Print Page - Phunkie Project Portafold (caravan!!)

Talking to Andy today, at the Windmill rods and chops meet, and he suggested that some of you guys out there might be interested in this restoration build up.
Well here goes, what is a Portafold caravan? It's a lightweight, fibreglass, folding caravan, weighs in at 10Cwt in old money and has been known to have been towed behind a trike (you can tow them with anything upwards of 800cc. They were manufactured between the late fiftys to the early sixtys in Fareham, Hampshire. They do have quite a following in the classic car and hot rodding circles. So here's what one looks like .............

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/491489878_tp.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/491489735_tp.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/491489981_tp.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/491490128_tp.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/491490943_tp.jpg)

So we have purchased one of these after getting soaked last year at Beaulieu, when the tent started to leak!!
We have found that it needed more work than was originally thought, so with a debut at the Victory Wheelers, South Coast Internationals in June, we'd better get going.

I appologise in advance to those on here that have been following the restoration on another channel ::)

Well, this is it, the Phunkie Project Portafold thread.
Collected the Portafold from Kidderminster on a Friday in late July. This is it as it arrived.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture001_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture004_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture006_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture008_640_x_480.jpg)

The following day it was inspected, to see what was required to get back to a good working caravan. Unfortunately, due to repairs to be done, it will require a full restoration!!
So now we need to strip it down. First to remove the roof. The outside has many spiders in the fibreglass, there is a huge sag in the rear of the roof and inside it has some coating that has started to peal off.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture009_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture010_640_x_480.jpg)

Now what is left is wheeled outside and raised using the jacks, all the chassis mounting bolts are cut/ground (far too rusted using spanners/sockets) and the chassis removed.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture019_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture020_640_x_480.jpg)

At this point the main body was turned on it’s side and the jacks removed, using the same method as the chassis bolts.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture021_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture039_640_x_480.jpg)

OK, the Portafold is now just a selection of parts as it would have been back in 1970, when it was assembled by, possibly a guy called S.Challoner, at the factory. On a lot of the construction of this type back then, the builder used to sign their names somewhere.
It’s now close of play on Saturday, a good days work. Oh, I’d better put the hinges in a bucket of penetrating oil to soak.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture075_640_x_480.jpg)

Next time, it’ll be time to work on the chassis and jacks.

OK, so before I start on the metal bits, I cleaned and pressure washed off the underside of the main body to see what repairs are to be done on the underside.
Before clean,

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture048_640_x_480.jpg)

After clean.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture049_640_x_480.jpg)

Now the thing is clean it’s apparent that there a large number (23) of “drainage” holes, that have been drilled in the main body floor, to be filled/repaired.
Also there’s damage on the front on the nearside from a reversing “jack-knife”.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture067_640_x_480.jpg)

Along the top side edges of the main body, where in production extra gelcoat was painted over the original due to the mould in that area being damaged and worn. This now peeling off.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture073_640_x_480.jpg)

There is an inherent fault in the shape of the storage bin holes, in that the holes are cut square which results in cracks radiating from these corners. Whenever square openings are cut, in just about any material, the corners need to be radiused. This spreads the load all round the corner, is general engineering practice and would have alleviated the problem we have here. Every single opening in this Portafold is the same and all require attention.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture064_640_x_480.jpg)

Some of the strengthening under the seating areas has deteriorated badly resulting in large cracks and sagging of the seats.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture062_640_x_480.jpg)

All the holes in the main body floor are sanded on the inside and fibreglass mat and resin are laid on to seal the holes from the inside. The split at the front is sand inside and glassed over.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture070_640_x_480.jpg)

The front mount to the chassis strengthening panel (wood) has collapsed on one side and the layers of mat are secured to nothing.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture060_640_x_480.jpg)

This is cleaned up and mat and resin layered up over the wood an finally over the whole area making sure that it extends at least a couple of inches out side of the wood.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture072_640_x_480.jpg)

In between repairing the body items, due to the drying times of the fibreglass, I will be looking at the chassis and jacks.
First the chassis and brakes. With the brake drums removed, the shoes are checked for wear and cleaned with emery paper. The drums are also cleaned, on the braking surface with emery.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture030_640_x_480.jpg)

As every thing in here is serviceable the drums are refitted.
The chassis is in good condition

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture020_640_x_480.jpg)

and just requires a sanding down and a repaint with chassis paint.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture033_640_x_480.jpg)

So onto the jacks. This shows two jacks, but the same process is carried out on the other two.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture039_640_x_480.jpg)

Strip these completely, removing the fixings.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture040_640_x_480.jpg)

To make it easier to refit the units, the fixing holes are countersunk

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture041_640_x_480.jpg)

and fitted with countersunk bolts, tack welding to secure and grinding clean.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture042_640_x_480.jpg)

All parts are then cleaned, sanded and painted with chassis paint.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture044_640_x_480.jpg)

And assembled.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture045_640_x_480.jpg)

Whilst waiting for fibreglass to ”go off” I put the handles on the polishing mop and also the front roof positioning brackets.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture116_640_x_480.jpg)

So now, back to the main body and strengthening the seating areas and radiusing the corners of the storage bins.
The strengthening of the seating areas is achieved by glassing “D” shaped “rope” within the layup.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture126_640_x_480.jpg)

Unfortunately the resin has deteriorated to such an extent that there is no support at all. Added to this is the fact that the strengthening is not long enough, stopping level with the edge of the storage bin holes. This results in more strain in the badly engineered corners.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture118_640_x_480.jpg)

The seating is pushed back into position using a scissor jack. The missing “rope” is replaced and laminated in. At the same time fibreglass is layered under the corners of the bin holes.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture119_640_x_480.jpg)

After the laminate is set, the corners and splits in the seating areas are ground out. These areas are laminated to the required height.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture125_640_x_480.jpg)

After drying the corners are cut out using a hole saw, and using an airsaw the bits between are cut out. All the repaired areas are sanded flat and then skim filled and finished for priming.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture127_640_x_480.jpg)

This operation is pretty time consuming, so it’ll be a while before all the storage holes are repaired.

Just a quick update, nothing much to show as the repairs to the openings for the storage areas are still ongoing (real work seems to be getting in the way!!).
In between laying up fibreglass, I’ve been able to spend some time on the hinges. There was probably a 50/50 split on seized and partially seized and one completely broken.
Last time they were mentioned, I had put all of them in a bucket of penetrating oil. They soaked for about two weeks.
It was then just a matter of “working” them, untill they were free. After which they were cleaned to get all the verdigris off.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture115_640_x_480.jpg)

Attention is now turned to the broken hinge. The actual fault is that the pin, through the middle is broken. The original pins are steel and 1/8” in diameter. So after sourcing a piece of steel rod that size, it is cut to length (a little more than the length of the hinge). The parts of the broken pin are carefully drifted out with a compatible parallel punch. Care must be taken to support each part of the hinge whilst this operation is carried out. I fabricated a small fixture, held in a vice, to do this.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture112_640_x_480.jpg)

The hinge is now assembled with the new pin and the pin carefully peaned over at both ends, hence the slight extra length of the pin, and cleaned.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture113_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture114_640_x_480.jpg)

As we are likely to tow the Portafold with our Peugeot 306, as well as the roadster, the law states that trailers being towed by post 1972 vehicles require the fitment of at least one rear fog lamp.
So rather than just bolting on some non descript bulky lamp that looks like it was just screwed there, it was decided to install some neat lamps that pretty much fit in with the general look of the rear.
The lamps being used are some I found a while ago, when sourcing fog lamps to fit to import cars (part of my day job). They are a readily available Hella lamp that measure about 2” across

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture107_640_x_480.jpg)

First, some mountings needed to be fabricated. So I found a piece of tube the right diameter and made a collar to fit to produce a top hat shape. This was used to laminate around.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture101_640_x_480.jpg)

The end result was then put in the lathe and turned down to end up with the required depth and diameter mounting.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture102_640_x_480.jpg)

A decision was then made where to place them, to not look out of place and the holes drilled for the mounts.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture103_640_x_480.jpg)

The mounts were then fitted and orientated to the correct angles, the lamp has to be fitted vertically.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture105_640_x_480.jpg)

It was then just a job of laminating the inside.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture108_640_x_480.jpg)

And then on the outside.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture109_640_x_480.jpg)

Finally, the outside was filled and shaped and covered in some hand painted two pack primer (this protects the “repair” from moisture).
This will be sanded down again when the final priming, to paint, takes place.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture111_640_x_480.jpg)

It might be worth noting that although I do have my own small workshop with all its facilities, apart from maybe the turning of the fog lamp mounts, all the repairs so far could have been carried out by any of you in the garage beside your house.
Whilst continuing with the storage holes, some times there is amounts of laying up resin over and so as not to waste it I look for other items in need of repair.
The small lower door had been backed into something resulting in a dent/split in it and where the number plate had been bolted on, it had crushed the inner and outer skins together.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture081_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture082_640_x_480.jpg)

So the first thing to do was remove the hinges. As the first securing bolt broke off, making a removal job difficult, I drilled the other three bolts out through the heads which enabled me to get a good “centre” on the bolt.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture076_640_x_480.jpg)

Small drill to begin with then out to 5mm, this enabled me to tap through into the strengthening steel with a M6 tap.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture077_640_x_480.jpg)

Unfortunately one of the holes didn’t want to play ball, so it was drilled out to take a M6 Rivnut. This is a threaded sleeve installed just like a pop rivet.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture078_640_x_480.jpg)

And this is it after installation (sorry about the blurry picture, but you get the idea).

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture080_640_x_480.jpg)

Now onto the fibreglass repairs, couldn’t get into the rear of the dent so it was either separating the skins of the door or cutting a “panel” out on the inside. The latter was chosen and carried out, this will be covered by a fabricated panel, secured by clips and trimmed in matching material to the interior.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture083_640_x_480.jpg)

Laminated fibreglass was then added to the inside of the repairs. One of the holes for the number plate securing was distorted so badly that over the years it had set in its collapsed position. Some times this can be helped out with some heat from a hot air gun (not too hot though, because this laminate is really thin!!).
As in the other repairs, the damaged areas were sanded back to the new laminate and Fibreglass and resin added as necessary and sanded back when dry. Body filler was then added to fill any dips or pin holes and sanded.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture087_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture086_640_x_480.jpg)

Finally, to protect the “repair” from moisture, hand brushed two pack primer was applied.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture140_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture141_640_x_480.jpg)

This is now ready to sand and prime with a two pack primer when everything else is painted.
Back to the main body, finally managed to finish the storage holes on the righthand side.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture144_640_x_480.jpg)

Whilst carrying out the repairs on the storage holes I was thinking about the electrics we would be using. There is obviously wiring for the rear lights. We are going to fit a hookup, so that has to be a consideration and we need some lighting, to be run off a leisure battery.
I thought the best way to tackle this would be to use 22mm plastic waste piping and fittings, installed in place of the random pieces of garden hose “laminated” in at the factory.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture136_640_x_480.jpg)

So measured out and cut to length, it was trail fitted together.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture137_640_x_480.jpg)

Before the body was turned onto its right hand side, the right side “conduit” was installed using strips of laminated about 150mm long.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture138_640_x_480.jpg)

That’s about it for the moment, it’s back to repairing holes and corners for a while now.

Right, back to the holes. All the side ones are now finished. Attention is now on the front centre storage hole. This actually has some quite bad damage (possibly where people have been using the front edge as a step to get onto the “sink unit bunk”).

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture165_640_x_480.jpg)

In view of the damage and the fact that we need to be able to store some larger camping items, that won’t fit through the 15” square holes, we’ve decided to open up the size of this front hole to 19” square.
First a square is cut out around the original hole, then a further 2” removed down both sides and 4” across the front of the remaining hole. Next the original “square” is cut into 4 in the centre of the sides, making 4 corners.
These corners are then fitted into the corners in the main body and then secured.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture166_640_x_480.jpg)

The underside of the join is then laminated and strengthened by adding electrical conduit to the layup.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture173_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture175_640_x_480.jpg)

The join is then sanded back and laminated as in previous repairs.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture179_640_x_480.jpg)

It is then shaped, sanded, filled and final sanded before hand priming.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture180_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture184_640_x_480.jpg)

That now finishes all the storage hole repairs. Whilst looking around I did find quite a bad crack in the left hand rear up right post. I’m not sure how “bad” this is but have ground away and laminated it just as a precaution.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture160_640_x_480.jpg)

So now back to the electrics………………………..
As I said, we’re going to use a hookup when we can, this will be also connected to a leisure battery via a charger (so the battery can be charged when we’re hooked up!).
I’ve managed to source a really slim hookup plug with flap from eBay. It’s going to be installed in the front, above the join seam and it will be hidden by the spare wheel (this will be mounted on a bracket from the front of the chassis.
The hole is marked out and a drill hole is drilled in each corner.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture155_640_x_480.jpg)

The rest is then cut out with a saw. The round corners help alleviate cracks radiating from the corners of the hole. Securing holes are drilled and the socket trial fitted.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture156_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture157_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture158_640_x_480.jpg)

We need some 13amp sockets inside some where, so it was decided there would be one at the front somewhere (to be decided) and one at the rear just inside the door.
The same method is used on this install as carried out on the hookup.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture146_640_x_480-1.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture147_640_x_480-1.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture148_640_x_480-1.jpg)

We’ve found some real slim sockets to use, including a lighting switch (all the lights will be 12v) to be installed on the opposite side of the footwell.
Before I installed the lefthand side electrical conduit, I laminated the areas connecting both sides at the rear (under the step). I could see, maybe small items rolling under here and not being able to retrieve them. At this point I also laminated a piece of conduit tube through, from one side to the other, just in case we need to run some wires across.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture186_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture187_640_x_480.jpg)

The excess conduit will be cut down as required.
The conduit for the electrics on the lefthand side is now laminated in, same as the righthand side previously.
The 16amp hookup wire is installed down the right side tube, into the socket box. The 7 core cable, for the rear lights is now prepared, split into 2 circuits left and right).

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture149_640_x_480.jpg)

There are some circuits that need to go down both sides, so wires with the correct corresponding colours are soldered in and sealed with heat shrink.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture151_640_x_480.jpg)

The 2 lots of wires are now loomed up and installed in to their respective conduits.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture152_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture188_640_x_480.jpg)

Well, that’s it for a while again, but at least the storage holes are finished now!!
If any one needs information on any of the items or suppliers of parts used on this project please drop me a line (PM or eMail).

On with some more electrics then. More wires have been added for interior lighting (This will consist of small spotlights that run 12volt halogen bulbs, to be purchased from B&Q) and a couple of 12volt auxiliary sockets.
All the wiring that is required, from front to back is now installed into the conduit. The ends of the individual wires are cut to length and nipples soldered on.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture190_640_x_480-1.jpg)

Expanded nylon sheathing is fitted and held in position with shrink tubing.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture193_640_x_480-1.jpg)

Whilst on electrics, we want to be able to use a TV, and need to have some sort of aerial. I didn’t want to put anymore holes in the front area so have incorporated an aerial socket into the hookup box.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture217_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture218_640_x_480.jpg)

Storage of items has been thought about since the start of the project and a couple of items require reasonably secure mountings, the battery and two Camping Gaz bottles.
A couple of small “steps” were fabricated from marine ply and test fitted. The ally angle was used to get both steps to be equally fitted both sides.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture197_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture198_640_x_480.jpg)

These were laminated in place at the front curved area inside. Prior to fitting the left hand one, the “rack” for the gas bottles was constructed. A couple of strips of thin steel were shaped.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture194_640_x_480.jpg)

A closing strip, with a over centre clip, added and test fitted to the “step” top.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture196_640_x_480-1.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture195_640_x_480-1.jpg)

As I say this was done before installing the steps, and now laminated in a 2nd test fit for the bottles and a size test for the “battery”. I won’t be buying a battery until nearer the time to use (over 6 months away) so I made one from cardboard to the correct size to make sure it fits!!

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture201_640_x_480-1.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture204_640_x_480-1.jpg)

An in between job that needed to be done was to plug the original hinge screw holes for the front and rear sections. This has been done because some of the original holes were drilled crooked and had produced cracked and spiders in the fibreglass inside, that will require repairing. It was just a matter of making some wooded dowels and hammer them home down the original holes. The holes have now been drilled straight.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture219_640_x_480.jpg)

Back to the storage area, it was decided that it would have to be painted in something to cover up the rusty waterline and other parts.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture057_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture056_640_x_480.jpg)

Having run out of materials, whilst doing the front mountings for battery and bottles, I came across a supplier in the west country who was cheaper with better quality on the resins I required. Looking through their web site I found they did a product called “Top Coat”. This product is like gel coat in looks, but unlike gel coat it has wax added to it so that it hardens off in air. Using gel coat for this leaves a sticky residue.
So we ordered the resins need plus grey top coat.
At this point, I have to say that bare laminated fibre glass is a nasty piece of work. If you are unlucky enough to rub it and suffer with a splinter, it hurts like **** and because it is practically see through, you can’t find it, so difficult to remove. Ask me how I know, got quite a few “T” shirts now. So another reason to use this stuff. Prior to using the fibreglass needs to be sanded, to remove any stray pieces of chopped strand.
It arrived, but what I thought was a nice light grey, it turned out to be dark battleship grey. Anyway, I had to go with it, but after painting both sides and the top inside it became evident that it as going to be too dark.
So onto plan “B”, order white top coat, we’ll need this for the interior sides and back, mix white in with the dark grey that’s left and hey presto, a much nicer colour.
So now the whole of the inside of the storage compartment is now coated with a smooth washable surface. I left the underside of the seating in the dark grey, as it was a pain to do and it doesn’t show, unless you stick your head right through the storage holes!!

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture249_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture252_640_x_480-1.jpg)

More to come soon…………………………

So I’m into the boring part now, filling and sanding. This will be by no means a show quality job, a huge amount of hours would be required for that. Just filling all the nicks and pock marked gel coat to a reasonable standard will take long enough.
Inbetween filling and sanding I’ve managed to get some other things done. Firstly the storage hole lids were in a pretty sad condition, with some delaminating and some broken in the same area as the damaged fibreglass edges. Using the old ones as patterns, new ones were cut and shaped to fit.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture259_640_x_480.jpg)

This included one for the now larger front middle storage.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture239_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture244_640_x_480.jpg)

They just require varnishing now.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture260_640_x_480.jpg)

As we are only going to use this to sleep and sit in, ie no cooking and washing up etc, I’ve made a largish table that covers the front area in the middle.
Here are the materials ready to assemble.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture263_640_x_480.jpg)

And now glued together in its intended position.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture273_640_x_480.jpg)

Now there’s a little trick to this, because I’ve cut an shaped some boards to span from side to side, making a bed.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture243_640_x_480.jpg)

When not being used they are stored underneath the table.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture288_640_x_480.jpg)

A tempered glass top will be made for the table, but we’ve not decided yet what will be under the glass.
Here we have all the panels out.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture287_640_x_480.jpg)

And varnished.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture304_640_x_480.jpg)

One more thing I’ve managed to do is the corner seal guides. They were all in pretty bad condition, mainly broken.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture286_640_x_480.jpg)

So we had no alternative but to make some new ones. After some quick measurements, a mould was constructed to make new ones to the old specifications.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture284_640_x_480.jpg)

So with the old ones and the adhesive removed.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture282_640_x_480.jpg)

The new ones, shaped to fit were installed using white sikaflex. This is a sealer/adhesive which is paintable.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture290_640_x_480.jpg)

They were then cleaned up and sanded to shape, ready for primer.
We can now supply, to order, new mouldings to do this job. They can come as just “U” section that requires shaping or roughly shaped pieces requiring finishing. Please note that all four corner pieces are different ( sizes and shapes) so they will require final finishing on the body.
That’s all for now.

Well, we are still here and moving forward with this rebuild. Managed to get some more done before Christmas and after, although during the Christmas/new year recess I was working on another restoration project, on this little baby ………………….

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/picture053_640_x_480.jpg)

Anyway onwards and upwards.
So, we’ve replaced our cardboard battery with a state of the art carbon fibre 100amp leisure battery. A securing needed to be fabricated for it, together with a mount for the 240volt breaker and the solid state charger connected into the hook up circuit and the stand alone 12v circuit.
Firstly the battery and breaker.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture325_640_x_480.jpg)

Then the charger.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture326_640_x_480.jpg)

And finally all in position.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture328_640_x_480.jpg)

Just got to hook up all the wiring now!!
Managed to get a final coat of boat varnish on the table frame edges, just need to get the glass cut and tempered now.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture329_640_x_480.jpg)

I think that the quote “no wood to rot and no metal to rust” describing the construction of these ‘vans is a little bit of an under statement. Our ‘van suffers from both, rot in the wood and rust in the metal strengthening plates.
Starting with the rear wall, the plates to strengthen the hinge mounts were rusted and had split the fibreglass laminates.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture246_640_x_480.jpg)

This lead to a large distortion of the fibreglass along those lower edges. Another connected reason for the distortion could also be the seized hinges.
The laminates were clamped together using “G” clamps and a long straight piece of wood running under both sides of the hinge mounting panels.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture247_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture245_640_x_480.jpg)

I’ll explain the drill holes later. A piece of plywood was cut to match the profile of the mount.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture254_640_x_480.jpg)

After a layer of resin and cut strand mat was added.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture248_640_x_480.jpg)

The ply was added and laminated in.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture255_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture261_640_x_480.jpg)

These parts were then sanded and filled and resanded.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture319_640_x_480.jpg)

Now the reason for the holes, we need to put in a lighting system. This will be 12volts and we need to get those 12volts from the main body (where they end now) to the walls (where the wires will terminate in some 12volt halogen 2” house lights).
The easiest way to do this, without having loose wires with plug in connectors draped all over, is to use some of these little devices.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture206_640_x_480.jpg)

These particular ones can be found on the tailgates of Fait Chinquichento’s, other makes are available.
They are spring loaded contacts and this will give you some idea of how they work.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture207_640_x_480.jpg)

The brass plate side will be fixed to the main body, whilst the spring loaded pins will be fixed to the end bases. When the ends are raised into position, the contacts will make the circuit to the lights.
Holes were made, to take the plates, in three places, two at the rear and one at the front.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture208_640_x_480.jpg)

And the plates inserted into them.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture209_640_x_480.jpg)

The holes for the spring loaded portion are cut into the added ply strengthening in the ends.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture319_640_x_480.jpg)

It was decided to just glass in the wires up the end pieces, so they were masking taped to the inner wall.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture321_640_x_480.jpg)

And then glassed in.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture323_640_x_480.jpg)

At this point we needed to get rid of the flaking inner surface. We did this using rotary wire brushes on a cordless drill.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture231_640_x_480.jpg)

Then finally to coat the inside with some “Topcoat” fibreglass resin, this time in white.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture324_640_x_480.jpg)

So next time we’ll be starting on the front wall ………………………….

OK, now to deal with the front wall.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture012_640_x_480-1.jpg)

Remove the window and inner covering (pretty bad condition and has been painted over, and not very well)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture223_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture226_640_x_480.jpg)

Remove sealing foam and fittings.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture225_640_x_480.jpg)

Check to see what holes require filling.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture228_640_x_480.jpg)

Sand off all the glue from the inner covering and the badly crazed over painting on the lower section. A rotary wire brush on a drill seems to do the job pretty well.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture331_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture231_640_x_480-1.jpg)

The fibreglass around the window area is so thin that over the years it has distorted quite a lot. This could result in water ingress even when the window is closed and locked.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture333_640_x_480.jpg)

This remedied by cutting, from a piece of thick wood (read old acoustic parcel shelf), a shape to fit exactly where the window mounts and fix it to the frame.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture334_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture335_640_x_480.jpg)

Fibreglass laminate is then laid around the sides, up to about 2.5 inches round the “frame”. this will make it stronger in that area and straight.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture336_640_x_480.jpg)

The same treatment carried out on the rear wall on the bottom rail/hinge mounting area has also been applied here, including adding mount for the contact set for lighting.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture337_640_x_480.jpg)

The lighting cables have then been glassed in……..

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture342_640_x_480.jpg)

……..before sanding and covering with a coat of bright white topcoat.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture368_640_x_480.jpg)

That’s it, for the moment, on the front wall.
Now to start on the side walls, first the left side.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture014_640_x_480.jpg)

First, as with the front wall, remove trim and window.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture348_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture349_640_x_480.jpg)

Then remove all the trim glue, with a rotary wire brush and electric drill. This came off quite easily.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture354_640_x_480.jpg)

Then to look at the hinge panel at the bottom. Due to a couple of reasons the two skins of this assembly had parted company.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture351_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture350_640_x_480.jpg)

Also at the end lower corners the fibreglass was breaking up.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture352_640_x_480.jpg)

The reasons for all this, a combination of partially seized hinges, not very good bonding along the edge and laminate being laid on gel coat finish with out keying first.
The end parts were cut away to uncover good fibreglass.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture358_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture359_640_x_480.jpg)

The top and bottom skins of the lower assembly were held apart and a generous amount of Sikaflex was injected in between, then the two skins taped together to “go off”.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture353_640_x_480.jpg)

After keying with a course sandpaper the end corners were laminated.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture362_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture363_640_x_480-1.jpg)

Then trimmed and sanded ready for a coat of “top coat”. The tape was removed from the Sikaflexed joint and also sanded.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture372_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture373_640_x_480.jpg)

The window received the same treatment as the front window opening.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture357_640_x_480.jpg)

Things are moving ahead quite well now, so next time the right side ………………

Following on, the window edge is laminated and trimmed. The same method is carried out on the other side. This side was in a less damaged condition, but the same areas required attention.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture386_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture385_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture388_640_x_480.jpg)

Now that both sides are repaired on the inside, it’s time to paint them over with topcoat.

Left side…………………….

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture377_640_x_480.jpg)

Right side…………………….

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture407_640_x_480.jpg)

I managed to get hold of some pre used battery terminals.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture404_640_x_480.jpg)

Which were cleaned up and soldered onto the necessary wires and finised off with shrink insulation.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture405_640_x_480.jpg)

Next piece to get attention has to be the roof. The coating on the inside was cracking and falling off.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture390_640_x_480.jpg)

So armed with a gasket scraper and rotary wire brush on a drill we turned this …………

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture389_640_x_480.jpg)

Into this ………….

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture400_640_x_480.jpg)

With the resulting roof interior looking like this …………

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture399_640_x_480.jpg)

There are some repairs to be made ……….

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture392_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture391_640_x_480.jpg)

The worst of which is a “sag” in the fibre glass on the right side at the rear. Not that obvious in this picture

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture394_640_x_480.jpg)

But we need to sus out what will have to be done to make it stable before we go any further.
I’m off to work on a plan, so see you next time.

Right, didn’t take too long to work out what was happening and put a plan into action, but first, on taking off the fittings and drilling out the pop rivets, the left rear supporting steel for the roof lifting handle exploded. It had rotted out on the upper edge, and is no good anymore.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture411_640_x_480.jpg)

So the old one was cut out.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture412_640_x_480.jpg)

And a new one fabricated from aluminium.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture415_640_x_480.jpg)

Then, after cleaning the old mounting surface, this was installed using Sikaflex to bond it to the roof.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture416_640_x_480.jpg)

Then a couple of layers of laminate to clean up the inside.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture430_640_x_480.jpg)

There was a small repair to do at the front edge where he roof pivots on the little aluminium sliders are.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture417_640_x_480.jpg)

Just set up a straight support outside, ground away part of the edge and laminated the repair from the inside. The outside will be addressed when we do the repairs on the outside.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture418_640_x_480.jpg)

Now, on to the “sagging” right side of the roof. The problem seems to have been caused by a weakness on the inside edge of the right hand “fin” allowing the roof to “flatten” out.
With the roof turned upside down on the base, this allows the roof to take its proper shape, weight was added to the “sag” area, expanded aluminium was cut to shape as a support to aid laminating.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture408_640_x_480.jpg)

Both inner portions of the “fins” were laminated over and the front portion as well. This gives us a Portafold roof on the outside and an Ansfold roof on the inside, but I has worked to give a non saggy roof.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture409_640_x_480.jpg)

To help to make this modification stronger but still light, holes were drilled into the fins from inside and the void filled with expanding foam.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture432_640_x_480.jpg)

Now to make a smoother/good looking roof surface, in side, it was sanded off and a complete one piece sheet of fibreglass cloth was bonded to it. This hasn’t added too much weight to the roof, as cloth is quite light compared to chopped strand mat.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture433_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture435_640_x_480.jpg)

As today has been pretty warm, the glass has been “going off” pretty quickly , so by the time I’m back on it again it’ll be fully hard and will only require a light sanding before painting it with the white top coat.

So, yes, the cloth laminate has now hardened and the edge has been trimmed and sanded. The inside has now been lightly sanded and painted over with white top coat.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture442_640_x_480.jpg)

Whilst that was drying, I made the trim panel for the lower rear door, from a piece of 3mm exterior ply. It was marked out for the trim clip positions and drilled through into the door. A trial fit was made using “clico’s”, now ready to drill holes full size in readiness for the clips.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture449_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture450_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture451_640_x_480.jpg)

Back to the main body, after removing the chassis, the body was turned over and the final external repairs carried out. The whole of the underside, up to the join, was then sanded. We’re doing in sections because it’s easier for us, to do it that way.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture445_640_x_480.jpg)

It was then sprayed with primer. Firstly with a Max Mayer epoxy 2 pack primer. This adheres to the fibreglass and makes a good base for the Max Mayer 2 pack primer/filler, which covers all the pinholes in the surface of the fibreglass. This is not going to be a “perfect” job, the preparation for that would take hundreds of hours, but it will be to a presentable standard.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture452_640_x_480.jpg)

I’ll leave that for a few days, or so, to harden, then next week end we’ll turn it back over and finish the top area, above the join line.
Be back soon

Thanks for that Merv, all this that I'm downloading at the moment is on word douments, so we are a bit further forward with it now.
Now the primer has hardened, the body has been turned over.
Before we go any further, the two front support/roof axis bracket fixing area needs to be addressed. Problem is that, the wooden block that the brackets are screwed into are not touching the fibreglass inside the body, hence all the cracks around the mount.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture472_640_x_480.jpg)

As soon as the screws are tightened, the glass is pulled in cracking the gel coat. So, just made up some packing “shims” out of 3mm exterior ply and tapped them in between the wooden block and the outer skin.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture471_640_x_480.jpg)

Now, having sanded all the upper part of the body, all the storage bin holes are masked up and the area painted firstly with epoxy primer and then hi build primer.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture475_640_x_480.jpg)

As we are going to add top coat colour this time, a guide coat of black is added.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture476_640_x_480.jpg)

This then sanded, untill all the black is gone. This makes sure all the marks and imperfections have been sanded out. The bins are masked up again.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture477_640_x_480.jpg)

The colour is now spayed on. The colour we’ve chosen for this is a period colour from the 60s & 70s, BMC “Old English White”.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture478_640_x_480.jpg)

After the paint has tacked off, the whole thing is demasked.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture481_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture482_640_x_480.jpg)

Need to let it harden off completely, then we can start to fit it up with lights and stuff

Right, whilst the main body is hardening we’ll paint the lower rear door, hinges and the hook up flap.
Hook up flap first, as it’s plastic we need to have some adhesion and flexability so firstly a coat of adhesion promoter then a couple of light coats of etch primer. This ensures that the textured finish is not lost.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture496_640_x_480.jpg)

Then a couple of coats of “Old English White” to finish.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture512_640_x_480.jpg)

So onto the lower door and hinges. It was decided to paint the hinges body colour, firstly ‘cos they just wouldn’t look right in black and in the early advertising and the video they are shown as a light colour, so either body colour or white. Same prep as the body, one coat of epoxy and two/three coats of high build primer all sanded down and painted with three coats of colour.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture514_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture513_640_x_480.jpg)

After painting the main part of hook up unit, where the hinges are, by hand (brush) it was fitted to the body and the flap fitted to that using it’s pivot pins.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture519_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture520_640_x_480.jpg)

To fit the lower rear door hinges, it was decided to use rubber gaskets. As these can’t be bought, they had to be made. A quite simple job, a piece of wood with two holes drilled for the bolts, some thin flat rubber (old truck inner tube) and a sharp craft knife. Cu two holes in the rubber, install hinge through the rubber into the holes in the wood and cut around the hinge.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture511_640_x_480.jpg)

Right we are now ready to fit up the rear end. Fit half the hinges to the main body and the other halves to the lower door. As the hinges had been badly fitted in the first place and this made the lower door too low, an easy fix to raise the door would be to make two oblong brass balls to fit between the two hinge halves. As luck would have it some of the Land Rover hinge balls are a larger diameter, which just meant turning down the middle diameter to make them oblong. The door was then assembled to the body and secured.
The original style new handle, obtained from www.vintagesupplies.com for 20 quid each, was fitted with stainless steel screws.
The refurbished original number plate light was reposition to the centre of the lower door.
Number plate fixings were made from a couple of import lower number plate fixings and a couple of Rivnuts for the top mounts.
The rear lights chosen were the same lights that we used on our Airstream camping trailer and are of the type used on an Austin A55. They were obtained from www.vintagemotorspares.com for 22 quid each. These were fitted and connected. Also the reflective triangles that came with the caravan originally were secured with SS screws. And now it all looks like this……….

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture538_640_x_480.jpg)

Now we’ve made a start on the sides. The left side has had a couple of small repairs in the gel coat done and sanded. Following what went before, one coat of epoxy and a couple of coats of high build ……….

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture531_640_x_480.jpg)

A guide coat ……………

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture532_640_x_480.jpg)

All sanded down and then three coats of colour …………….

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture535_640_x_480.jpg)

I thought that while that was starting to dry off, I’d install the hinges ready to fit the whole side to he body once it was completely dry. I seem to remember reading on one of the other forums that people were having a problem getting the correct countersunk rivets (something about they were only available in metric). Well the original ones would have been 3/16”, these are still available all over the place, but you need to look outside the box as they are now listed as 4.8mm. These are the guys we got ours from, on eBay..
http://www.ebay.co.uk/itm/170408253445?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649 , 100 for 7 quid delivered.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture536_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture537_640_x_480.jpg)

Until next time then ……………………..

Just a small update, managed to a little bit today (waiting for parts, so couple of hours around lunch time).
Didn’t want the side kicking around getting the new paint damaged, so cut the rubber cord seals for the end channels, glued the channels and the cord (on one side only) and then fitted them.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture549_640_x_480.jpg)

After fitting the flat seals on the end flanges of the painted side and also along the top edge a small amount of silicone grease was put on the rubbers and the side installed into position. The inner parts of the hinges were then riveted to the main body.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture550_640_x_480.jpg)

The operation of the side was then checked, both in the up and down position.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture552_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture551_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture557_640_x_480.jpg)

Then to complete the installation, the “sealing strip” was added. I have tried to obtain some thing like the original, but to no avail. I managed to find some wide gaffer (duct, racers) tape and just ran 3 overlapping lengths. His seems to work OK.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture555_640_x_480.jpg)

Back onto the other side later in the week……………

Just a quick update, managed to sand and get some primer on the right side during the week. I was then able to sand and add 3 coats of colour yesterday (Saturday).

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture559_640_x_480.jpg)

Whilst waiting for the paint to “go off”, ‘cos I hate watching paint dry, I finished off the lower door catch.
We had been having problems with the lower door not closing level. This was to do with the position of the hinges, having not been fitted correctly at the factory. Although these are self aligning hinges, they have to be fitted with the axis vertical for them to work properly. Inside the body is a strip of metal that is drilled and tapped with a thread to take the securing bolts for the hinges. It wasn’t possible to retap the threads further down, by the small amount needed, so I made up a new striker plate to fit on the door “frame” and a wedge device to fit on the door. As the door is closed the final amount, the wedge contacts the striker and lifts the door into its proper position. The items were fabricated from stainless steel and polished. Just need to substitute the black screws with some stainless ones now.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture560_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture561_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture564_640_x_480.jpg)

‘Till next time …………….

Quote from: merv on May 08, 2012, 08:34:49 AM

Whens the next instalment? :)

Now ....................

So with the right hand side riveted on, it’s now time to turn attention to front and rear walls and the upper door.
The upper door did require some considerable repair work. All the “damage” probably happened, either when it was pulled from its mould or when the inner and outer skins were clamped and laminated together. All the cracks were ground out to below the gelcoat and filled with resin and chopped strand mat. This was then sanded and filled with normal body filler to get a smooth finish.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture566_640_x_480.jpg)

The ends really didn’t need too much attention, so together with the upper door were sanded and primed. A quick guide coat and left overnight. The following day all the panels were sanded and sprayed with three coats of “Old English White”.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture568_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture569_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture571_640_x_480.jpg)

Once the paint was dry, the hinges were added to the ends. The following day the flat seals were added to the main body, at the ends, and the ends then fixed to the main body using stainless steel screws (they don’t rust like the old ones!!).

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture573_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture574_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture575_640_x_480.jpg)

So now onto the major problem of it all, the roof. This was pretty bad and even with the work carried out on it so far, it’s far from perfect. What has got to be remembered the more strength we add the more weight we add, therefore making it more difficult to lift.
All the starring has been ground back to below the gelcoat and more so on the structural repair area on the right side (where obviously the wind had caught the roof at some point and split that side and damaged the centre strip of the roof). The normal repair to all these areas was carried out (resin and chapped strand mat).This will be allowed to harden off before sanding and filling.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture577_640_x_480.jpg)

Will get round to a bit more this weekend …………

Sorry it’s been a while since I updated this thread, but we’ve been really busy. So anyway here’s the next short instalment ………………………..

Now the roof has been repaired (ish, really it needs replacing) it has been sanded down and all the repairs filled.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture581_640_x_480.jpg)

After which it was sanded down again and sprayed with epoxy primer and 2 pack hi build primer and sanded down again for the colour coats.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture582_640_x_480.jpg)

The colour coats were added and then 3 coats of clear lacquer. We decided on another period colour, Rootes “Electric Blue”, that was very popular back then, to paint the roof.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture583_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture585_640_x_480.jpg)

Whilst the paint was drying, I cleaned up all the windows and refitted them to the walls.
After the paint had dried the fixings were riveted back on and the roof placed on top of the rest of the assembly.
To hold down the roof we have had made a couple of leather straps, which have to be shaped and treated before they can be fitted.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture593_640_x_480.jpg)

These will be shaped (into a flat circle) and then treated with dubbin to protect them from the weather.
Managed to get the Portafold back to home yesterday (Saturday) afternoon to start fitting the interior out over the extended weekend. We’ve less than a week before we need to tow it down to the New Forest (Pylewell Park) for its first event!!

Ha, you wish ;D

We wanted to put a floor in it that was of the period, so when some mini parquet flooring became available (for nothing), that’s was what decided on. The flooring came as separate pieces.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture443_640_x_480.jpg)

We started with a thin wood base.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture440_640_x_480.jpg)

Then using sikaflex, each tile was individually placed on the board.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture441_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture444_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture462_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture486_640_x_480.jpg)

It was then sanded down flat using a belt sander.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture503_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture505_640_x_480.jpg)

It was then coated in 3 coats of 2 pack lacquer.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture507_640_x_480.jpg)

And finally fitted into the floor area of the Portafold.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture508_640_x_480.jpg)

Well here we are at the final furlong.
We decided to put some period alloy wheels on and, as luck would have it, a friend of ours had some wolfrace slots that he was willing to donate to the project. Wolfrace wheels, owned by Barry Treacy, started making and selling these wheels in 1971, so well in period.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture232_640_x_480.jpg)

They did need a bit of a cuddle ……………..

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture280_640_x_480.jpg)

These were wrapped in some new rubber and fitted.
Now it was time to look at the interior. We needed to sort the number and layout of cushions needed.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture375_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture374_640_x_480.jpg)

We had for some time been thinking of denim to cover the cushions. Eventually we found a roll of stone wash denim, from a haberdashers in Hounslow.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture436_640_x_480.jpg)

Had four more cushions made.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture437_640_x_480.jpg)

This is a picture of all the covers finally sewn up, ready to fit to the cushions.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture439_640_x_480.jpg)

At this point we realised that we finally had a name for the caravan …………… Levi. So Levi Portafold it is.
Whilst things were being sewn up, some scatter cushions were constructed.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture497_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture498_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture499_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture501_640_x_480.jpg)

Gingham was the preferred material for the curtains, and Sue made these up at the same time as the rest.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture579_640_x_480.jpg)

Having decided the name we had this panel embroidered

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture586_640_x_480.jpg)

And this prototype decal for the window

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture594_640_x_480.jpg)

A square of gingham was cut out and inserted onto the “table” which was then covered with a tempered glass top.
So now we have an interior that looks like this

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture600_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture607_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture612_640_x_480.jpg)

And with the bed laid out

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture614_640_x_480.jpg)

This weekend (first time out) we had a pinstriper, “Tootal” Paul Dorrington ( http://www.tootall.info/ ) do what he does best.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture598_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture596_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture599_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture635_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture634_640_x_480.jpg)

Now, with the addition of a few period themed pictures we’re pretty much finished. A few more pictures of the outside.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture615_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture617_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/portafold/picture629_640_x_480-1.jpg)

Well that’s about it. Thanks to all those that have been looking in since last year and those that have helped with information.
We’ll just go and have fun with it now.

Manky Monkey Motors

Technical Section => General Tech => Topic started by: phunkie hiboy on May 06, 2012, 08:07:41 PM