Traveller Wood Repairs / Replacement

Information supplied by 'Minor Matters' magazine of the MMOC

Possibly the worst part of any Minor is the renovation of the Traveller's wooden back end. It is part of the structure of the car, so it is very important to retain its strength. Only a Morris Minor would have the wooden framing on the OUTSIDE of the car. Most cars had it inside in the dry, covered in aluminium or steel panels.

Tools required for this job are a basic carpentry set, including tenon saw, drill, screwdrivers and chisels.

Preparation
Before attempting to fit new sections apply a good coating of linseed oil and white spirit; followed by a good quality Yacht varnish - not polyurethane. A waterproof glue obtainable from any DIY store should be used. The sealer required is called 'Dum-Dum' obtainable from any motor accessory store. Window runners are available from any of the Morris Minor Specialists. When fitting a complete side, the order of fitting should be: top rail, front pillar, middle rail, foot rail, front WA section, middle WA section, centre upright, rear WA section, rear pillar.

1.   Replacing Rear Pillar
Remove rear door and lights. Remove the screws holding at top, middle and bottom; the coach bolt and the bolts under the wheel arch through the rear wheel sections. CAREFULLY separate the glued joints. To fit the new section, it will be necessary to chamfer the top of the rear pillar to enable it to fit well under the roof. Any screws preventing this should be chiselled off. When a satisfactory fit is obtained, mark the hole for the bottom coach bolt and drill. BEFORE final fitting, place rear door in position to check the fit. Apply a liberal coat of glue and replace screws. Care should be taken to correctly align door bolt holes. Replace
lights and check they work. If not, check the earth wire.

2.   Fitting a new Top Rail
Remove rear pillar. Cut joints on new rail as illustrated in the diagram No. 1. Remove interior rail and windows. The rail is held by pins through the roof which are covered by the external beading, and at the front pillar. These should be removed and the top rail carefully levered away from the roof, and the attaching panel pins. Take care not to damage the roof. Chisel off any remaining panel pins. Drill through the beading along the length of the roof and countersink, to accept the pins when fitting the new section. To fit new section, screw and glue to the front pillar, with a layer of sealer along the top of the rail and pin the roof to the section. Touch up pin holes. Then refit rear pillar.

3.  Replacing the Front Pillar
Remove the three cross-headed bolts which hold the front pillar to the bulkhead. The top seat belt anchorage, and the wooden panel behind it to reveal the screws into the middle rail, also need removing. Remove front interior trim and the felt vertical window stops from the pillar to reveal two further bolts through the front pillar into the bulkhead, which should be removed. Undo the screws into the front pillar from the top rail, middle rail and foot rail, and carefully separate the front pillar from these sections. To fit new sections, mark holes from the old section and drill; re-seal the edges of all the panels, insert the bottom of the pillar behind the footrail and swing into position. Replace bolts, re-glue and screw to top rail, middle rail and foot rail.

4.  Replacing the Middle Rail
Cut joints on new rail as illustrated in diagram No. 2, by measuring old middle rail before removing. Remove interior rail and windows and interior trim to expose the screws into the panels along the bottom edge of the rail, which should be removed. Undo the screws from the front pillar, centre upright and rear pillar and carefully separate glue joints to remove the rail. To fit a new section, reseal the edges of the panels, insert rear joint into rear pillar from inside the car and swing into front pillar. Re-glue and replace all screws.

5.  Replacing Foot Rail
Remove screws from front pillar and front of wheel arch section. Carefully break glue joints and remove. Re-seal panels, glue and screw new section into position.

6.  Replacing Wheel Arch Sections
Remove interior trim. If replacing more than one section of the wheel arch, unscrew the wing and remove. Unscrew all screws from inside, holding section to be replaced. Note: these screws go through a double skin which hides another set of screws. These cannot be undone and have to be carefully chiselled off. When all screws have been removed, withdraw the section. To fit an individual section, carefully measure and cut joints on the new replacement. Re-seal the panels and around the wing and glue into position. Replace screws and drill extra holes
through both skins, to replace those which were chiselled off. To fit a complete wheel arch section, remove the wing and all the interior trim. Remove as for one section. When replacing, start with the front wheel arch and work towards the rear, cutting the joints on one section at a time. Replace the wing either with replacement bolts or with brass screws and large washers.

7.  Replacing Centre Upright
Remove interior trim, immediately behind the section and unscrew the panels from the upright, then the upright from the middle rail, and centre wheel arch. Carefully break glue joints and remove. To fit new section, re-seal and glue into position.