Vin6409 engine rebuild

[ROBLAMROCK]

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My galvanised coal scuttle is always kept in the garage and isn't that old but look at the rust!

[cis6409]

Deffo some top work going on here ! As Andy said though, how has it rusted so badly if it was galved ?

Thanks

I've thought about it for a while but this is best I can come up with from what i can see . (Usually when something is galvanised it's not usually de- galvanised- Lol! )

The main rust sandwich pieces that Is being replaced like the rear doubler plate to the rear links and front shock towers etc is a hangover from the 1st time I did it.
Like any good paint job, I've had to learn the hard way. it's only as good as the preparation. I opened some but not all the box sections I should have.
The shot blasting process to strip the epoxy was not able to remove the inner areas of expoy like the rear doubler plates as there was no access.

Using someone like prostrip or sps in dudley is the only way to go as that would have removed the epoxy from those areas properly. Nothing like that was available in Ireland back then.

I wrongly misunderstood whatever epoxy was left would be burned off in the galvanising process.

The galvanising could not adhere to the base metal as clumps of old epoxy and sand "were in the way " and interrupted the metalurrigical bond. So the double skin or other hidden box areas got stripped of epoxy but not galvanised. The metal was left exposed and uncoated. The clumps likely also floated around and caused air pockets for other areas not to be coated.
On the outside and everywhere else where there was Clean metal it was fine.
Then inevitably the rusting started from the inside out in those areas over the years.

If I had used prostrip or dudley in first place I would have not needed to go through this all over again.
As I said before it's not the galvanising fault, it was mine.

As for the very browny rust colour of the chassis overall I'm not sure about that I can only assume it's Left over from the de-galvanising bath which is hydrochloric and the pickling effect has made it more susectpible to the moisture but I could be way off. Lol


Shane

[cis6409]

Some tidying up of previous weld patches at the front where the tank sits was needed

[cis6409]

The 'y' section double skin plates at the rear were suspected of hiding rust so they were removed. Unfortunately Nicky s suspicions were right

[cis6409]

The front 'y' section was worse unfortunately.. Glad we opened them up seeing what was left behind from the last time. No way galvanising would adhere properly with that stuff laying inside

[cis6409]

Some close up pics of the front 'y'. Apologies for the poor quality as I had to take these from an older phone video stills.

[cis6409]

Yes this bucket was empty before all the rusty stuff was taken out of the y sections! .

Must weigh it for the laugh

[dmc4087]

You're making a great case for going stainless on the frame Shane!

[cis6409]

I suppose I am thom!

[cis6409]

In between the chassis work i ve been continuing trying to get the wiring looms Tidyed and or fixed where needed.
Very tedious but should be worth it.

Anyways Found a few bad crimp connections and then that nasty black oxidisation on the strands. These were just the side marker lights so not a super essential circuit but none the less after seeing this l ll be on the lookout for similar on other parts of the looms when I get to them.

I had it cut back around 20 inches of the loom on each wire to get back to Clean strands so I could solder to. The black oxidisation was on both the power and earth side but a little bit more on the power side which i wasn't expecting.

Hopefully after this, the voltage drop/resistance on the circuit will be alot better.