Norms Restoration of 1939 Leyland TD5 [1635]
2025
Body October
Norman Julian 16th Oct
I have jumped projects again, sorry.
Still thinking about the roof for 2547 so here I am doing this.
I did say I wasn't going to be this particular, but when I saw some of the areas I needed to repair I thought it
would be better to take the guard off.
I am glad that I did. The way it was put on is somewhat bizarre.
I'm not sure whether this guard is off this bus or something similar but the main brackets (pictured) have a piece
of flat thin plate coming off it and that is what is bolted to the guard.
Not what I would call a factory fit but it did the job.
I can't in good conscious repair and put it back like it was.
I also noticed the brake hose being hard and crispy, so I need to deal with that.
The other side will no doubt be the same.
This guard has its battle scarrs and rust but being over 80 years old now it ain't too bad.
I have jumped projects again, sorry.
Still thinking about the roof for 2547 so here I am doing this.
I did say I wasn't going to be this particular, but when I saw some of the areas I needed to repair I thought it
would be better to take the guard off.
I am glad that I did. The way it was put on is somewhat bizarre.
I'm not sure whether this guard is off this bus or something similar but the main brackets (pictured) have a piece
of flat thin plate coming off it and that is what is bolted to the guard.
Not what I would call a factory fit but it did the job.
I can't in good conscious repair and put it back like it was.
I also noticed the brake hose being hard and crispy, so I need to deal with that.
The other side will no doubt be the same.
This guard has its battle scarrs and rust but being over 80 years old now it ain't too bad.
Norman Julian
This patch will no doubt be hiding rust.
Drilled 2 holes to hide this piece of metal to hold the bog that is on the other side.
This patch will no doubt be hiding rust.
Drilled 2 holes to hide this piece of metal to hold the bog that is on the other side.
Norman Julian
A series of tack welds and painted over.
A series of tack welds and painted over.
Norman Julian
This is no doubt bog.
This is no doubt bog.
Norman Julian
This plate that has been bolted to the bracket has that hole (pictured) and that is what was bolted to the guard.
When the guard was still in position, from underneath I could see at least a 10mm gap between the guard and the bracket.
Hense the reason for this floating support piece.
This plate that has been bolted to the bracket has that hole (pictured) and that is what was bolted to the guard.
When the guard was still in position, from underneath I could see at least a 10mm gap between the guard and the bracket.
Hense the reason for this floating support piece.
Norman Julian
You can't see it in this shot but the hose is hard and has cracks.
You can't see it in this shot but the hose is hard and has cracks.
David Wilson
plate would have been a depot repair I suspect.
Was there any lead wipe over the patch ?
Norman Julian
David Wilson will investigate and tell you.
Nick Webster
My TS2 is like this.
It has a plate on the brackets which in turn is fastened - welded it looks like - to the underside of the wing.
It seems on the single deckers the idea was to have a completely smooth top to the wing, with no bolt head showing.
In pictures I have seen TD with coach bolt heads showing, but don't know how original that might be.
The bottom line is the double skin leads to rusting out of both wing and plate.
I have a very similar hole!
Norman Julian
Nick Webster hmm! Interesting!
Nick Webster
It is a terrible picture - a rusty bit in a rusty bit.
You can hardly pick out the inner plate so I have marked the ends with a yellow dot.
Hopefully helps
plate would have been a depot repair I suspect.
Was there any lead wipe over the patch ?
Norman Julian
David Wilson will investigate and tell you.
Nick Webster
My TS2 is like this.
It has a plate on the brackets which in turn is fastened - welded it looks like - to the underside of the wing.
It seems on the single deckers the idea was to have a completely smooth top to the wing, with no bolt head showing.
In pictures I have seen TD with coach bolt heads showing, but don't know how original that might be.
The bottom line is the double skin leads to rusting out of both wing and plate.
I have a very similar hole!
Norman Julian
Nick Webster hmm! Interesting!
Nick Webster
It is a terrible picture - a rusty bit in a rusty bit.
You can hardly pick out the inner plate so I have marked the ends with a yellow dot.
Hopefully helps
Norman Julian 18th Oct
A bit more progress today.
I wanted to remove all the add-ons from underneath.
There wI'll always be issues with metal sheeting joined on in this matter.
Needed a clean canvas so as to see what needs to be done.
After 80 odd years of battering, it's time for a rebuild.
A bit more progress today.
I wanted to remove all the add-ons from underneath.
There wI'll always be issues with metal sheeting joined on in this matter.
Needed a clean canvas so as to see what needs to be done.
After 80 odd years of battering, it's time for a rebuild.
Norman Julian
These pieces are what was under the guard.
Most weren't doing anything.
These pieces are what was under the guard.
Most weren't doing anything.
Norman Julian
This is the middle bracket after cleaning and antirust applied.
It will be painted.
This is the middle bracket after cleaning and antirust applied.
It will be painted.
Norman Julian
This guard (fender) bracket which is at the very front has had a reinforcing plate added to it as you can see.
To be honestly, I don't see the advantage of having it there.
I'm almost certainly going to cut it off.
This originally only had the 2 holes like the other bracket.
This guard (fender) bracket which is at the very front has had a reinforcing plate added to it as you can see.
To be honestly, I don't see the advantage of having it there.
I'm almost certainly going to cut it off.
This originally only had the 2 holes like the other bracket.
Norman Julian
This is how the bracket would sit.
I think I may weld bolts to the underside of the guard and build it up with spacers and washers.
This is how the bracket would sit.
I think I may weld bolts to the underside of the guard and build it up with spacers and washers.
Norman Julian
Scratching my head on this one.
Patches applied and rusted out and new patches added which are also rusted out.
Scratching my head on this one.
Patches applied and rusted out and new patches added which are also rusted out.
Norman Julian 26 Oct
My next job.
Going to do them together.
The bonnet compared to the guard is in poor condition.
It is also for me more complicated to repair because of the mixing of different materials namely aluminium and steel.
I could make a new shell out of steel, which would be easier but the curve in the frame isn't as easy as you would think.
Some point in time the flutes have been panelled up from underneath, not sure why, they have a function.
Maybe water getting in was a problem.
We will never know.
I do and did decide I wanted to keep as much as could be saved.
This can be saved but is a lot of work.
Anyway, I will start on the guard first and think a little more on the bonnet ( hood).
My next job.
Going to do them together.
The bonnet compared to the guard is in poor condition.
It is also for me more complicated to repair because of the mixing of different materials namely aluminium and steel.
I could make a new shell out of steel, which would be easier but the curve in the frame isn't as easy as you would think.
Some point in time the flutes have been panelled up from underneath, not sure why, they have a function.
Maybe water getting in was a problem.
We will never know.
I do and did decide I wanted to keep as much as could be saved.
This can be saved but is a lot of work.
Anyway, I will start on the guard first and think a little more on the bonnet ( hood).
Norman Julian 31st Oct
This wasn't an easy decision but the bonnet was too badly damaged and warped, so I now have a new bonnet
(unfluted) to go with the new side cover.
The Fluted area on the bonnet was panelled over in any case.
The same was with the TS7, so there must have been issues with them.
Unless you are my height or taller, it would be hard to see the flutes in any case.
This wasn't an easy decision but the bonnet was too badly damaged and warped, so I now have a new bonnet
(unfluted) to go with the new side cover.
The Fluted area on the bonnet was panelled over in any case.
The same was with the TS7, so there must have been issues with them.
Unless you are my height or taller, it would be hard to see the flutes in any case.
David Wilson
Norm -keep the old one as a spare.
Norm -keep the old one as a spare.
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