Mercedes vario 814 self build bus to FLT palace

[gus-lopez]

Tack a 'u' bolt on the inside middleish & use one of the inside roof supports to lift it with a thin rope or cord.

in fact tack a U bolt & a big bolt below it so if lifting it your self inside alone you have something to grab to help it up whilst tieing off. long a s you get it nearly there then you could screw it to get exact

 

[Mikey RV]

What’s your mum doing she can’t be busy all the time.

 

[eurajohn]

Not criticizing but when doing plug welds (or whatever you choose to call them) the base area needs to have the paint removed to allow a proper weld, not just the hole in the plate.

 

[Bonsaiman]

Not a welder or a van converter but could you drill a hole in the van window area, centralish to where the plate is going, tack weld a bolt through the hole, hang the plate on the bolt so it can pivot so you can get it level and then tack in place

Does that make sense?

 

[Northernraider]

Not criticizing but when doing plug welds (or whatever you choose to call them) the base area needs to have the paint removed to allow a proper weld, not just the hole in the plate.

It already is ...the paint is all off and bare metal.

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[Northernraider]

Panic over i went and asked one of my neighbours ...who was happy to lend a hand for 10 minutes so i have it up in place and a few puddle welds in to hold it for now and ill finish it off at my leisure tomorrow. That was the biggest panel so at least its up now ...but the neighbor scot has said hes happy to help with the others if i need it

Looks quite good though it should look the part when finished.
Theres some rotten bits that ill need to cut out from around where the window was but ill get them from the inside when im adding welds to that ...

 

[Lenny HB]

Are you going to weld a couple of uprights on that panel to stop any flexing?

 

[Eggs]

Are you going to weld a couple of uprights on that panel to stop any flexing?

I was just about to type similar.

 

[Manic]

Are you going to weld a couple of uprights on that panel to stop any flexing?

And droning

 

[jockaneezer]

Are you going to weld a couple of uprights on that panel to stop any flexing?

I was just about to type similar.

I was thinking similar but maybe the kingspan or whatever that gets bonded to it should hopefully stop it flexing, a couple of diagonal creases folded into it would have helped, but wouldn't have looked too good unless you highlighted them like a Saltire !

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[Dutch 68]

Its a pita this working alone fiasco .....this is when i miss my dad as he would have been out here helping out ...

Im at the stage now where i want to get this rear window panel welded in but i cant physically lift it up there and hold it in place to get a few tacks on it . ....View attachment 535952View attachment 535953

Little self tapper in the corners, then weld a few, take self tappers out and then weld those too, you really get very creative if you always work alone, I have done it for many years, but admittedly it is quicker to have a extra pair of hands!

 

[Northernraider]

Are you going to weld a couple of uprights on that panel to stop any flexing?

Yes monzer folded 20 of them for me they will be welded to the frame but only glued to the metal sheet. Same as the originals

 

[Northernraider]

Little self tapper in the corners, then weld a few, take self tappers out and then weld those too, you really get very creative if you always work alone, I have done it for many years, but admittedly it is quicker to have a extra pair of hands!

It was lifting it in to place that was the biggest problem but sorted now

 

[EssexBoy]

It was lifting it in to place that was the biggest problem but sorted now

Bit late now, but next time could you use those suction handle things that they use for carrying glass?

 

[Eggs]

Bit late now, but next time could you use those suction handle things that they use for carrying glass?

Bit late now, but next time could you use those suction handle things that they use for carrying glass?

It's the size of the sheet that makes it difficult for one person to handle, 1740X820

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[gus-lopez]

I see you have welded it to the surround rather than to the lip the glass sat in. More sensible way as long as you seal the edges from water ingress. seam sealer?.

 

[Northernraider]

I see you have welded it to the surround rather than to the lip the glass sat in. More sensible way as long as you seal the edges from water ingress. seam sealer?.

Yes taking it up to where the doors would have been had it had doors ..that way once its welded i can run a bead of sikalfex down that seam and it should look original. The top will be seam welded and then blended in with filler. The bottom edge spot welded then blended in to that edge . A few tacks here and there on the inside and sealed around with sikaflex ...2 vertical supports bonded on the inside and it should be quite solid.

 

[Northernraider]

Bit late now, but next time could you use those suction handle things that they use for carrying glass?

It was more the weight and sheer size of the panel as it had to be centralised but couldn't see both sides from the middle

 

[Minxy]

With the type of welding you're doing you're gonna have to call it 'Puddle'!

 

[Mikey RV]

Looking good Tam but with all this new metal going in your payload is shrinking.

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[Mr porky]

When do you think you will finish the welding and make the van secure.
Is this the goal for this year then off for a jolly around Europe ?

 

[Northernraider]

Looking good Tam but with all this new metal going in your payload is shrinking.

Ive 3.5t to play with lol so im not concerned thats almost the entire weight of toby loaded .

 

[tonyidle]

Ive 3.5t to play with lol so im not concerned thats almost the entire weight of toby loaded .

No payload anxiety, no battery anxiety. That isn't proper motorhoming .

 

[Northernraider]

When do you think you will finish the welding and make the van secure.
Is this the goal for this year then off for a jolly around Europe ?

I don't like to jinx it but if weather is kind im hoping to have all the bodywork welding done by the start of october. IF in that time i spot a decent van around the 10k mark i might then escape from the worst of the winter for 3 months. If nothing comes up ill just press on with as much as i can get done ..
I have to get the vario to a stage though where it isnt going to leak or rust anymore over winter though as it wont be painted till next year ... Ive still the roofrack to make too before the roof can be painted or insulated and lined etc.

This stage seems to take forever but i do think the interior work will be much quicker.

 

[Northernraider]

No payload anxiety, no battery anxiety. That isn't proper motorhoming .

I can't wait for the day when i never have to worry about it to be honest. But its different when you live in it fulltime to just being away for a few weeks here and there.

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[The Dotties]

Are you able to put some cord through it and 'hoik' it up and tie it off so that it is supported whilst you get some tacks in then remove the cord?

Or, dare I suggest using the rope trick, which could get in the way if going around the sheet, a couple of magnets to hold it?

 

[EssexBoy]

It was more the weight and sheer size of the panel as it had to be centralised but couldn't see both sides from the middle

Sorry... wasn't clear, was I... my thinking was that once the panel had "handles" it could be hoisted/dangled/swung by them into position with some rope...

 

[Chrisallys]

Hi, Tam following your post with great interest as I did a similar project on a 614 some 17 years ago, luckily for me there was nothing like the body problems youve had. I have a small problem now with the lights warning lamp on the dash staying on but all lights and bulbs are correct and working and wondered if you have had any problems with warning lights etc, sorry if youve already covered this i may have missed it. please carry on posting and it looks like youre doing a fab job, great project.

 

[Northernraider]

Hi, Tam following your post with great interest as I did a similar project on a 614 some 17 years ago, luckily for me there was nothing like the body problems youve had. I have a small problem now with the lights warning lamp on the dash staying on but all lights and bulbs are correct and working and wondered if you have had any problems with warning lights etc, sorry if youve already covered this i may have missed it. please carry on posting and it looks like youre doing a fab job, great project.

To be honest ive not driven it enough to have any lights on ...but theres a good facebook group specifically for varios that you might get some advice on ...ive found it to be quite helpful

 

[Northernraider]

Got the panel all spot welded on now and the welds buffed down and filled ....still a lot of work to do and still to seal it inside and out ..but getting there

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