LRCC

Hello all!
This is Richard from California. I have got my hands on what I found out is a 1967 109" Carawagon. It had been sitting for some time but the California climate is kind to old cars. It has a 2.25L diesel and it is not that common in the states so has been a bit of a hunt for some of the parts. The engine had some odd parts on it as you can see in the pics. I found out the exhaust and oil pan were from a marine version of the 2.25L. It is like a big puzzle. Started in on it with all mechanical systems to get it running. So far so good. I could rebuild most of what I found. Done with the Brakes,Clutch,Cooling system, fuel system, working on the electrical and seats now. Removing 50 yrs of experimental wiring from past owners. everything in the back had been removed and as I look around it seams like each truck was unique so I am free to build it back as I wish. My next job will be the pop-up roof. I have the seals on order and will fabricate new wood sections. I do have questions for anyone that have done this before. Any tips would be appreciated but I'm most interested in how to safely remove the old rivets and piano hinge with out damaging the aluminum roof panel. Enjoy the pics! FYI the guy in the photo is the old owner not me!

Welcome, Sir, amd good luck with your new obsession.



You made a nice job of that seat cover.

Thanks for the compliment on the seat. My daughter could not believe I knew how to sew. She laughed as I pulled out and dusted off my 30yr old all metal sewing machine.

Happiness is a warm machine.

I have secured a place in Tewkesbury to work on larger pieces of canvas so I can now tackle awnings and sew (sic) on.

I just need a machine with a longer arm I guess.

Hi, that's a nice project a long way from its original home

As you say, they were all bespoke so you can do what you want with the inside.
However, to get the same look/feel of the original Carawagon, you can use ply or block board with mahogany trim on the edges, and either covered in 1960's pale grey or white Formica or varnished.

There should be plenty of pictures of Carawagon interiors on the forum, so you should get some ideas.

To answer your question about removing the rivets, we've done several roofs and there's not much alternative to drilling them out or grinding the tops off, carefully!
You should find, if they haven't been replaced in the past, that they are closed end rivets, which means they are left with the steel 'pin' inside and so can't be taken off with a chisel like you can with all aluminium rivets.

If you take out all of the screws that haven't already fallen out, you can lay the roof panel upside down on the ground and if you lay the hinge on a length of timber, you can drill out the rivets from the hinge side.
Or, lay it right side up and use a grinder with a slitting disk to take the top off each rivet.
We've used both methods and the slitting disk was a lot faster and easier though you do have to be very careful not to catch the alloy roof panel.



If you are using the old timbers as patterns, try to get exactly the same thickness as there is very little tolerance when you are trying to fit it and make it fold and lift properly.

A roof with new timber certainly makes a nice spectacle



Hope you have fun restoring it, and please come back with progress reports and any questions you might have.

Cheers,
Robin.

Thanks for the tips Robin.
Yes the rivets are the close ended type so they may have the steel pull head in them.
My timber is rotted and split. What size is it stock? looks like two different thicknesses.

Hello Richard and welcome! Where about in California are you based? I think that makes two of us on this list in California! Good luck with your project!

Ian

I am just west of the antelope Valley. How about you?
Richard

Stricklen wrote:Thanks for the tips Robin.
Yes the rivets are the close ended type so they may have the steel pull head in them.
My timber is rotted and split. What size is it stock? looks like two different thicknesses.

As far as I remember the sides are 3/8" and the ends 1/2", though I think at least one of mine was all 3/8".

It could be that Searle changed their stock over the years, either to save weight or cost by using the thinner ply, or a previous owner replaced the wood many years ago

I suspect once you remove the old wood you should be able to find enough good sections to measure, even if it means cutting through a piece to get to a good bit in the middle.

Of course, you can use any thickness, but you then have to allow for the difference with the sides as the hinges are on opposite sides of that piece, so an 1/8" difference in thickness will throw the whole lifting and folding process out.

I usually have to trial fit a couple of times and trim the ends to make it work properly, and that's with using the same thickness as original and using the old pieces as patterns, that's how tight the tolerances are

Cheers,
Robin.

Hi Richard,

I'm at the west end of Zuma beach at the cheap end of Malibu(!). Which in California terms, makes us next-door neighbors. I usually head up through the Antelope Valley and along the Old Sierra Highway on my way to points east a couple of times a year, usually ending up on Route 66 for the most part. Sorry I can't help you much with Carawagon specifics (well, except for sympathy) as I have a Dormobile, but if I can help with anything else, let me know.

Best regards,
Ian