Renovated the brake cylinder and replaced brake pads with new ones.


Here's the remounted brake.

Kind regards from

Hannes

Great work... You have some excellent metal fabricating skills... I must agree with Eric, good English too.. Probably better than mine 

Zig

Really GREAT work.  Not many people (myself included) know how to use lead over here.  You will be able to fix cars for a long time with your ability. 
This is going to be a project to follow.

Thats some VERY nice work carl.

Thank you for your kind comments Zukipilot, BRD HNTR and TNTracker. Doing bodywork with lead isn't rocket science BRD HNTR. It's a myth that it is difficult. Anyone can learn. I learned that in just some days by my father.

Filling with thick layers of polyester is actually a problem in the long run. Plastic and metal, as steel, do have very diffrent thermic properties. That means that they expand and shrinks very differently when it turns from warm to cold to warm (in Sweden we can have +40 centigrades in summer and -40 centigrades in winter). So it's a big risk that the plastic will loosen from the sheet metal. Also if there is microscopic holes in the welding water will come up between polyester and steel by the capillary effect. So it's a big risk that the rust is comming back in a short time. Tin/lead, on the other hand, has thermic properties near steel and will attach by other physical laws.

Here is the local blacksmith shop. That is a good place searching for cheap surplus steel.


Here I have found a 3 meter long 80x80x4 millimeter square pipe. Hmm... what could that be used for?  

Kind regards from

Hannes

You're 16 and you did that yourself? Thats some real skill there.

00:32, never mind it'll be probably be light again in about 10 minutes  Whereabouts in Sweden do you live?

  Ya got skills kid! Your going to go far, good for you!

I'm glad you like my project Rhinoman and bentparts but I'm not going to work with restoring cars. It will be studies in computer science. Cars are funny  as a hobby though.

I'm living 270 kilometers north of Stockholm. It's a bit south ( I dont know maybe 600 km)  from the polar circle but in mid summer the sun is just dipping down under the horizon (so we are near the polar circle enough). So in practice we have daylight 24 hours for some week and very short nights rest of the summer (but it's not real midnight sun).

When I pulled away the plastic side panels under the doors large parts of the sheet metal under it (is it called rockers in english?) was non-existing

So I decided to replace everything there with the 80x80x4 square pipe. I think that will have strength enough for hard driving in the terrain.


So here I have started to make place for it on the right side


The paint that the former owner had used was some cheap shit so I have to remove that. That paint will dissolve by the two component paint that I'm using. Also I want to be sure that it isn't rust under it.

The floors are also rusted out. So I have to make new ones later on. Here I have just cut out a bit of the floor on passenger side. It's easer to make a new beam that iattaches the body to the frame this way.


So this is the new made beam (also with zinc on it). I have to make this before the 80x80x4 square pipe is welded in to place though it also must be welded in to the beam.

Kind regards from

Hannes

Looks good, we replaced the rocker panel on BRD HNTR's Tracker with 2x4 square stock and it has held up pretty well. 

Here's the square pipe welded in to place. This is after I formed the ends and closed them with some sheet metal, lead filling and grinding/sanding and zink.

The floor was rusted out so I had to fabricate a new one.


It should also look nice from the underside. Here you can see the rocker, beam and floor from an underside view. Zinked and painted.


The floor and rocker seen from back to front.

And here's the rocker from underside in a view from front to back. As you can see there's also rust in the floor under the seat so it has to be done something about that. Also the beam under seat isn't what it should be.


Floor and beam under the seat must be rebuilt.