DAF Wheel arches

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Brian-reynolds
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DAF Wheel arches

Postby Brian-reynolds » Thu Jan 19, 2017 9:12 pm

The front wheel arches on my DAF are seriously corroded!

I think this is a problem with all of them... so....

Would it be worth trying, as a group, to get someone to start a repair project, or maybe get someone to make a batch out of fibreglass or aluminium, or shall I try and just fix my own set and ignore the rest?

I did wonder of visiting a scrappy and see if I can get a pair and have them repaired, fit them, and try and get my old pair repaired and then pass them on and repeat the process....

Thoughts please?

B.

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seadog1
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Re: DAF Wheel arches

Postby seadog1 » Fri Jan 20, 2017 12:59 pm

I would say a pretty common problem Brian , I had a guy cut the rot out and weld bits in so not to bad now , I did find someone on line breaking a daf but he wanted about a £100 per wing and there still second hand so didn't bother

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Re: DAF Wheel arches

Postby Savarus » Sun Feb 05, 2017 1:16 pm

Hello Bri!

Yes, a common problem. Mine were patched when I bought the truck, though I didn't notice until after it'd been out in the weather for a few months & the welds started to show a bit of rust. To be fair, whoever did the repair made a very tidy job of it.

If you want, post some photos (or email me some) and I'll tell you exactly how worth repairing your arches are & how difficult or easy it'd be.

Fibreglass duplicates would be easy enough to make but you wouldn't want to stand on them like you can with steel ones.
You could reinforce the fibreglass with steel tubes but that seems like more hassle than it's worth, as you'd need to create mounting points for the steels (as they'd be what bore the weight), which would probably equate to a lot of work. Plus Fibreglass moulding can get really expensive as I'm sure you know, so unless you're having lots of them made, it probably wouldn't be worth the money to have the mould made - unless you did it yourself.

If anyone could dig up a company that would be willing to copy an existing pair in Aluminium, that'd be the perfect solution. If need be they could be reinforced, though I don't think it'd be necessary, as the curved shape puts enough tension into the metal that they should be pretty strong.

I for one would jump at the chance to get hold of an Ali pair. Mine don't need replacing but I'd spend the money all the same, just to know they'd never rot out.

I don't know anyone local to me who's into Ali sheet (not in that size anyway). If I had a rolling machine or an English Wheel (and more time on my hands) I'd offer to make a batch myself.
The ideal solution would be to have them pressed but short of contracting a major auto manufacturer, there'll be almost no-one out there with the equipment to do that - and if there were, having the press tooling made would cost 5 - possibly 6 digits.

Surely someone out there would have the wherewithal to make them the old fashioned way...

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Re: DAF Wheel arches

Postby crinklystarfish » Mon Feb 06, 2017 8:50 am

I'd be in with an order if it helps encourage a fabricator to take the job on. Aluminium sounds good to me. Paul's box fabricator might be worth an approach.

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Brian-reynolds
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Re: DAF Wheel arches

Postby Brian-reynolds » Mon Feb 06, 2017 8:56 am

yet another post of mine gone missing..... try again....

Hi Stu, good to hear from you.

I am contemplating visiting an aluminium fabricator as I think one bent sheet across the top and welded outer side and maybe a welded part on the rear.

If the ali is thick enough the welds could then be chamfered for the safety aspect, job done....

Maybe a bit simplistic but I think it would work......

I had thought of learning basic panel beating, but not for long..... some things need to be left for the experts!

As for fibreglass.... masses of work to make a pair then make the plug them the mould... lots and lots of sanding.... the time involved would be too long for me, plus I do not now have any fibreglass working tools...... and I am lazy......

I think they are beyond repair but thanks for the offer of a look anyway, good of you.

B.

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Zoltan
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Re: DAF Wheel arches

Postby Zoltan » Mon Feb 06, 2017 10:04 am

By the time half a dozen of you have had a pair, making a mould to turn out some really thick fibreglass ones wouldn't be that expensive

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Brian-reynolds
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Re: DAF Wheel arches

Postby Brian-reynolds » Mon Feb 06, 2017 10:14 am

Back in my hovercraft days I was using fibreglass a lot and I have many (old) friends that manufacture craft of various sizes and uses, maybe I will try and contact some of them and see what they can come up with but believe me it is a lot of work...

They can probably be colour matched as well.

I would need to know the sort of numbers that would be required to be made on the first run......

So that would be me, Steve, Stu(?), probably all of us T244 owners... What about Vince-how are your arches (ahem) Vince?

B.

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Zoltan
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Re: DAF Wheel arches

Postby Zoltan » Mon Feb 06, 2017 10:36 am

The beauty of fibreglass is that all that work is done just the once. Someone must have one decent enough pair and just take a mould straight off of those.

You could also have a kevlar race version :lol:

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Re: DAF Wheel arches

Postby Savarus » Mon Feb 06, 2017 9:08 pm

Bri - your description of how you'd make them in Ali would work just fine. In fact it'd be the most economical way of doing it. They might not be quite so rounded as the originals but that'd all depend on how much time & skill you poured into them... and a good coat of paint hides a multitude of sins anyway.

If you wanted more rounded edges without using thicker material, those could be produced really easily on a fly press or sheet roller with some improvised tooling, Hell, even without a proper machine it'd be easy & cheap enough to rig up an ad-hoc former to bolt to a workbench. All you'd need is something for a die - a bit of solid round bar should do; and something for an anvil - say a large ball bearing with a pin through the centre; and some bits of scrap plate or box to make the stand from.

Here's a rough proof-of-concept I found, just to give you the idea...
https://www.youtube.com/watch?v=pJhWx4xRkqc

I personally wouldn't want fibreglass arches.
I'm thinking from a field repair perspective.

Mainly because there'll be no other fibreglass on my truck & I couldn't justify carrying the extra gear just to repair the arches on the off-chance they got damaged.
Also because the resin, gel coat & hardener have shelf lives, even if unopened. Guaranteed the one time you needed them, you'd open the tins to find one had gone off.
Then there's the issue of working with it on the roadside - collision repairs etc in the event the thing ends up fouling the tyre & needs to be cut away. Fibreglass is a bitch to work with & really requires a workshop. Getting a fist (or lung) full of invisible splinters in a country plagued by Malaria for example might not be fun. That or it's carrying things like paper dust suits & filter masks with you, which is more space & more weight. Plus, fibreglass leaves nasty shards everywhere when cut - you'd be leaving them behind for someone or something to tread on or potentially eat.
Finally there's availability. Depending on where you are in the world, fibreglass & resin may be extremely difficult, if not impossible to get hold of.

Metal on the other hand...
Doesn't go off
Is easy and relatively clean & safe to work with
Can be beaten back into shape with a hammer for a quick fix
Can be cut with shears so as to leave no harmful waste behind
Can be patched with a dissimilar metal if need be.
Can be readily sourced almost anywhere in the world

Also, no matter where you go, there's a high chance someone nearby will have metalworking tools & know-how.

Just some thoughts anyhow.

Let me know if you find an Ali fabricator.
In the meantime I'll look into making some tooling up to produce the curvy bits. Can't really invest the time right now to make said tooling but I can at least design it & figure out costs.
Off the top of my head, stockholder price for 1off 2500x1250x3mm Ali sheet is around £180.00. One sheet should do 1 complete arch with a bit spare, so for the pair, material cost would likely be around £360 ish.

Good luck Jonathan
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Re: DAF Wheel arches

Postby Good luck Jonathan » Tue Feb 07, 2017 3:32 am

How about trying to get hold of the original Daft tooling since they are no longer making the rust buckets. :oops: :oops:


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