Vent Panel Replacement

Post by **cam3r0n** » Sat Jan 12, 2013 1:37 pm

Over the last couple of months I have replaced my rotten vent panel with a new Galvanised one bought from eBay. I have learnt a few lessons along the way but I'm pleased with the result.

As you will see from the photos it was one of those jobs that needed to be done but once started there was no going back! The vent panel almost disintegrated as I unbolted it. Taking it off was very easy only a few bolts and it was free. The bulkhead was in really good condition but the old foam between vent panel and bulkhead had really perished and was soaking up water and rusting the vent panel. As a result my new vent panel has more paint on it that a North Sea oil rig! Not only is it zinc coted, but I applied Mordent Solution to allow etch primer to stick, then etch primed 2x coats, red oxide primer 2x coats, grey primer x 1 coat and three coats of Nato Green.

Rather than falling into the trap of putting the same type of foam back on, I did a bit of research and found a replacement foam made from EPDM which is used in outdoor applications (roofing, etc.) and should not perish in UV or Ozone. Hopefully with the paint, zinc and EPDM foam it shouldn't rust for a few years.

The replacement vent panel itself initially appeared to be good quality, but it was an early Series 3 panel (with the bracket for mounting the washer bottle inside) and my LWT is a 1980 so should have the later type, I also had to put bungs into the washer jet holes. The biggest problem though was the 6 threaded holes which hold the windscreen and windscreen retaining bolts to the vent panel, when it was dipped in Zinc a bolt should have been screwed into these threads to stop them from being filled up and wasn't! This issue proved a pain in the bum, I had to find Taps of the right size and carefully tap the holes out to accept the correct bolts.

Swapping the parts from the old panel to the new panel was fairly simple, a few holes had been zinced over and needed drilling but that was easy enough. The fly screens arenâ€™t compatible with the older type vent panel though so Iâ€™m looking for some early S2 fly screens. I bought brand new seals for the vents themselves, these are great but a little too stiff and hard to close tightly. I hope that they will soften over time, with use.

In summary if you buy one, try and contact the seller in advance and make sure you get one of the right type (early or late) and ask him to put some bolts into the threads before dipping. Oh yeah and when you spray paint don't ware your good glasses, as next day you think "why can't I see properly!"