Phunkie Project Portafold

[phunkie hiboy]

Just a small update, managed to a little bit today (waiting for parts, so couple of hours around lunch time).
Didn’t want the side kicking around getting the new paint damaged, so cut the rubber cord seals for the end channels, glued the channels and the cord (on one side only) and then fitted them.

After fitting the flat seals on the end flanges of the painted side and also along the top edge a small amount of silicone grease was put on the rubbers and the side installed into position. The inner parts of the hinges were then riveted to the main body.

The operation of the side was then checked, both in the up and down position.

Then to complete the installation, the “sealing strip” was added. I have tried to obtain some thing like the original, but to no avail. I managed to find some wide gaffer (duct, racers) tape and just ran 3 overlapping lengths. His seems to work OK.

Back onto the other side later in the week……………

[Isaacsman]

Damp proof coarse sealing tape would be better and longer lasting. Get it from you local builders merchants or Screwfix.

Mike

[phunkie hiboy]

Thanks for that Mike, I'll go have a look, we have a Screwfix just down the road.

[DanBoy]

I have to say, I think you are doing a fantastic job and the finished product will be better than new. Keep up the good work!

[phunkie hiboy]

Keep up the good work!

We've got to, we're out in it second weekend in June!!!!!!!!

[phunkie hiboy]

Just a quick update, managed to sand and get some primer on the right side during the week. I was then able to sand and add 3 coats of colour yesterday (Saturday).

Whilst waiting for the paint to “go off”, ‘cos I hate watching paint dry, I finished off the lower door catch.
We had been having problems with the lower door not closing level. This was to do with the position of the hinges, having not been fitted correctly at the factory. Although these are self aligning hinges, they have to be fitted with the axis vertical for them to work properly. Inside the body is a strip of metal that is drilled and tapped with a thread to take the securing bolts for the hinges. It wasn’t possible to retap the threads further down, by the small amount needed, so I made up a new striker plate to fit on the door “frame” and a wedge device to fit on the door. As the door is closed the final amount, the wedge contacts the striker and lifts the door into its proper position. The items were fabricated from stainless steel and polished. Just need to substitute the black screws with some stainless ones now.

'Till next time …………….

[phunkie hiboy]

So with the right hand side riveted on, it’s now time to turn attention to front and rear walls and the upper door.
The upper door did require some considerable repair work. All the “damage” probably happened, either when it was pulled from its mould or when the inner and outer skins were clamped and laminated together. All the cracks were ground out to below the gelcoat and filled with resin and chopped strand mat. This was then sanded and filled with normal body filler to get a smooth finish.

The ends really didn’t need too much attention, so together with the upper door were sanded and primed. A quick guide coat and left overnight. The following day all the panels were sanded and sprayed with three coats of “Old English White”.

Once the paint was dry, the hinges were added to the ends. The following day the flat seals were added to the main body, at the ends, and the ends then fixed to the main body using stainless steel screws (they don’t rust like the old ones!!).

So now onto the major problem of it all, the roof. This was pretty bad and even with the work carried out on it so far, it’s far from perfect. What has got to be remembered the more strength we add the more weight we add, therefore making it more difficult to lift.
All the starring has been ground back to below the gelcoat and more so on the structural repair area on the right side (where the wind had obviously caught the roof at some point and split that side and damaged the centre strip of the roof). The normal repair to all these areas was carried out (resin and chapped strand mat).This will be allowed to harden off before sanding and filling.

Will get round to a bit more this weekend …………

[phunkie hiboy]

Sorry it’s been a while since I updated this thread, but we’ve been really busy. So anyway here’s the next short instalment ………………………..

Now the roof has been repaired (ish, really it needs replacing) it has been sanded down and all the repairs filled.

After which it was sanded down again and sprayed with epoxy primer and 2 pack hi build primer and sanded down again for the colour coats.

The colour coats were added and then 3 coats of clear lacquer. We decided on another period colour, Rootes “Electric Blue”, that was very popular back then, to paint the roof.

Whilst the paint was drying, I cleaned up all the windows and refitted them to the walls.
After the paint had dried the fixings were riveted back on and the roof placed on top of the rest of the assembly.
To hold down the roof we have had made a couple of leather straps, which have to be shaped and treated before they can be fitted.

These will be shaped (into a flat circle) and then treated with dubbin to protect them from the weather.
Managed to get the Portafold back to home yesterday (Saturday) afternoon to start fitting the interior out over the extended weekend. We’ve less than a week before we need to tow it down to the New Forest (Pylewell Park) for its first event!!

[phunkie hiboy]

We wanted to put a floor in it that was of the period, so when some mini parquet flooring became available (for nothing), that’s was what decided on. The flooring came as separate pieces.

We started with a thin wood base.

Then using sikaflex, each tile was individually placed on the board.

It was then sanded down flat using a belt sander.

It was then coated in 3 coats of 2 pack lacquer.

And finally fitted into the floor area of the Portafold.

[phunkie hiboy]

Well here we are at the final furlong.
We decided to put some period alloy wheels on and, as luck would have it, a friend of ours had some wolfrace slots that he was willing to donate to the project. Wolfrace wheels, owned by Barry Treacy, started making and selling these wheels in 1971, so well in period.

They did need a bit of a cuddle ……………..

These were wrapped in some new rubber and fitted.
Now it was time to look at the interior. We needed to sort the number and layout of cushions needed.

We had for some time been thinking of denim to cover the cushions. Eventually we found a roll of stone wash denim, from a haberdashers in Hounslow.

Had four more cushions made.

This is a picture of all the covers finally sewn up, ready to fit to the cushions.

At this point we realised that we finally had a name for the caravan …………… Levi. So Levi Portafold it is.
Whilst things were being sewn up, some scatter cushions were constructed.

Gingham was the preferred material for the curtains, and Sue made these up at the same time as the rest.

Having decided the name we had this panel embroidered

And this prototype decal for the window

A square of gingham was cut out and inserted onto the “table” which was then covered with a tempered glass top.
So now we have an interior that looks like this

And with the bed laid out

This weekend (first time out) we had a pinstriper, “Tootal” Paul Dorrington ( http://www.tootall.info/ ) do what he does best.

Now, with the addition of a few period themed pictures we’re pretty much finished. A few more pictures of the outside.

Well that’s about it. Thanks to all those that have been looking in since last year and those that have helped with information.
We’ll just go and have fun with it now.