The last few days have been spent in manufacturing the hinge plates for the boot doors. Once completed, there was an issue with the right-hand boot door not closing freely. Investigation revealed that with the door mounted correctly, it was binding both at the top and bottom of its opening. The remedy was to sand wood from the bottom of the door and relieve the boot door sill slightly ans well as removing a little wood from the top tight-hand corner of the boot door aperture. It was clear that the right-hand door, at lest, has never fitted properly for many years, so it was good to be able to correct this.
Attention then turned to the right-hand door itself. The edges of the existing aluminium skin are badly frayed and there are a a few dents. The bottom edge is split where it folds over the steel bottom edge of the door, which itself is badly corroded. So I stripped the door down to the frame so I could repair any damage then reskin it. I also decided to replace the chrome budget lock hardware as one was broken and the pull ring for the door was missing. I ordered exact replacements from Vintage Car Spares, not cheap!
The previous few days and today have been about reinstalling the rear window. The glass had dropped and was loose due to the rotten sill and the rubber edging having disintegrated. Having replaced the timber above the boot and below the window and the N/S corner, I reinstalled the glass today with new rubber. Whilst it was a good fit top to bottom, there were gaps at the sides which must have always been there. So I centred the glass and filled the cavities with an air-setting rubber compound called Tek. Once this had been done and set I was able to install the triangle section beading that stops the glass falling out the back of the bus. This was a long and tedious job that was started yesterday afternoon and finished today.
The next job is to hang the boot doors, so I marked out the 1/8″ galvanised steel plate ready for cutting tomorrow to make the hinge plates.
Full view of rear window glass back in place with new rubber
Close-up of RH corner of rear window after refitting but before the beading had been replaced.
Restoration diary of a 70-year old AEC single-deck bus and the trials, tribulations and adventures of our 1966 Bristol bus.