The Ins and Outs of getting Trev's revs going

Here we are, for those mechanically minded amongst you, this is a run down of the work the Husband had to do to get Trevor on the road...in his own words (cos I don't know what the heck he's talking about):


Cut away inner and outer sills and sill rear closing plates and welded replacement parts (either obtained from Mr Collier in Kempston who hand makes replacement panels or hand bodged by me by cutting up old car bonnets to get the spare metal) -(you can imagine our driveway looked like Steptoe's yard with bits of old car stacked up ready for welding.) Rear sills (around the back corner of the van) also replaced in similar fashion, and bottom edges of all doors welded back up.

Structurally most things were OK except one plate in the Front wing outrigger. Several small weld-ups (front wing lower edge, A pillar to front wing joint, small holes in doors, gutter rail at rear etc.) and a fairly big job repairing all around the windscreen aperture. The Screen had to be taken out and patches welded in all around (as water was leaking into the cabin). Screen was re-inserted using the washing line trick with new screen seal (From Adrian Bailey Classics). Re-painted using Rustoleum combicolour and gloss rollers and lots of masking tape.

well good at welding!

Mechanical stuff: Initial problem was the fuel pump. It worked on the bench but not in the van. I found the arm was bent. I ditched it and bought an electronic fuel pump and adjustable pressure regulator (both from ebay). After lots of messing about with points I ditched them and got electronic ignition - that was the best thing I ever did and solved loads of issues. Completed new exhaust system including stainless rear section from ABC. Got the van running but still pretty rough so fitted new carb bought from Dingocroft (a Land rover supplier). It`s a copy part of the old Zenith IV made in India. Had to modify the choke mounting bracket to fit the old bedford one but only a 1/2 hour job. First one I bought had no float valve, second one worked (initially). All new brake lines (home made with flaring kit), brake cylinders (from ebay) and shocks fitted (ABC) and finally MOT achieved.

Further problems over the next few years with plugs sooting up turned out to be a leaky float valve in the carb, but it took a lot of diagnosing (intermittant fault). Led to many many sets of plugs being used and numerous oil changes to empty the sump which had becme diluted with fuel. Finally (fingers crossed) solved and van now running well.

Improvements: Leisure battery fitted with separate circuit for interior lights and fridge. Keep blowing fuse though so something slightly wrong... Maybe just over powering fuse (30A). Radio fitted and several immobiliser circuits.

New and improved Trevor!

Things to do: Having trouble with sealing the joint between the manifold and down pipe. Seems I`ve got the old type joint that requires a sealing ring but hard to come by exact size (80`s vauxhall equivalent 47mm I.D. is too small, need exactly 1 7/8 inch...) Rust coming through at top corner of front wing, suspect leaking from flange around bonnet top corner so will weld that up when I get a chance.

No doubt more updates in the future as our ventures with Trevor continue...