109 GS Resto

[Phoenix]

Aren't they all soldered together, or is the outer part welded?  Remove and repair.  The series 3 tank is pretty easy to remove truth be told!

Re the data plate, the series 3 ones noted both on them, note it says 6028 , 6028B, covers all bases! 

[Chazza]

Your rusted support is the twin of my S3 one!

I have started doing the following:
1. Remove tank and remove sender unit; pick-up pipe and filler hose.
2. Inspect inside of tank - mine was filled with a foul-smelling varnish that was once petrol.
3. Replace sender and pick-up and fill tank with caustic soda solution.
4. Flush tank with high-pressure garden hose.
5. Repeat 3&4 with tank upside down.
 
The next steps, which I haven't started yet are to:
6. Heat the base of the support plate where it is still soldered onto the tank and remove plate. SAFETY DO NOT do this if the tank has recently had fresh petrol in it; send it away to be professionally cleaned by experts. In my case the risk of explosion seems to be very low, especially with the sender; pick-up and drain plug removed.
7. Make new support plate.
8. De-rust base of tank and treat with Penetrol.
9. Glue new base in place with Sikaflex Adhesive.

Cheers Charlie

[Aussie Jeepster]

When I had my Series 2A FFW. I had a leaky tank and found that 3M make a fuel resistant glue which I coated the inside of the tank with.
Basically you pour a goodly quantity in the tank, move it around to coat the affected areas, then pour it out and let dry for 2 weeks.
It worked great and was still good 3 years later when I sold it.
I know that is not your issue, but it might help others with small leaks/weeps from their tanks

[Polizei]

http://www.kbs-coatings.com/auto-fuel-tank-sealer-kit.html

I was thinking of using this to restore tanks if I was going to all this trouble.

I already have Aqua Klean and Rust Blaster from the chassis pack I bought. Would only need to purchase the fuel tank sealer.

It is highly probably my tank is full of lots of muck 

[Vixen]

Redkote http://www.ftrs.com.au/redkote/red_kote.php worked well in Castrol's tanks. Sealed a couple of larger holes (ie clearly visible holes not just pinprick sized) and has stayed sealed for maybe 5yrs now

[Chazza]

I have just completed a trial on a rusty baked-beans tin using the glue used for joining PVC pipes together - Back In on AULRO mentioned it some time ago - anyway the results so far on the tin are excellent for both diesel and petrol; and a fraction of the price compared to the proprietary kits. Caustic soda is is fantastically good for removing grease, oil and petrol gum; also at a fraction of the price,

Cheers Charlie

[Polizei]

Thanks Charlie I will look into it.

Cheers,

Ed

[Polizei]

Anyone have strong opinions on the colour of the chassis?

I assume they all came from the factory black, but over the years were often over sprayed with olive drab. As you can see mine was over sprayed with the olive drab.

Either way I am going to put on the black but I may then top coat with green if 'more correct'

Cheers

[Polizei]

KBS Rust Sealer
Sprayed on chassis this morning. There are a few awkward spots I cant get to with the gun.
Looking good! Few areas of overspray will be taken care of when I do the body.

[Phoenix]

Looking good! 
\
Yes, mostly new was black chassis, but many were oversprayed.

[Polizei]

So...after a long delay I finally got around to sorting out the body today. Paint went on really well. I also had a few aerosol cans to touch up any minor areas I missed. The colour match was perfect between the two so no worries there.

Next to paint will be the wheels, bull bar and air lift brackets. Reassemble and then on to the mechanics.

I think it looks pretty good!









First coat


Second coat

[rednjoey]

A thing of beauty, I look forward to seeing the finished job.

Well done that man...

[Polizei]

More olive goodness!

Did the wheels, bullbar and rear jerry can holders. Once again paint went on well without any issues. 20% thinners seams to work well.

Anyway I only have a few photos half way through. Wish I had painted the rims before the tyres went on, but for various reasons this was not possible at the time.





Bullbar got a coat of penetrol before olive



My spray gun

[rednjoey]

Hi Ed

Interesting that you use an 80-20 mixture in your gun. I use a HVLP gun with a 50-50 mixture at about 30psi. What pressure you running in yours?

[Polizei]

30-35 psi

I spoke to the guys at protec re thinning. The guy said start are 20% and inreaseto 25% if necessary. Seemed to o on fine at 20...

50% sounds very thinned out!