Post by Brian M on Oct 28, 2008 13:12:56 GMT
From: Brian (Original Message) Sent: 30/04/2006 19:31
OK - so having a few days off, today I took the plunge and started to rebuild the front of my 14-2.
I had previously taken off the locker, grab handles, marker lights and cleared the interior.
Next job was to remove the screws in the awning rail, the vertical cappings, the gutters across the top and down the sides, the small canopy over the window, those under the trim on the window frame, and the trim between the bottom white panel and the ally panel - it is a lot of screws! Some came out ok but others had to be forced a bit. I found I couldn't drill the heads off, no matter what size of drill I used.
All the trim bits and awning rails were carefully put to one side for wire brushing and painting later. The window came out easily enough.
From previous prodding and poking I knew I had to replace the timbers all around the window, the panels to either side and wanted to replace the big panel under the window as mine was in a bit of a mess. But I could not see any damp below the window line from the inside.
Unfortunately I was wrong on this last point and when the big panel came off, the cross members and the curved supports for it were sodden as was a bit of the inner wall behind it. Also the curved bits either side of the ally splash panel were also wet through. So I need a few more bits of hardwood framing, an extra sheet of hardboard, and some new polystyrene insulation sheets. Not too much cash, but a bit more work.
Pictures of the work so far are in my album at:
community.webshots.com/myphotos?action=viewAllPhotos&albumID=550745591&security=apQZvX
So tomorrow I will start the timber cutting, and on Tuesday go to the repairer I met a few weeks ago for the ally panels and for him to "roll" the big one.
So for now the front is sheeted up and I hope it doesn't rain too much.
I will report on the progress as it goes along and provide measurements for other members information.
Brian Miller
From: Sylvesteruk1 Sent: 30/04/2006 20:05
Brian,
Would you like to to put Wicksteed Park rally back a few months? One thing your pictures have shown is that it is not the first time the front window has been out. The two inner panel black plastic plugs are shown at the top of the window where as they should be at the bottom.
They are always at the bottom of the window so that should the panel start to mist up on the inner surface you can remove the plugs to vent it. Aircraft cabin windows have a similar arrangement.
By the way talking of plastic windows the best product to polish them with is BRASSO just pour it on and polish using mutton cloth. Another tip from the aviation industry, we seemed to use gallons of BRASSO as it was good for cutting in paintwork--a bit kinder then TEECUT.
Anyway must not stop you as you have a fair bit to do!!!!!!!!!!!!!!!!
Mike
From: Brian Sent: 30/04/2006 21:25
Mike
I have got two car shows before Wicksteed and I need to sleep in the Safari at both of them, I reckon four good days work should see it done, but I am not taking any bets!
Good spot on the window plug - from the state of the screws holding the window in it must have been a long time ago that it was inverted.
Perhaps the factory fitters didn't care which way up they threw them in! Let's have a census to see if any other members have plugs at the top.
Brian Miller
From: Sylvesteruk1 Sent: 01/05/2006 10:09
Brian,
I made the statement about the vent plugs having looked at the two spare front side windows I have at home which have the plugs at the bottom corners. This morning having gone to see my caravan I noticed that SAFARI had already taken care of "Murphy`s Law" and the window has vent plugs fitted diagonally so it makes no difference which way up they are fitted as at least one vent will be fitted at the bottom. Of course the front side windows canot be fitted upside down so we have two vents at the bottom.
Regards
Mike
From: Brian Sent: 01/05/2006 10:36
Mike
You have be running in and out checking my window!
Mine has two plugs that were both at the top.
I now have to make a decision - on my window there is a period Caravan Club sticker, do I remove it and put the window in with the plugs down, leave it on but have it upside down, or leave my plugs at the top?
But if they are there to vent the gap, does it matter where they are in the window - they will still let air in? Just a thought.
See the quandry you have put me in!
Do we now have to add new Dating Reference? - "the mysterious moving of the anti condensation plugs"
Brian Miller
From: Sylvesteruk1 Sent: 01/05/2006 11:45
Brian,
The vent plugs are only removed should condensation form between the panels, as the moisture drops to the lower portion of the window then that is why the plug is at the bottom.
So in your case, as you do not want to spoil your caravan club sticker then you can always drill an extra hole at the lower corner, in fact both corners then yours will be unique!
Mike
From: Brian Sent: 03/05/2006 22:53
The continuing adventures of a Safari restorer!
As the Caravan Club Sticker was missing a bit, I spent a bit of time with my "garage" hair drier melting the glue to be able to remove it without damaging the window. All done.
But if I turn my window the right way up, I will have the worst part of the frame along the bottom where it is more visible instead of hidden under the visor at the top. Going to spend some more time trying to get rid of the corrosion on the ally frame and will then make the decision.
I have cleaned up the cappings and gutters ready for respraying. Also have made most of the top frame.
Went to the Caravan Repairer yesterday with the original curved front panel, expecting to have to wait a week or so, he pulled out a large offcut and started to roll the panel there and then! I told him it wasn't that urgent as I also wanted some offcuts made, for the top side panels and the thin horizontal strip along the top, as well as ordering 20 metres of the plastic window capping and black plastic inserts for the front and side trims.
Also got a square metre of a wallboard that has a very similar pattern to the original, for the upper side panels alongside the window
On their advice went for IFA sealant rather than Sikaflex. Sikaflex is an adhesive that goes hard and is a b***** to remove later. IFA remains tacky and is messy to remove but will enable cappings to be removed every 2-3 years without damage.
I had my three year old grandson with me and he was fascinated by the repairer's chickens and he chose half a dozen fresh eggs straight from the laying house!
Another tenner spent at lunchtime today on 1200 stainless screws so I will have plenty of spares. From a wholesaler rather than the hardware shop!
Ordered two new running lights and side indicators from Leisure Direct.
Will collect the extra bits of timber I have found are necessary on Friday. So this Sunday will be cutting the rest of the frame. I am going to improve the grab handle fixings with a bit of extra re-inforcement.
It looks to me as if part of the problems is the front horizontal gutter dropping its water load onto the corner bodywork, I am going to see if an adjustment is possible to make sure the water goes into the vertical gutter, or away from the bodywork. I don't really want to make a longer gutter but it may be the best solution.
More after the weekend.
Brian Miller
From: Sylvesteruk1 Sent: 04/05/2006 09:30
Brian,
Interesting comments about the caravan club sticker, I was cleaning and polishing (with good old BRASSO ) my stock of double glazed windows yesterday.
On the big front window the previous owner was a sticker fan and there were seven to remove all attached on the inside. Those with a dark colour on removal showed the inner panel to be badly crazed in that area, the crazing was on the surface inside the window and not on the sticker surface side.
So be warned sticker fans a dark coloured label obviously absorbes the heat from the sun and then crazes the plastic window.
If you are thinking of rally sticker for the "Big Safari Caravan Rally" at Wicksteed then count me out.
Finnally do not be to concerned about really polishing hard with BRASSO on the windows, it does no harm and will remove the scrathes, it even removed the etched chassis number on my windows.
Regards
Mike
From: Sylvesteruk1 Sent: 04/05/2006 19:22
Brian,
Not wishing to manopolise the web site and I do have another life besides SAFARI caravans, I thought that as I am finding out things then they should posted for other members interest
Today I decided to replace my lower door on the 13/4 as it was damaged with a better one I had salvaged from my spares. The coloured panel is easy to transfer over once the alloy strips are removed. The panel is adhered to the door outer skin with double sided tape and by tapping a 12" steel rule between the interface I was able to seperate them. The adhesive is easily removed with white spirit.
Also on the inner face of the door the sliding air vent was damaged and I was able to purchase a new identical one from our DIY store. They are manufactured by CENTURION as part number VE02P and the size is 9 1/2" x 6 1/2" at £4.20. I think the company is in Doncaster 01302 788700.
Off to Cornwall soon in the SAFARI so you will here nothing from me for a couple of weeks.
Regards
Mike
From: Brian Sent: 05/05/2006 06:28
Mike
Don't ever apologise for lots of contributions to the group - I am sure every little snippet of information is of use to someone.
Can't you divert to Essex on your holiday, and bring your tools and overalls!! If not you must find internet cafes and keep me fed with your daily bit of advice!
The new marker lights and indicators arrived from LeisureDirect this morning, but neither of them had bulbs in! Bit mean of Britax I think.
When do you actually go away? I only ask as it can give me another target to get mine finished before you get back!
Cheers
Brian
From: Sylvesteruk1 Sent: 05/05/2006 10:40
Brian,
Bulbs grow filaments glow! The filaments were packed seperatly in a poly bag in each box with mine so shoot the box packer.
Going to Cornwall May 13th to 21st on SAFARI with two 13/4`s just hope we don`t find anymore caravans.
Regards
Mike
From: Brian Sent: 05/05/2006 20:43
Now this is getting silly - if you had filaments packed separately do you have to put them inside the BULBS?
Below is the Oxford English Dictionary definition!
filament
/fillmnt/
• noun 1 a slender thread-like object or fibre. 2 a metal wire in an electric light bulb, which glows white-hot when an electric current is passed through it. 3 Botany the slender part of a stamen that supports the anther.
— DERIVATIVES filamentary adjective filamentous adjective.
— ORIGIN Latin filamentum, from filare ‘to spin’.
I still didn't get any filaments either inside or outside the bulbs!
Brian Miller
From: Sylvesteruk1 Sent: 05/05/2006 21:01
Brian,
I bought four of those BRITAX front marker lamps and the first two boxes I opened and fitted a week ago had filaments in them. Today I opened the other two boxes and the bloody bulbs are missing!
I tell what is missing on them all is the little "0" ring that fits in the recess in the lens to keep out the water. The screw is far to small a head to clamp on the rim so I have drilled and tapped the threaded anchor nut 4BA. If you do the same you will have to open the two holes in the lens with a very small round file, it would shatter if you drilled it.
Tomorrow I am gardening and I will be lifting the daffodil filaments for storage!
Regards
Mike
From: Brian Sent: 08/05/2006 07:00
Weekly Update
Had some other things to do yesterday so only had a few hours but managed to get all the rest of the framework cut ready to go in.
The panelwork is now ready for collection and will be picked up tomorrow.
We had showers yesterday and I didn't want to disturb the sheeting to trial fit the frame as I want to put the wood and panelling in in one go.
If we can all pray for good weather on Thursday (my day off) I can make some real progress.
Brian Mille
From: Jan_Gareth1 Sent: 15/05/2006 17:31
Hi Brian
You are very brave to restore the Safari yourself.
We were going to but decided that Gareths skills were perhaps not quite as refined as needed,we also have no where undercover.
So after a year of searching we have found a caravan repair guy to do the job .He is having dificulties getting parts though and I wondered where you were getting the inside wall (the bit that looks like wallpaper)from as it looks very similar to ours. Do you have a supplier?
The guys son also helps in the business and when he saw the Safari he was very impressed and she is not even looking her best.
I am keeping a close watch on your rebuild and when we finally get together for one of the Safari meets we can compare notes.
From: Brian Sent: 15/05/2006 20:26
The repairer who is helping me find the parts, had half a shed full of wall board off-cuts so armed with a bit of wall paper I had removed from the wall of mine, we found a metre square piece that was close but not an exact match.
He says there are, by his reckoning, over 600 different wall boards available. He is away on holiday at the moment but when he gets back I will ask him who still makes it, and perhaps with a sample we might be able to identify the best possible match.
I only need to replace the verticals alongside the front window that are largely covered by the curtains and so I am not too concerned that is doesn't exactly match. If I did find the exact match, it would not be too hard to replace it at a later date.
Brian Miller
From: Jan_Gareth1 Sent: 16/05/2006 14:04
Thanks Brian
I am still waiting for the guy to phone me back and let me know if he has been able to find any.
He has someone going to Hull this week (I think maybe today Tues) for other parts and he is going to check for the board too.
I am hoping to have a good match and have her back for the Scotland Safari Session(meet)
Keep me up to date with your work.
Jan
From: Brian Sent: 21/05/2006 08:53
In case any of you were wondering why there have been no more progress reports the answer is simple - there hasn't been any more progress.
I work every Saturday, but have Thursdays off, and guess what? Each Thursday and Sunday it has either been raining or threatening to rain. As my sheeting is waterproof and no water is getting in, in spite of the driving rain and wind we have been suffering in the South East, I don't want to disturb it until I can be sure of getting the whole front back in the day.
So I spend Wednesdays and Saturdays checking the weather forecast, set my alarm for 06.30 and wake up to check the clouds and for the last two weeks have decided not to risk it.
All the wood is cut, the aluminium shaped and cut to approximate sizes, the cappings and gutters have been painted, and my workshop is full of hardboard, polystyrene sheets, bits of the Safari, all waiting for a sunny day for it all to go back on.
From Wednesday this week I have a whole week off work and surely my luck with the weather must change. The next person who says the rain is good for the garden is going to end up eating the old panels as a penance!
I will keep you all posted.
Brian MIller
From: Brian Sent: 01/06/2006 07:44
Progress Report
Well in my 10 days off I only had two rain free days.
On Sunday I managed to fit the lower woodwork. The drop to the front window may make our Safaris more stylish but it means there is a horrible jigsaw of little bits of shaped wood to the front corner sides. I managed to replicate all of them, but it took longer then expected.
I ran into a snag with the wall board at the foot of the beds. The offcut I got was too short to reach from one side to the other, so I had to cut along the line of the chest of drawers and replace each side making a three piece section.
As I was working from 08.00 to 21.00, I was tired when I came in and downloaded the pictures I had taken, rotated some and resized all of them in Photoshop, after deleting them from the camera card and found I hadn't copied them to the PC! What a twit.
So yesterday I started by taking pictures of the work so far, but it means some of the detailed pictures of the work being done are missing. I made good progress, getting the top wood work installed, glued and screwed. It seems by Safari is not quite square and whilst the window fits perfectly, the right hand side bows out by less that half an inch so the outer vertical has had to be set at a slight angle. You can see this in the pictures but with the ally cladding it is hardly noticeable.
I have trial fitted all the panels but have not started fixing them as I wanted to do all the sealant in one go. The big curved panel is not going to be easy to fix. The roll section is not quite right but my hope is that when fixed at the bottom I can force it to the correct shape.
When I started I estimated 4 days work, but reckon 5 days should see it done.
There are 18 more pictures in the album at
community.webshots.com/myphotos?action=viewAllPhotos&albumID=550745591&security=apQZvX
More to come.
Brian Miller
Progress Report
ITS FINISHED!!
and to prove it there are more pictures at
community.webshots.com/myphotos?action=viewAllPhotos&albumID=550745591&security=apQZvX
but if I never see any more non setting sealant I will be a happy bunny - the d**n stuff gets everywhere. Every tool in my garage is covered in it, and I have been washing in white spirit every time I went near the Safari.
The curved front panel is a real b****** to work with if you are doing the job single handed. You need a helper to watch one end while you fix the other. Anyway got it looking about right and fixed at the bottom and sides. I cut out the hole for the window, fitted the two side panels and dry fitted the window - perfect. Decided I needed a lot of sealant and applied it liberally all round the window, and guess what - it wouldn't go in the hole. Another job for which you need a helper or eight foot long arms.
After two hours fixing it in different places it popped in but caused a small deformity to the big front panel but not serious enough to warrant taking it all apart again. The joint cappings were easy to fix but yet more sealant to clear up afterwards.
I was about to fit the grab a handles and realised that they would further deform the front panel so I raided my parts store for a pair of rear handles which could fit on the flat area of the side panels alongside the window.
I have not put the window visor back yet as I want to respray it first.
I have got most of the inside refitted but still need to panel the sides. But I have a car show tomorrow and can hide the gaps with the curtains!
All in all I am pleased with the results, got rid of a lot of rotten damp wood and made my Safari look a lot smarter.
I predicted 4 or 5 days and took 6 full days. Total cost was just over £170.00.
Now I need to paint the roof before Wicksteed!
Brian Miller
OK - so having a few days off, today I took the plunge and started to rebuild the front of my 14-2.
I had previously taken off the locker, grab handles, marker lights and cleared the interior.
Next job was to remove the screws in the awning rail, the vertical cappings, the gutters across the top and down the sides, the small canopy over the window, those under the trim on the window frame, and the trim between the bottom white panel and the ally panel - it is a lot of screws! Some came out ok but others had to be forced a bit. I found I couldn't drill the heads off, no matter what size of drill I used.
All the trim bits and awning rails were carefully put to one side for wire brushing and painting later. The window came out easily enough.
From previous prodding and poking I knew I had to replace the timbers all around the window, the panels to either side and wanted to replace the big panel under the window as mine was in a bit of a mess. But I could not see any damp below the window line from the inside.
Unfortunately I was wrong on this last point and when the big panel came off, the cross members and the curved supports for it were sodden as was a bit of the inner wall behind it. Also the curved bits either side of the ally splash panel were also wet through. So I need a few more bits of hardwood framing, an extra sheet of hardboard, and some new polystyrene insulation sheets. Not too much cash, but a bit more work.
Pictures of the work so far are in my album at:
community.webshots.com/myphotos?action=viewAllPhotos&albumID=550745591&security=apQZvX
So tomorrow I will start the timber cutting, and on Tuesday go to the repairer I met a few weeks ago for the ally panels and for him to "roll" the big one.
So for now the front is sheeted up and I hope it doesn't rain too much.
I will report on the progress as it goes along and provide measurements for other members information.
Brian Miller
From: Sylvesteruk1 Sent: 30/04/2006 20:05
Brian,
Would you like to to put Wicksteed Park rally back a few months? One thing your pictures have shown is that it is not the first time the front window has been out. The two inner panel black plastic plugs are shown at the top of the window where as they should be at the bottom.
They are always at the bottom of the window so that should the panel start to mist up on the inner surface you can remove the plugs to vent it. Aircraft cabin windows have a similar arrangement.
By the way talking of plastic windows the best product to polish them with is BRASSO just pour it on and polish using mutton cloth. Another tip from the aviation industry, we seemed to use gallons of BRASSO as it was good for cutting in paintwork--a bit kinder then TEECUT.
Anyway must not stop you as you have a fair bit to do!!!!!!!!!!!!!!!!
Mike
From: Brian Sent: 30/04/2006 21:25
Mike
I have got two car shows before Wicksteed and I need to sleep in the Safari at both of them, I reckon four good days work should see it done, but I am not taking any bets!
Good spot on the window plug - from the state of the screws holding the window in it must have been a long time ago that it was inverted.
Perhaps the factory fitters didn't care which way up they threw them in! Let's have a census to see if any other members have plugs at the top.
Brian Miller
From: Sylvesteruk1 Sent: 01/05/2006 10:09
Brian,
I made the statement about the vent plugs having looked at the two spare front side windows I have at home which have the plugs at the bottom corners. This morning having gone to see my caravan I noticed that SAFARI had already taken care of "Murphy`s Law" and the window has vent plugs fitted diagonally so it makes no difference which way up they are fitted as at least one vent will be fitted at the bottom. Of course the front side windows canot be fitted upside down so we have two vents at the bottom.
Regards
Mike
From: Brian Sent: 01/05/2006 10:36
Mike
You have be running in and out checking my window!
Mine has two plugs that were both at the top.
I now have to make a decision - on my window there is a period Caravan Club sticker, do I remove it and put the window in with the plugs down, leave it on but have it upside down, or leave my plugs at the top?
But if they are there to vent the gap, does it matter where they are in the window - they will still let air in? Just a thought.
See the quandry you have put me in!
Do we now have to add new Dating Reference? - "the mysterious moving of the anti condensation plugs"
Brian Miller
From: Sylvesteruk1 Sent: 01/05/2006 11:45
Brian,
The vent plugs are only removed should condensation form between the panels, as the moisture drops to the lower portion of the window then that is why the plug is at the bottom.
So in your case, as you do not want to spoil your caravan club sticker then you can always drill an extra hole at the lower corner, in fact both corners then yours will be unique!
Mike
From: Brian Sent: 03/05/2006 22:53
The continuing adventures of a Safari restorer!
As the Caravan Club Sticker was missing a bit, I spent a bit of time with my "garage" hair drier melting the glue to be able to remove it without damaging the window. All done.
But if I turn my window the right way up, I will have the worst part of the frame along the bottom where it is more visible instead of hidden under the visor at the top. Going to spend some more time trying to get rid of the corrosion on the ally frame and will then make the decision.
I have cleaned up the cappings and gutters ready for respraying. Also have made most of the top frame.
Went to the Caravan Repairer yesterday with the original curved front panel, expecting to have to wait a week or so, he pulled out a large offcut and started to roll the panel there and then! I told him it wasn't that urgent as I also wanted some offcuts made, for the top side panels and the thin horizontal strip along the top, as well as ordering 20 metres of the plastic window capping and black plastic inserts for the front and side trims.
Also got a square metre of a wallboard that has a very similar pattern to the original, for the upper side panels alongside the window
On their advice went for IFA sealant rather than Sikaflex. Sikaflex is an adhesive that goes hard and is a b***** to remove later. IFA remains tacky and is messy to remove but will enable cappings to be removed every 2-3 years without damage.
I had my three year old grandson with me and he was fascinated by the repairer's chickens and he chose half a dozen fresh eggs straight from the laying house!
Another tenner spent at lunchtime today on 1200 stainless screws so I will have plenty of spares. From a wholesaler rather than the hardware shop!
Ordered two new running lights and side indicators from Leisure Direct.
Will collect the extra bits of timber I have found are necessary on Friday. So this Sunday will be cutting the rest of the frame. I am going to improve the grab handle fixings with a bit of extra re-inforcement.
It looks to me as if part of the problems is the front horizontal gutter dropping its water load onto the corner bodywork, I am going to see if an adjustment is possible to make sure the water goes into the vertical gutter, or away from the bodywork. I don't really want to make a longer gutter but it may be the best solution.
More after the weekend.
Brian Miller
From: Sylvesteruk1 Sent: 04/05/2006 09:30
Brian,
Interesting comments about the caravan club sticker, I was cleaning and polishing (with good old BRASSO ) my stock of double glazed windows yesterday.
On the big front window the previous owner was a sticker fan and there were seven to remove all attached on the inside. Those with a dark colour on removal showed the inner panel to be badly crazed in that area, the crazing was on the surface inside the window and not on the sticker surface side.
So be warned sticker fans a dark coloured label obviously absorbes the heat from the sun and then crazes the plastic window.
If you are thinking of rally sticker for the "Big Safari Caravan Rally" at Wicksteed then count me out.
Finnally do not be to concerned about really polishing hard with BRASSO on the windows, it does no harm and will remove the scrathes, it even removed the etched chassis number on my windows.
Regards
Mike
From: Sylvesteruk1 Sent: 04/05/2006 19:22
Brian,
Not wishing to manopolise the web site and I do have another life besides SAFARI caravans, I thought that as I am finding out things then they should posted for other members interest
Today I decided to replace my lower door on the 13/4 as it was damaged with a better one I had salvaged from my spares. The coloured panel is easy to transfer over once the alloy strips are removed. The panel is adhered to the door outer skin with double sided tape and by tapping a 12" steel rule between the interface I was able to seperate them. The adhesive is easily removed with white spirit.
Also on the inner face of the door the sliding air vent was damaged and I was able to purchase a new identical one from our DIY store. They are manufactured by CENTURION as part number VE02P and the size is 9 1/2" x 6 1/2" at £4.20. I think the company is in Doncaster 01302 788700.
Off to Cornwall soon in the SAFARI so you will here nothing from me for a couple of weeks.
Regards
Mike
From: Brian Sent: 05/05/2006 06:28
Mike
Don't ever apologise for lots of contributions to the group - I am sure every little snippet of information is of use to someone.
Can't you divert to Essex on your holiday, and bring your tools and overalls!! If not you must find internet cafes and keep me fed with your daily bit of advice!
The new marker lights and indicators arrived from LeisureDirect this morning, but neither of them had bulbs in! Bit mean of Britax I think.
When do you actually go away? I only ask as it can give me another target to get mine finished before you get back!
Cheers
Brian
From: Sylvesteruk1 Sent: 05/05/2006 10:40
Brian,
Bulbs grow filaments glow! The filaments were packed seperatly in a poly bag in each box with mine so shoot the box packer.
Going to Cornwall May 13th to 21st on SAFARI with two 13/4`s just hope we don`t find anymore caravans.
Regards
Mike
From: Brian Sent: 05/05/2006 20:43
Now this is getting silly - if you had filaments packed separately do you have to put them inside the BULBS?
Below is the Oxford English Dictionary definition!
filament
/fillmnt/
• noun 1 a slender thread-like object or fibre. 2 a metal wire in an electric light bulb, which glows white-hot when an electric current is passed through it. 3 Botany the slender part of a stamen that supports the anther.
— DERIVATIVES filamentary adjective filamentous adjective.
— ORIGIN Latin filamentum, from filare ‘to spin’.
I still didn't get any filaments either inside or outside the bulbs!
Brian Miller
From: Sylvesteruk1 Sent: 05/05/2006 21:01
Brian,
I bought four of those BRITAX front marker lamps and the first two boxes I opened and fitted a week ago had filaments in them. Today I opened the other two boxes and the bloody bulbs are missing!
I tell what is missing on them all is the little "0" ring that fits in the recess in the lens to keep out the water. The screw is far to small a head to clamp on the rim so I have drilled and tapped the threaded anchor nut 4BA. If you do the same you will have to open the two holes in the lens with a very small round file, it would shatter if you drilled it.
Tomorrow I am gardening and I will be lifting the daffodil filaments for storage!
Regards
Mike
From: Brian Sent: 08/05/2006 07:00
Weekly Update
Had some other things to do yesterday so only had a few hours but managed to get all the rest of the framework cut ready to go in.
The panelwork is now ready for collection and will be picked up tomorrow.
We had showers yesterday and I didn't want to disturb the sheeting to trial fit the frame as I want to put the wood and panelling in in one go.
If we can all pray for good weather on Thursday (my day off) I can make some real progress.
Brian Mille
From: Jan_Gareth1 Sent: 15/05/2006 17:31
Hi Brian
You are very brave to restore the Safari yourself.
We were going to but decided that Gareths skills were perhaps not quite as refined as needed,we also have no where undercover.
So after a year of searching we have found a caravan repair guy to do the job .He is having dificulties getting parts though and I wondered where you were getting the inside wall (the bit that looks like wallpaper)from as it looks very similar to ours. Do you have a supplier?
The guys son also helps in the business and when he saw the Safari he was very impressed and she is not even looking her best.
I am keeping a close watch on your rebuild and when we finally get together for one of the Safari meets we can compare notes.
From: Brian Sent: 15/05/2006 20:26
The repairer who is helping me find the parts, had half a shed full of wall board off-cuts so armed with a bit of wall paper I had removed from the wall of mine, we found a metre square piece that was close but not an exact match.
He says there are, by his reckoning, over 600 different wall boards available. He is away on holiday at the moment but when he gets back I will ask him who still makes it, and perhaps with a sample we might be able to identify the best possible match.
I only need to replace the verticals alongside the front window that are largely covered by the curtains and so I am not too concerned that is doesn't exactly match. If I did find the exact match, it would not be too hard to replace it at a later date.
Brian Miller
From: Jan_Gareth1 Sent: 16/05/2006 14:04
Thanks Brian
I am still waiting for the guy to phone me back and let me know if he has been able to find any.
He has someone going to Hull this week (I think maybe today Tues) for other parts and he is going to check for the board too.
I am hoping to have a good match and have her back for the Scotland Safari Session(meet)
Keep me up to date with your work.
Jan
From: Brian Sent: 21/05/2006 08:53
In case any of you were wondering why there have been no more progress reports the answer is simple - there hasn't been any more progress.
I work every Saturday, but have Thursdays off, and guess what? Each Thursday and Sunday it has either been raining or threatening to rain. As my sheeting is waterproof and no water is getting in, in spite of the driving rain and wind we have been suffering in the South East, I don't want to disturb it until I can be sure of getting the whole front back in the day.
So I spend Wednesdays and Saturdays checking the weather forecast, set my alarm for 06.30 and wake up to check the clouds and for the last two weeks have decided not to risk it.
All the wood is cut, the aluminium shaped and cut to approximate sizes, the cappings and gutters have been painted, and my workshop is full of hardboard, polystyrene sheets, bits of the Safari, all waiting for a sunny day for it all to go back on.
From Wednesday this week I have a whole week off work and surely my luck with the weather must change. The next person who says the rain is good for the garden is going to end up eating the old panels as a penance!
I will keep you all posted.
Brian MIller
From: Brian Sent: 01/06/2006 07:44
Progress Report
Well in my 10 days off I only had two rain free days.
On Sunday I managed to fit the lower woodwork. The drop to the front window may make our Safaris more stylish but it means there is a horrible jigsaw of little bits of shaped wood to the front corner sides. I managed to replicate all of them, but it took longer then expected.
I ran into a snag with the wall board at the foot of the beds. The offcut I got was too short to reach from one side to the other, so I had to cut along the line of the chest of drawers and replace each side making a three piece section.
As I was working from 08.00 to 21.00, I was tired when I came in and downloaded the pictures I had taken, rotated some and resized all of them in Photoshop, after deleting them from the camera card and found I hadn't copied them to the PC! What a twit.
So yesterday I started by taking pictures of the work so far, but it means some of the detailed pictures of the work being done are missing. I made good progress, getting the top wood work installed, glued and screwed. It seems by Safari is not quite square and whilst the window fits perfectly, the right hand side bows out by less that half an inch so the outer vertical has had to be set at a slight angle. You can see this in the pictures but with the ally cladding it is hardly noticeable.
I have trial fitted all the panels but have not started fixing them as I wanted to do all the sealant in one go. The big curved panel is not going to be easy to fix. The roll section is not quite right but my hope is that when fixed at the bottom I can force it to the correct shape.
When I started I estimated 4 days work, but reckon 5 days should see it done.
There are 18 more pictures in the album at
community.webshots.com/myphotos?action=viewAllPhotos&albumID=550745591&security=apQZvX
More to come.
Brian Miller
Progress Report
ITS FINISHED!!
and to prove it there are more pictures at
community.webshots.com/myphotos?action=viewAllPhotos&albumID=550745591&security=apQZvX
but if I never see any more non setting sealant I will be a happy bunny - the d**n stuff gets everywhere. Every tool in my garage is covered in it, and I have been washing in white spirit every time I went near the Safari.
The curved front panel is a real b****** to work with if you are doing the job single handed. You need a helper to watch one end while you fix the other. Anyway got it looking about right and fixed at the bottom and sides. I cut out the hole for the window, fitted the two side panels and dry fitted the window - perfect. Decided I needed a lot of sealant and applied it liberally all round the window, and guess what - it wouldn't go in the hole. Another job for which you need a helper or eight foot long arms.
After two hours fixing it in different places it popped in but caused a small deformity to the big front panel but not serious enough to warrant taking it all apart again. The joint cappings were easy to fix but yet more sealant to clear up afterwards.
I was about to fit the grab a handles and realised that they would further deform the front panel so I raided my parts store for a pair of rear handles which could fit on the flat area of the side panels alongside the window.
I have not put the window visor back yet as I want to respray it first.
I have got most of the inside refitted but still need to panel the sides. But I have a car show tomorrow and can hide the gaps with the curtains!
All in all I am pleased with the results, got rid of a lot of rotten damp wood and made my Safari look a lot smarter.
I predicted 4 or 5 days and took 6 full days. Total cost was just over £170.00.
Now I need to paint the roof before Wicksteed!
Brian Miller