24HOURSOFNEVADA
Expedition Leader
Again, this is just awesome. I hope one day our paths may cross so I can see this in person and shake your hand.
109 Expedition rig build
- Thread starter Mercedesrover
- Start date
Mercedesrover
Explorer
Repairs to the tub begin....
The floor is shot as are the rear tail-light panels, all the x-members and the front toe-board pieces. I've gotten new x-member galvanized, new tail light pieces on the way and a fresh sheet of .080 6061-T6. Guess I know what I'm doing for the next week or so.....
The floor is shot as are the rear tail-light panels, all the x-members and the front toe-board pieces. I've gotten new x-member galvanized, new tail light pieces on the way and a fresh sheet of .080 6061-T6. Guess I know what I'm doing for the next week or so.....
TeriAnn
Explorer
Mercedesrover said:
Don't forget to put the access holes for connecting the fuel lines to the top of the fuel tanks. There are 2 holes & cover plates used so you can connect/replace hoses, electrical connections & fuel sender unit without dropping the tank.
Of course you can make the whole rear part of the floor removable for even better access.
Just a reminder
Michael Slade
Untitled
TeriAnn said:
A good reminder. I think I'd do what TeriAnn is suggesting.
Mercedesrover
Explorer
TeriAnn said:
These holes?
Michael Slade
Untitled
Mercedesrover said:
Looks like you're going stock. Nice.
You going to put in a new strip on the rear lip for the bolt holes?
Mercedesrover
Explorer
Michael Slade said:
Yeah, that will get replaced as well as that rusty x-member you see in the photo as well as everything else up front. I want to get the floor and the 5 x-members in place and locked down permanently before I cut anything else off the tub. There's not much holding it together at this point!
Michael Slade
Untitled
While you have the tub off, you might consider putting some recessed tie-downs in the corners. Way back in the day when I had my 109 I thought about actually having them made and sell them. I have an idea scribbled on a napkin if you want to see what I was imagining. You can probably pretty much guess what a pocket and a piece of bar at the corner would look like. 
ttravis5446
Adventurer
The quality of this build is amazing to me.
I Leak Oil
Expedition Leader
Crazyfish said:
That's what I did with my check straps when I took them off. Works great!
Jason T.
Mercedesrover
Explorer
TeriAnn said:Of course you would not forget this minor but important detail
Don't be so sure!
Mercedesrover
Explorer
Some more work on the tub in the past few days....
Bonded and riveted the three lateral supports and the two tabs that hold the trap-doors down. After that the floor was again bonded and riveted to the inner fender wells. In "bonded" I mean 3M #8115 panel bonding adhesive. Very strong stuff and will keep any water out of the seams. For rivets I used counter sunk aluminum rivets with coated steel mandrels from McMaster Carr.
After the floor was in for good I fabricated the "heal" board and the little floor fillers, end caps, etc. that make up the front of the tub. These will get bonded and riveted tomorrow night. After that I'll flip it over and move to the rear. I have a good used rear sill that needs to be installed along with new end panels. From there the whole underneath will get painted. The five X-members have been galvanized and won't go on until the underside is painted.
Anyway, here are some photos. One more night's worth of work tomorrow and then we're off to Alaska for a couple weeks. More photos when we return.
Bonded and riveted the three lateral supports and the two tabs that hold the trap-doors down. After that the floor was again bonded and riveted to the inner fender wells. In "bonded" I mean 3M #8115 panel bonding adhesive. Very strong stuff and will keep any water out of the seams. For rivets I used counter sunk aluminum rivets with coated steel mandrels from McMaster Carr.
After the floor was in for good I fabricated the "heal" board and the little floor fillers, end caps, etc. that make up the front of the tub. These will get bonded and riveted tomorrow night. After that I'll flip it over and move to the rear. I have a good used rear sill that needs to be installed along with new end panels. From there the whole underneath will get painted. The five X-members have been galvanized and won't go on until the underside is painted.
Anyway, here are some photos. One more night's worth of work tomorrow and then we're off to Alaska for a couple weeks. More photos when we return.