Chassis repairs

The repairs to the chassis are important, as this is fundamental to being roadworthy.
But I have not enjoyed this part, and because I delayed it, it caused extra problems. I also needed to use in total 3 mechanics and ordered various bits and bobs - this is now complete more or less!

The van is old - estimate 1985-1988. Not only does this mean some parts are shot due to age but some are no longer available.

So the instructions to the mechanics went like this:

1. (On purchase) "Yes, I know its a wreck, just do what you have to so I can tow it without killing anyone."
2. (Before driving Lancashire to Surrey) "Yes, I know its a wreck, but the first mechanic told me the chassis was basically sound?... just help me work out how to get all the workings around the A frame at the front fixed. Oh, and do that work please."
3. (After 2 months use, mostly on the same site in Surrey. After the site owner refused to move it having 'done his back in' trying to get the jockey wheel to behave, and after a few conversations where they said, 'it just won't move,' to which I said, 'well I did it'. My welcome is worn out... ) "Yes, I know it's a wreck, but I've hot most of the parts. My last mechanic just didn't have time to get the missing bits so I had to delay the work. I know it was unsafe, still I got here and I didn't kill anyone..."

This has been a slow piece of investigation work. The good news was that the basic chassis rectangle is fine, as is the axle. The wheels are adequate, new tyres were installed at the start.

The hitch worked on the first move, but after 6 months in the Darwen elements, it was seized. The hitch is attached to a large piece of steel which bolts onto the A frame. It also includes the damper, handbrake and emergency cable.

Detective work on the chassis reveals this label retrieved from the axle centre in the rain by Keith (father-in-law, thanks).

The correct coupling for this chassis is ALKO 90S, which I duly ordered. However, it is not that simple.

The handbrake on this is a 'gas lift' one, this is fundamentally different from the ratchet type on my van. ALKO don't sell that anymore. This part could not therefore be fitted, the brake cable under the van was also seized. What mechanic 2 did was remove the hitch bit on the left and fitted that only. So I did the long drive with no handbrake, the van is probably about 6-700 kg, I was assured this is OK as long as driven cautiously.

Mechanic 3 was very perplexed when confronted with this. After much head scratching and googling, I got hold of the following parts, which he came back and fitted in an afternoon.

In the intervening months, the handbrake cable had freed up, so that's something! Above is the required type of handbrake. Another issue was that the jockey wheel was an integral part of the removed coupling, meaning I needed a new jockey wheel and a clamp to bolt to the side of the coupling (this was also wrecked, hence the back problem described above... ). The other part in the picture is an energy store to assist the brake mechanism, its predecessor was likewise wrecked. The parts pictured cost £55 and the coupling was £180 but I hope to sell the handbrake from that - it's no use to me. No picture of van, I haven't even seen the work yet.

The other chassis related problem I had is using the corner steadies/ legs. These were really difficult to move with the standard 19mm socket often sold for this purpose. With much added grease and scrubbed of dirt, these now turn much better, but I have found the bolt heads were getting rounded. This problem was getting worse, but using an 18mm socket instead more or less resolves the problem - I have one spindle quite bent but can live with that. It would be a major hassle to replace the spindles or leg assemblies.