1939 Leyland TD5 [1635 DD]

2018

Norman Julian 4 Jul
: Time to get back into the rear exit door.
: I made a simple template from wood.
: I simply traced the old door shape to get the right angle.
: Then using a jigsaw I cut the shape out.
: Here you can see it is roughly the same shape.
: When you cut it out you are left with the reverse on the other piece of wood.
: Me being a little padentic got the reverse piece and checked it on the bus frame and as you can see it is out by a mile then some.
: My advice to anyone contemplating doing one of these never ever assume anything.
: These are all individually made and things wont be interchangeable.
: In this case I will make a new template using the bus frame as a guide and make the right shape.
: It will seal much better then it originally did.

Norman Julian 5th Jul
: This group is about the complete overhaul of this vintage 1939 Titan Double Decker Series 5 Leyland.
: It wont be a total restoration.
: The idea is to save most body panels and parts from the day she was decommissioned.

Norman Julian 5th July
: I'm back to the hinges again.
: I'm borrowing the hinge covers off the donated door I was given and will now make a pair of hinges to suit the TD5. These covers are another hide-d-hole for rust.

Norman Julian
: Unfortunately this door frame is suffering the same problem as the AEC did.
: There is a piece of steel plate behind the aluminium to take the 1/4" metal threads to hold the hinges on.
: The only thing is the metal plate didn't cover enough area in the frame and the aluminium frame collapsed under its on weight.
: That's why there are so many fractures.
: Scott Wilson
: That happens when trying to close it with frozen hinges. The frame bends .
: Norman Julian
: I know the way these things are put together and the hinge doesn't have to be frozen all that much to do this damage.

Norman Julian 6th July
: Hopefully the weather will be kind over the weekend so I can get these jobs done.
: The destination box will be a challenge because of the design of it.
: I thought about it and came up with a way without making too much work for myself.
: I got made up these angles which should work.
: The other panel which carries the number rolls is pretty much straight forward.
: I now have everything I need to fix the back upper end of the bus.

Norman Julian
: There is too much rust in the 90 deg.angled facing inwards on this box to repair so the whole lot will be cut out and replaced with new angle.
: It will be spot weld from underneath onto the main body of the box.
: It wont be so noticeable from underneath.

Norman Julian
: This is how it willl look except the wide part will be underneath and welded

Norman Julian 10th Jul
: I had some spare time this afternoon so I got stuck into this.
: I replaced 2 verticals, I used my powerfile and sanded out the spot welds.
: The holes are drilled and lign up well.
: Tomorrow I will start on the main box.

Norman Julian 11th jul
: Another short day but I did manage to finish this ready for its white colour.

Norman Julian 12th Jul
: First stage of this done.
: The repair of the outer lower corner.
: Patch in.
: Deliberately didn't do a pristine job.
: I did get a bit premature and bogged the corner before doing the inner strips.

David Wilson
: well done
: Norman Julian
: Thanks David!
: Norman Julian
: These 2 side rails are in position to show you what will happen.
: There will be a top and bottom as well to replace the rusted section that was cut out.

Norman Julian 14th Jul
: The inner frame is ready for welding onto the main box.
: These 2 other route number guide rails are not easy to reproduce so I thought about it and decided to cut two 1mm strips of steel to 32mm wide x 250mm long with a 6mm x 220mm long piece of steel in the middle.
: 1 strip being longer than the other so as to weld onto the frame.
: The whole lot is sandwiched together.
: This will work OK.
: These channels are only a guide for the edge of the calico or plastic number to sit in.

Norman Julian
: I had to reuse the end channel sections from the original piece I cut out.
: The metal was too thin to risk welding so they were soldered on.
: I put solder on one surface of both end pieces then clamped each channel section down to their respective ends then heated them up with a blow torch and fused the surfaces together.
: Urs Mueller
: Looks like new Norman.Well done.
: David Wilson
: I'd like 6 please
: Norman Julian
: Ha ha! The only thing is that I have seen at least 3 different shapes and sizes so far.
: Charles Shipway
: You would be relived now it is all back together Norman well done

	Home \| top
This site is hosted on Crazy Domains & Hosting Unlimited Web Hosting	Last updated July 2018	This web site may contain Copyright material If you find any problems with the site, please email the Web Editor