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Abstract:

This video segment focuses on the mechanical restoration and modification of a heavy vehicle's rear frame. The primary tasks shown are the fabrication, test-fitting, and final welding of custom engine mounts onto the chassis. The process includes addressing engine clearance issues with the sump and transmission output shaft. Significant work is done on the rear deck, involving the repair of a damaged section with a new plate, preparation and fitting of new sheet metal decking using adhesive sealant (Sikaflex), and the decision to replace traditional tread plate with modern non-slip grip tape. A considerable effort is made to locate and clear existing wiring conduits running through the vehicle's counterweight, but these are ultimately abandoned due to obstructions and a problematic path that could trap water. The decision is made to drill new vertical wiring runs instead. Final welding of the deck is completed, but sealant application is postponed due to high humidity affecting cure times.

Engine Mounting and Rear Frame Restoration

• 00:05:04 Goal Setting: The main objective for the session is to get the engine mounted on the rear frame.
• 00:05:21 Engine Mount Fabrication: Work begins on creating the engine mounts, which will be bolted to the engine and welded to the chassis.
• 00:07:03 Mount Design: The engine mounts are noted to be two different sizes, designed to position the engine correctly offset within the bay.
• 00:11:53 Test Fitting Engine: The engine is lowered into the bay for a test fit with the mounts loosely bolted.
• 00:11:56 Mount Function: The importance of engine mounts absorbing vibration to prevent damage is highlighted.
• 00:13:15 Clearance Issues Identified: The test fit reveals potential clearance problems with the rear transmission output shaft and the engine sump relative to the chassis.
• 00:14:10 Mount Placement: After confirming the engine position, the chassis-side engine mounts are tacked securely onto the frame.
• 00:15:27 Engine Removal for Welding: The engine is lifted back out to allow full access for completing the welding of the mounts to the chassis.
• 00:19:31 Deck Repair: Attention turns to repairing a damaged top plate on the rear deck, which was gouged out previously.
• 00:23:06 New Plate Alignment: A new section of plate is measured (to match the original 60mm height) and prepared for welding into the damaged deck area.
• 00:24:17 Tacking New Deck Section: The replacement plate section is carefully aligned and tacked into position on the chassis.
• 00:25:17 Rear Guard Fabrication: Sheet metal pieces for the rear mudguards are tacked onto the frame.
• 00:28:12 Strengthening Welds: The engine mounts are fully welded, and the gap between the new deck plate and the existing structure is welded for reinforcement.
• 00:32:32 Deck Sheet Metal Preparation: New sheet metal for the top surface of the deck is prepared, including applying etch primer to the underside for rust prevention.
• 00:34:41 Adhesive Application: Sikaflex adhesive/sealant is applied between the layers of the deck sheet metal to bond them, hold them in place, and prevent vibrations.
• 00:37:32 Modern Non-Slip Surface: A decision is made to use modern adhesive non-slip grip tape instead of traditional metal tread plate for the final deck surface, offering better grip even with oil or grease.
• 00:37:50 Wiring Conduit Challenge: The task of running wiring from the engine bay to the taillights begins by attempting to clear the original conduits.
• 00:39:01 Obstruction Encountered: Attempts to drill/clear the conduit hit a steel obstruction, suspected to be part of the internal counterweight.
• 00:39:57 Conduit Path Discovery: Using a jackhammer, the path of the conduit is successfully exposed, revealing it runs into the wheel arch.
• 00:42:52 Counterweight Complication: Clearing the conduit on the opposite side reveals it passes through the counterweight, which seems filled with loose material (black sand), and the drill hits an obstruction.
• 00:43:48 Decision to Abandon Old Conduits: Due to the discovered convoluted path (dipping down into the wheel arch, risking water ingress) and obstructions, the plan to use the original conduits is scrapped.
• 00:44:08 New Wiring Plan: New vertical holes will be drilled through the deck to create a more direct and water-resistant path for the wiring. The old conduit openings will be sealed.
• 00:44:36 Welding Complete, Sealant Delayed: Final welding on the deck structure is finished, but applying more Sikaflex is postponed due to high humidity, which would prevent it from curing properly.