1939 Leyland TD5 [1635 DD]

Ben Summers
Looking good, Norman! I wish I had had a shed that big when I owned 2775.
Ben Summers
Did you have the shed built for you, or was it already on the property?
Norman Julian
Ben Summers I got it built
Ben Summers
Thanks Norman.
How must did it cost?
Norman Julian
Ben Summers about 88k with the concrete and power.
Over 100k now!
Ben Summers
Wow!
I won't be buying a bus for some time, though I'll keep those figures in mind.
Norman Julian
Ben Summers hey I think 25k for a d/decker bus that you don't have to touch is a bargain don't you!
Ben Summers
Indeed Norman!
Ben Summers
I will be sticking to buses from the seventies and eighties.
Ben Summers
Like Leopard Mk2s and O305 Mercs.
Avsie Paul
Looking great 👍
Phil Steele
Avsie Paul Looking good 👍
David Reynolds
Looks fantaastic

Norman Julian 17 Apr
Well the staircase is out and now that I can see it properly I have a better understanding of how it was put together.
There is quite a bit that has to be replaced and some has to be repaired.
I will put a few more reinforcing parts on the external frame to hold the sides of the treads better.
You can see that there was a fire under the staircase area because of the scorched timber treads.
The very top step which is part of the top floor will have to be inspected to see if it needs work done on it.
This was supposed to be just a quick check of things and makeover.
How silly of me.
You can also see a new panel around the number box.
I won't tell you about the headaches I had with that.
I will leave it for another time.

Gregor Neil Robertson
Terrific work Norman.
Structure looks too flimsy.
When I was young and crowds of us lads used these stairs I can’t imagine how the whole structure didn’t collapse.
We were so rough and disrespectful.
Steve Hartnell
Gregor Neil Robertson Light and strong.
Avsie Paul
Great to see how they are constructed under the skin.

Norman Julian 19th Apr
Well this is all I'm taking off for now till I catch up.
I spent some time cleaning off the frame work with a wire brush and a scraper to start with.
Then the vacuum cleaner in combo with the blower on the compressor.
There is so much dirt in the box section of the frame that the vac.
gets a lot but not all and I'm covered in it.
There is also the very top step box that as you can see is rotted out.
It has been repaired at some stage as you can see with the angled pieces that have been pop riveted on.
This has to be structurally sound or a person is likely to go through it when climbing the steps.
Originally It would have been covered with wood and then bitumen paint covered then with malthoid but that won't stop this area from rotting eventually.

Lee Hall
The back of my aec ceiling panel is exactly the same and I was also wondering how it had happened.
Thought the frame might have been rotten and twisted it but the frame is like new.
Your idea about heat could make sense as the guy I bought it from had his house burn down and the bus was parked right next to it.
Another mystery on the old bus's 🤔 great job your doing mate I get plenty of inspiration from your posts

Stuart Brown Difference between functional repair and careful restoration perhaps?

Avsie Paul
Proper job..

Norman Julian 20 Apr
Well my theory about heat with the roof panel appears to be correct.
After nearly an hour taking nuts and bolts and dozens of screws off the roof panel this is what was found.
The timber is scorched.
It must have been a serious spreading fire to do this and also under the staircase or maybe they could have been at different times.
Just don't know.
The first roof panel entering the saloon down stairs is also a little warped and by pulling down the roof a bit I can see the timber there is a little affected as well.
I don't begin to even understand how the timber can burn like this and the aluminium not melting a little but it must have been hot.
Anyway, the frame around the staircase has been rust converted and tomorrow will be ready to prime.

Robert Stevenson
Is it possible that the fire started in the area above the sheeting?
An electrical fault or someone deliberately lighting it?
I attended a fire years ago where it was spreading slowly along a timber in a shed.
Fire wasn't visible from outside but the tins of dog food on top of the timber exploded one at a time as the fire progressed.
Just a theory. But could explain the sheet not actually melting.
Sorry for the long post.
Norman Julian
Robert Stevenson wouldn't have a clue.
All I know is that this could have ended up being a lot worse.

Norman Julian 25 Apr
Time to look at this.
To be honest when you first look at the way this staircase is made and the way it goes together it is a little bit overwhelming but after breaking it down it is even worse.
LOL.
The bus has curves everything.
It tapers in on the side and on the back wall and on top of that you have a sloping floor.
The frame of this staircase has to be shaped to cater for all that.
There isn't too many positive things to say about the existing frame and metal verticles of the stair treads.
Each verticle of the step on the outside is slightly tapered from top to bottom inwards and each one narrows down a little on the top set of steps.
Anyway, this is a real challenge.
The easy part is the very top box section.

Norman Julian 25 Apr

Norman Julian
This new cross piece has flat 6mm reinforcing brackets on the back that can be threaded for the new staircase when made.

Norman Julian
This is what is left of a foot.
The frame section it sits on is corroded that much that it has collapsed and now I'm not sure of its original length.

Norman Julian
These heavy brackets are what bolts onto the horizontal piece that is on the right hand side bulkhead wall that holds the top part of the staircase.
The next shot shows the piece that was on the wall.
I replaced it for a new one.

Norman Julian 29th Apr
The other thing I picked up today was this new upper step frame.
I'm using zincaneal in these areas because there is painting required.
The original material used was 1.2mm thick but I'm using 1.5mm.
Just a little cutting and welding to do.

Pablo E. Laredo
1.2mm would be 1/16" not a size that'd be kept these days.
Norman Julian
Pablo E. Laredo I used slightly thicker material on the AEC frog.
Pablo E. Laredo
That don't hurt, wouldn't be too many "anoraks" running around with vernier calipers 😉

Norman Julian 30th Apr
I'm thinking that all things being equal that this part of this particular job is the easiest.
Anyway, it is a few millimetres larger in some areas to make it fit a little better but in reality a few more could have been better.
I welded the walls to returns if the floor by plug welding.
This way the welds are hidden by timber flooring and can't see any welds in the bottom saloon.
I am happy with it.
At this stage it is just sitting in position.
I want to start the stairwell first to see if I have to make adjustments.

Charles Shipway
Norman Looks like it’s going well for you ?