Mike's 1973 D22 Complete tear out. From the Roof down!

[RockwoodMike]

I checked to be sure the bearings would slide on the hub shaft nice..The inner(big) wasn't nice!!

Pic 1..After 50+ years and 1000s of miles you can see the pounding(not much) the shaft takes..

Pic 2..Emery paper to smooth it out and the bearing slides on now..Before it would just jam up

Pic 3..Outer area of the smaller bearing..The bearing was chattering because it wasn't adjusted right..More emery paper smoothing..

Pic 4..Bearings are all ready to go together..Threads on the adjusting nut are smooth

[RockwoodMike]

Found a power steering pressure side hose..1 to install and a spare to carry where ever I go..Gotta start collecting spare parts to carry on the coach

[RockwoodMike]

Pic 1..Emergency cables all set up..

Pic 2..Emergency brake handle.

Pic 3..Drum and hubs on..Brake shoes adjusted..

Pic 4..Work on the front calipers tomorrow..

[Eyez Open]

Ahh dual pistons,nice setup. GM uses a single piston in my 83,odd how they cheaped out. Are you going to hone those cylinders out? Never seen a caliper sandblated before,little paint and just like new.

[RockwoodMike]

Are you going to hone those cylinders out?

No..You are not suppose to do that..With moisture in the brake fluid, it will cause pits in the walls of the open bore..But if you hone the bore you make it bigger possible causing the piston to seize because it tilts in the larger bore..

The seal is the piston and the square cut o ring..If the piston has pits in it, then you will need to find a new piston..Simpler to find a rebuild..

My pistons are very smooth..A little 3M scotch bright and they cleaned right up..

little paint

Paint!! Paint??  It's powder coat or nothing!!

After sand blasting, then into the sink with Simple Green to wash dust and grit away..Blow dry and then into the oven to burn out any oils or moisture out..400 degrees for an hour or so..

Let them cool down..And it's time for powder!!

Mechanical engineering states that anything made in Red will be more powerful..go faster..have more duration and with brake calipers, make you stop faster!!  

So I have a color called Blood Red..Here are the pictures..

Pic 1..Hung up and ready to powder..

Pic 2..Powdered..

Pic 3..Out of the oven..400 degrees..1 hour


 

[RockwoodMike]

All done..just need to install seals and pistons

[RockwoodMike]

[RockwoodMike]

Working on the front eyebrow some more..4 sections to make this shape..

Pic 1..Section 1 and 2

Pic 2..The droop over piece..That was not an easy piece to make!!

Pic 3..from the inside

[RockwoodMike]

The windshield must be in place, held with clamps, to make the rest of the eyebrow structure..The eyebrow locks into the top channel of the windshield frame..

This is a ton of work..And I am doing it all by myself..

[originalkwyjibo]

Nevermind, just made it to page 10 and saw the post about the transfer of the site and the loss of all the photos.

[RockwoodMike]

All the pieces are made..Need to screw and glue it all together..Just held with clamps right now..Once everything is solid then I need to sand and shape the pieces to smooth them over and blend them together

A ton of work!!

[RockwoodMike]

https://www.rockauto.com/en/moreinfo.php?pk=11572185&cc=1504224&pt=1684&jsn=902

The brake pads that are going in this..

[RockwoodMike]

Brakes for the front installed..Still need to make some brake lines to complete the system..

[RockwoodMike]

more pics

[RockwoodMike]

You have to bleed out the new master cylinder, before you start on the brake bleeding..

Made these lines that go right back into the reservoir..It took about 20-25 pumps of the brake peddle to burp the MC of air..

Ran out of daylight..will bleed the rest of the system tomorrow..

[Eyez Open]

Speed bleeder's I've used them and they worked to purge the system. A long term evaluation has not occurred yet but they work quite well.

https://www.oemys-performance.com/speedbleeder.htm

https://youtu.be/35zk5txah8c?feature=shared

[RockwoodMike]

https://youtu.be/TOF4vhblUvw?t=186

[RockwoodMike]

This is the thing I made to do the brakes like in the video..The hose kept curling up out of the fluid so I strapped a bolt to it to weigh it down..

I had a completely empty system when it came to brake fluid..I ended up using 3/4 of a quart, with the reservoir topped off

You could see the bubbles in the bottle as you slowly pumped the peddle..then there were none and you knew you were done on that wheel.. 

After everything was bled, the brakes are very solid..And that is without a vacuum source..I guess that is what you get when EVERYTHING is new or rebuilt!!

[Edmather]

Hi Mike, great work on the restoration. I've been looking through your pictures as I need to repair my front corners: rotted wood where the curved outer trim is attached. However I can't see the photos from your post of these areas, just the comments. Do you have an album that I could view? Thank you, and keep up the good work!
Ed

[RockwoodMike]

Hi Ed,

Are you talking about the front face pieces as shown in these 4 pictures??

If so, I haven't arrive at that point yet..Other than tearing them off and storing them away..

Everything that involved wood was rotted on this..everywhere it leaked..

I am currently working on the front end..And these pieces will be involved soon enough..

Mike

[RockwoodMike]

Pic 1..All sanded and shaped..

Pic 2-3..First layer of polyester resin..After it is hardened, then I will fill all the screw holes and imperfections in the wood..

Then begin glassing with 1708 cloth and then a chop strand to blend everything..

Never done any fiberglass work..Just watching plenty of YT!!

[RockwoodMike]

Pic 1-2..Doing the first section of glassing..About a foot wide..Takes about 1.5 pints of resin to lay it up..

Pic 3-4..Second section with about an inch overlap..

[RockwoodMike]

The beginnings of my fuel system..A pump for each tank feeding to a water separator spin on filter..

I think that will fix my fuel delivery problem!!

[RockwoodMike]

Working on the fuel filler neck area...

Pic 1..Here is the piece I have to work with..not much there..

Pic 2..Time to make something new..The joys of having your own CNC plasma cutter!!

Pic 3..Test fitting..this was trial 3..first 2 attempts didn't fit right..

Pic 4..test fitting the filler necks..

[RockwoodMike]

Pic 1..With the new rubber..2.25 from NAPA..

Pic 2..After powder coating and bolting it down..After the skin of the wall is on, I will make a locking door to cover it up..Nice clean look..