Yo...
A few more hour of progress today..
Built a new tailgate /bootlid.
Cut down the existing 2 side rails from 150mm to 75mm. cut 4 new cross rails. screwed together. Trial fitted.
Clamped and sanded side rails so they are exactly the same shape as the body of the TD.
Then cut a couple of corner gussets to help keep the frame square..... (screwed a temp bace across three of the cross slats later on)... all good.
Sat the frame back in place and got to thinking about a hinge..
.
Was going to use a length of "Hurricane Hinge" that Koala used on his TD a while back...
Then I got to thinking there is another way to hinge the lid without using a hinge.... if that makes sense
With the frame sitting exactly in place I drilled a hole in the body of the van to line up about 15mm in and 25mm down from the frame corner on either side.
Then screwed in a 75mm X 10g woodscrew through the bondwood body and into the end of the top cross rail......
Grabbed hold of the rear of the frame and gently lifted it up .. waiting for it to bind on the vertical cross wall of the kitchen....
But it cleared it all the way up....
.. as the tailgate rises .. the front of the lid at the hinged point actually drops and comes away from the wall... couldn't believe my luck
With it fully open there is about a 10mm gap.... with it closed it has about a 3mm gap between tailgate frame and kitchen cross wall of van.
I spent the rest of the arvo dreaming about how to waterproof the gap ...
In the end.. answer is dead set simple..
just drill and mount a length of 25mm wide J mould to the roof so it protrudes 20mm over the join and rubs on the tailgate lid when shut.
If I do have trouble with leaks later I can also use a 50mm wide strip of rubber across the gap like I did on the first TD .."Splinter Hilton"..
So.. at the end of the day.. not a massive amount done.. but... progress just the same.
I spent the rest of my free time removing the sports steering wheel off the EH panno and putting the original one back on... man.. it feels like I am driving a mack truck with that big wheel... but hey.. at least the horn doesn't beep everytime I go around a corner now like it did with the cheap Chinese racing wheel on it..
Can cure the problem .. but not for a while now.
Reddo