Mercedes 1222A.. The beginning!

[Neil]

Hi Simon , looking fantastic.

On a different note, your picture of the front end of the truck with its grills removed reminded me of something.

On the NG cab which is vey similar the cavity in the pillar on the right of your photo , accessed by the vertical elongated circular appeture, is a common location for corrosion. This is due to a build up of moisture in the cavity.

In the base of the cavity is a rubber drain plug that often gets blocked up. Many remove the plug completely.

Just a thought

Neil

 

[Sitec]

It's a good thought, and I'll have a look at ours tomorrow. Cheers.

 

[Sitec]

Good news. Both front cab cavetys are clear of blockages and the rubber outlets are working as they should. So, time for a progress update. I had not been 100% set on my home made roof hatches for a while... They'd have worked fine, but it was kust more weight and work for me building them so that they were insulated properly. The decision was made to invest in some marine Boat Deck Hatches (similar to those that Ian has used in his build). A purchase was made from Keogh's Marine up in Queensland and we now have two Vetus Magnus 627 x 627mm escape hatches. They are secure, solid, lighter than my hatches and strong!





They have inbuilt mozi screens, and also come with a simple surround. Happy days! So, the new hatches need new frames! My originals were only resting in place so were easily removed. Once out I set too and knocked up some new lightweight 50 x 50 RHS frames.

 

[Sitec]

Progress report. A few more evenings had the roof framework all done. This included a center spar up front with some threaded holes to accept a lifting jig for gearbox removal if ever needed... A past experiance changing a clutch on a 1617 in Durban



I've also managed to locate and collect some 'roof coil' meaning the roof can be all one sheet. Here's our 2.4m wide, 7m long .8mm thick roof coil.

 

[Sitec]

With all the major metalwork done, it was finally time for a thorough sand and de glue of the body framework. Even Wifetec got involved. She wasn't that impressed at being stood on top of a ladder and having to hold on while sanding though! The joys of a stepped workshop. The right side of the body is 1.2m higher up than the left!



With everything sanded, de glued and wiped down, it was time to start applying some primer. This was a pretty tedious job!



In the last few weeks I've also sheeted the lower floor and sealed the sheets in. By last night I had the whole framework primed, including the underside. That wasn't much fun!



This morning was spent pondering where to start... Now I have a painted framework, it means I can start the rebuild. Trying to work out what wires etc have to go in now, and trying to work out the best way to clad the rear locker. After a few hours thinking, and then a coffee, I managed to make a start. First up was the location of the electrical hook up, and where the switch board will be located. Here's the hook up supply line in place. Tomorrow will be spent working out the best use of the floor boards!

 

[MogsAndDogs]

That is a beautiful frame.

 

[Blowby]

That is a beautiful frame.

Got to agree, that is definitely some seriously fine work!
Love it!

 

[Sitec]

It's a solid frame... That's for sure! Today's task was working out how best to use the 6 sheets of form ply I have. This was interupted a few times by my loyal helper, who was more intent on being daft than helping...



Anyway, once the antics were over we got on with it. Radio cranked, some accurate measuring and cutting saw the shower, lobby and bathroom flored with one sheet! The second sheet has filled the center of the rear locker where the second water tank is going, the offcuts completed the bathroom and toilet sections, and formed the floor in what will become the leisure battery locker under the lobby floor... More on this later. Once happy with how it all sat, it was lifted and the voids filled with insulation. Each top face of the fraework had a bead of Bond and Seal applied, and the floor was dropped into place and weighted for gluing.



Tomorrow, I will remove the weights, seal the edges and work my way forwards. Once the floor is complete, I can build in the framework for the second raised lobby floor. This framework will also be the base of the internal dividing walls. This will give me the depth I need for the leisure batteries below, as well as acting as a step, lessening the difference between the living floor and the bedroom mattress level. It also gives me space underneath for wiring and plumbing, as well as forming a higher floor level so we can step down into the shower and bathroom. It will become clearer as I go on! Pic below for reference!

 

[Sitec]

Hi all. Quick update. After a week away in a hired motorhome (for a holiday, to see that Wifetec loves that way of life, and to see what we do and don't like), it was back into the build. With the floor finished I could map out to scale where everything is going to go. It's also much easier for Wifetec to visualise it all then, and she came up with several valid points too!



With the floor all done, it was time to start cladding the body. First up is the front as it involves no bends. Here's the bottom sheet bonded in place.



Here's the next sheet preped for positioning tomorrow morning once the lower sheet is firmly glued.

 

[ITTOG]

What are you using to create the bond.

Sent from my Pixel 5 using Tapatalk

 

[Madoxen]

Looking good and Wifetec's always come up with valid points. How was the holiday? And what did you learn

 

[Sitec]

Hi all.

So, I'm using Wurth Bond and Seal. After keying each surface, and then cleaning with thinners, I apply one decent bead on the RHS mating face and then push the sheet into place. Once held with a couple of supports below, I then try to smooth the sheet over each beam underneath, aiming to have 1mm of sealer between faces. Once cured, I'm then running another bead around the inside section of each void that will hold the insulation. Prob overkill but it guarantee's each area is water tight! Part of me says that there should be some sort of mechanical fix on each sheet, like countersunk blind rivits or similar... but the effort that was required to remove the original sheets that were bonded in the same way is telling me otherwise! Time will tell I guess!

The better half has come up with many a good suggestion! We learned that I need to finish the truck quickly so we can head out and not have to come back! We also learned that you can be really comfortable in a small space! In fact, the small shower in an insulated box was more comfortable then the large area shower at home with it's cold tiles and cool room! We were not considering a microwave... We are now. I'm glad we are going with a seperation toilet, as I hate the cassette toilet option and its necessary emptying every second day!

 

[Sitec]

Whoops! So, when you find some parts you want for your truck (later front grille and the badge out of the center of the steering wheel...) on a truck that's sat doing nothing, what do you do? You buy the whole truck! Meet donor No 2! Funnily enough it has exactly the same problem donor 1 had. A leg out of bed! It was the right oney though, so we brought it home!



In other news, cladding is well under way with the front face now clad. I'll probably tackle the roof over easter.

 

[Madoxen]

And here i thought i was the only one to keep collecting whole vehicles as spares. Still if ever u have a breakdown atleast you can have some one send you any part you need from your collection of spares.

Pass through looking good and the panals have come up well

 

[Iain_U1250]

It's a solid frame... That's for sure! Today's task was working out how best to use the 6 sheets of form ply I have. This was interupted a few times by my loyal helper, who was more intent on being daft than helping...


Anyway, once the antics were over we got on with it. Radio cranked, some accurate measuring and cutting saw the shower, lobby and bathroom flored with one sheet! The second sheet has filled the center of the rear locker where the second water tank is going, the offcuts completed the bathroom and toilet sections, and formed the floor in what will become the leisure battery locker under the lobby floor... More on this later. Once happy with how it all sat, it was lifted and the voids filled with insulation. Each top face of the fraework had a bead of Bond and Seal applied, and the floor was dropped into place and weighted for gluing.

View attachment 647784

HI Simon, if that is fibreglass batts, then I would not be using that type of insulation if I were you, fibreglass absorbs moisture, and that will cause things to rust. The insulation I bought was from Higgins Insulation in QLD, and it is a polyester type developed for use in trains and busses. It doesn't absorb moisture, is self extinguishing and doesn't give off toxic fumes.