bumper gains some space as well.

Handbrake and heater cables installed.

[sparkywig]

I ordered some stainless steel braided flexi brake hoses and they arrived this week.
Porsche 996 fronts and VW Golf Mk IV estate for the rear.

I've trimmed the stainless ties, so don't worry about that.

All the brake pipes are fitted and connected to the master cylinder.

[sparkywig]

Small issue with the brake pedal.
I've got a later dual circuit master cylinder and the push rod takes a 10mm pin, the brake pedal lever only has an 8mm hole, so I've had to drill that out.
All fitted now.

Registration documents were delivered today.

[sparkywig]

I'm doing an engine/gearbox raise to gain a little more ground clearance as I want to run a deep sump with the new stroker engine.
Trying out with a later engine support bar.

But then a mate turned up to help with the rest of the glass and vent window install.

Rear screen out, reveal cleaned and touched up.

While that's drying, on with the others.

The sliding door and opposite window just popped in.

But this one was a right pita to get in.

Rear screen back in place.

[sparkywig]

Christmas 2023
Starting the sound deadening in the rear.

Prepping, painting, sound deadening and insulating engine hatch.

I'll trim the carpet over the engine bulkhead when the Westy bed frame is fitted.

[sparkywig]

Insulation and carpet

I'm using the Dodomat 6mm foam insulation over the top of a spaceblanket type insulation. I'm not terribly impressed with the Dodomat as it shrinks and stretches when applying. It'll be covered with carpet, but I'll know it's like that underneath.

Ply flooring, with insulation glued to the underside.

[Abscate]

Whew! I’m tired after reading that. It’s indeed starting to look Bristol

I would up those spindle bolts from 8.8 to 10.9 and wouldn’t use stainless there, get good hardware from a good source, I.e. not Amazon or EBay
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[sparkywig]

I'm tired after posting it all.
Thanks for your comment.

[sparkywig]

March 2024
There's another set back.
I bought a brand new LHD late bay steering box, but it's leaking from every orifice now it's full of steering box lube.
I do have a good OE LHD late bay box, but the case is different.

New box

OE box

So it looks like I'll have to modify the chassis where it mounts.
Cardboard template made and chassis marked, out with the tools.

Not my best work, but the new steering box fits.
Primed and painted.

Pitman/drop arm fitted and torqued, new boots on draglink and steering joints.