Project Navara Body tub

  1. Blackolive

    Blackolive Member

    Messages:
    368
    uk lancs
    Shortly after taking on two Horses, I decided that our trusty Zafira whilst handy for carting hay etc was going to get killed doing the yard run twice a day and I "needed" a truck.

    One rainy saturday afternoon I was browsing ebay and decided to go have a look at Tonka, and ended up coming home in it. so far its been the best motor Ive ever owned, and is proving to be ideal for towing horseboxes, carting stuff about, and supporting antennas for my hilltop radio exploits.

    Ive already done a couple of chassis repairs and given it a clean up and a blasting with rustproofer underneath, and for its age its quite solid.

    Onto the rear tub, its had a replacement tub fitted at some point, but
    Id noticed rust bubbling around the arch extensions and fuel filler flap, and along the front corner of the tub.

    As Im intending keeping the truck for a long time, Id already thought of getting hold of a better tub, so it can be fettled up and swapped over in the summer. thought Id take the nearside arch extension off and have a poke about, and it confirmed that this is the right course of action.

    the design is brilliant for an off road vehicle in a wet climate in there are no inner arches, instead two pressed steel splashguards open at the front and rear serve to collect any muddy water splashed up rom the wheels, and hold it for just long enough for the silt to settle and sit on top of the splashguard, and behind the fuel filler flap. the fuel filler pipe shield on the offside also serves a similar purpose enabling wet silt to be held against the steel fuel pipe.

    Anyway, after poking about at the nearside, and finding that most of the holes for the arch flare retaining plugs were actually much larger than the plugs, and removing a cubic foot of earth, and most of the inner splashguard from the nearside I decided to gaffer tape it all back together and look for a replacement tub.

    found a black one on Ebay and took a punt on it. was £145 delivered, I think the poor bloke had understimated the faff of getting a body tub onto a pallet though and it took a while for him to find a courier that would take it.

    its duly arrived, and had a power wash. the offside splash guard is confetti, but part of the plan is to cut these out anyway so I can get behind them and do a proper rustproofing job, and if I can, either design out the mud traps, I dont think I can do a fully sealed rear arch on the offside as the fuel filler pipe has to go through it, but I think I can fully box the nearside in, and maybe build in a row of drain holes on the offside one ( which will also let me get the power washer into it- any ideas gratefully accepted here )

    Its also looking in a lot better condition than mine round the plastic arch flare plugs which Im quite relieved about

    the nearside splash guard's good and solid too.

    just need some decent weather now to crack on as Ill have to work outside on it.
     
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    andy_v likes this.
  2. Blackolive

    Blackolive Member

    Messages:
    368
    uk lancs
    more pics
     
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    andy_v and slim_boy_fat like this.
  3. Blackolive

    Blackolive Member

    Messages:
    368
    uk lancs
    couple of questions.

    1) would a mobile sandblaster be likely to come and do the rusty bits underneath, or could I do it with a machine mart pot type blaster ( compressor 14cfm with 250L tank )

    2) whats a recommended rustproofing primer for the underside that can be brush or roller applied ?
     
  4. frank horton

    frank horton V twins are great but 4"s rule.........

    Messages:
    1,351
    Location:
    Soon 2 B Crete
    unless a spare tub was cheap and rust free (hahaha) I'd make me on body for the back....but won't be so pretty........if it has to work for a living who cares........1/2 the style of a Landrover !!!!!!!!!!!!!!!easy to make and easy to fix........
     
  5. postie jon Member

    Messages:
    787
    Location:
    Aberdeenshire, Scotland
    wot kind of miles has it done?
     
  6. Muppet Member

    Messages:
    94
    Location:
    Lancashire
    I would be more worried about the engine dropping a rod,
    I had a d22 from new, 04 plate , most of the engines from Spain had a design fault ,
    Big end bolts stretched and fell off , leading to the con rod popping through the block,
    Mine rattled twice befor I turned it of , 3k for a new rods , bolts , bearings , oil pipe re designed,
    Still a good pick up though
     
    Ruffian likes this.
  7. postie jon Member

    Messages:
    787
    Location:
    Aberdeenshire, Scotland
    friends did the same ,no warning, bang , trail of engine parts along the road. it was an 05.
     
    Ruffian likes this.
  8. Blackolive

    Blackolive Member

    Messages:
    368
    uk lancs
    Its done 110k. Previous owner did the billcar mod (new shells and big end bolts) so hopefully trouble free.

    Spent the afternoon stripping the tub and getting back to good metal
     
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    andy_v likes this.
  9. optima21 Forum Supporter

    Messages:
    2,615
    Location:
    halifax, England
    jotun 87 epoxy primer seems to have a good reputation on here.....so I bought some of the wintergrade and used it on mine. this was brush applied, and mixed up in 150ml or 250ml batches, you have up to 2 hours to apply it.

    [​IMG]

    [​IMG]

    three coats were applied after taking the shell back to bare metal and welding in new sections
     
  10. Blackolive

    Blackolive Member

    Messages:
    368
    uk lancs
    That looks like good stuff
     
  11. postie jon Member

    Messages:
    787
    Location:
    Aberdeenshire, Scotland
    jotuns epoxy primer, if this stuff is as hard as it sounds what do you use to key it before applying topcoat? we used to use spencers RS2000 on hgv chassis but had to make sure it wasnt cured beforeapplying the finishing colour. just a query ,may try some if others recomend it.:thumbup:
     
  12. optima21 Forum Supporter

    Messages:
    2,615
    Location:
    halifax, England
    I don't topcoat the primer I just use it as it is under the car......I may regret that 10 years from if it turns chalky due to damage from ultraviolet light.
     
  13. Tigman

    Tigman Forum Supporter

    Messages:
    2,779
    Location:
    Watford UK
    So while the truck is in the refurb what's doing the work in its place ? Back to killing the Zaffira ?
     
  14. Blackolive

    Blackolive Member

    Messages:
    368
    uk lancs
    Bought another tub off ebay so I could do it slow time then swap over. 6 bolts and a loom plug so should be a quick swap.
     
  15. Blackolive

    Blackolive Member

    Messages:
    368
    uk lancs
    Made a wheelarch today. Havent gone overboard grinding welds flush as they will be covered up by the extension flares
     
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    andy_v likes this.
  16. Tigman

    Tigman Forum Supporter

    Messages:
    2,779
    Location:
    Watford UK
    Sorry my fault I came down the thread and thought optimal pictures were yours too !:scared:
     
  17. Blackolive

    Blackolive Member

    Messages:
    368
    uk lancs
    no worries haha
     
  18. ukracer Forum Supporter

    Lots of spare tubs without rust available.....
     
  19. And I thought Land Rovers were bad....................
     
    zx9 likes this.
  20. bricol Member

    Messages:
    763
    N.Yorks, UK
    I hope you keyed the surface well. 13 yrs after applying 2 part epoxy primer under mine by brush, the areas where I'd sand blasted the metal it was still stuck like poo to a blanket - ie keyed as per instructions. Areas I'd only wire brushed, by hand or grinder, it had separated from the metal in large areas (several inches) letting water underneath. It was easy to pick off with a fingernail.
     
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