Front Door Steps, Filler, Primer and Paint Left To Go! Woop! Woop!

Nearly all of the welding and fabrication is complete now, just some tweaks to the front panel to dress the door gaps and the front door steps. Is now sporting a new Empi quiet pack and new heat exchangers.

Begone Skeletor, Welcome Back Smiley Fun Bus!

Both battery trays, rear corners and rear arches are complete and we have now finished the cargo area floor. Keep watching over the next couple of weeks for continuing progress.

Pressing on with the Rebuild

Smiley Fun Bus Rebuild Continues

Cargo Floor Chassis Complete!

With four of the top hat floor supports replaced and the others repaired, we have now fitted front and rear centre cross members, four new jacking points and six outriggers. You do have to tweak the outriggers and the jacking points slightly, in order for them to fit correctly. A few bits and bobs to tidy up around the inner wheel arches and the bulk head, and the floor's ready to go in. Happy days!

Rear End Rebuild

The rear of the Smiley Fun Bus was quite bad to say the least. The last six inches of the rear chassis legs were missing and about six inches on the rear vertical strengtheners, all this has to be cut out and renewed before the new battery trays, rear valance and rear corners can be put into place.

Left Hand Sill Replacement

The inner sill, the middle strengthener and the outer sill are all rotten through to the core. So we have removed it all and replaced with new! Luckily all of these panels are available to buy, so we don't have to fabricate them, however most replacement panels need some tweaking of some sort.

Fun Bus Fabrication Continued!

Inner Sills, Strengtheners and B-Pillar Replacement

Making good progress this week! We've gotta put the right hand inner sill and strengthener in, so that we can aline the inner B-Pillar and then outer, so that we can plate the bulkhead and fit the front outriggers and jacking point. It's like a giant jigsaw puzzle, you have to do one thing in order to do another!

Ongoing Chassis Rebuild On The Fun Bus

This weeks inputs so far are a stealth butt plate welded into the front to rear, left hand chassis leg. The rear centre cross member welded into place, and inner sills clamped into place ready for welding tomorrow.