Cab

Chapter 3 - Cab

With the initial inspection complete, attention turned to one of the most visible areas of the project – the cab.

Although structurally sound, the cab showed the typical signs of age expected from a nearly forty-year-old military vehicle. Various components were damaged, missing, seized or suffering from corrosion, while years of modifications and repairs had left plenty of work to be done before the truck could be considered comfortable or reliable.

The objective was not simply to make the cab look better, but to restore functionality, improve safety and establish a solid foundation for future expedition use.

Seats and other Equipment

The existing seats were removed, allowing the floor and mounting points to be inspected and cleaned. Years of accumulated dirt, dust and debris were removed while locating and preparing the original seat belt mounting points hidden beneath carpet and sound deadening material.

Doors, Glass and Window Mechanisms

Attention then shifted to the doors and windows.

Both doors required disassembly to assess their condition. Damaged window regulators, worn seals and broken glass components were identified during inspection.

The left -hand door was stripped down completely, it has significant impact injury requiring surgery. Replacement glass was sourced and cut to suit.

New window seals were purchased and fitted as work progressed, gradually improving weather sealing and overall appearance.

Mirrors and mounts were checked and bolts replaced and threads cleaned. Wiring was replaced to clearance lights and new rubber gaskets between mount and door

The process highlighted how many seemingly simple components required attention after decades of service.

Rust and corrosion Repairs

As trim and panels were removed, several areas of corrosion were uncovered. But really nothing at all that i was expecting.

Rust was identified in sections of the right-hand door, floor areas adjacent to the door opening and portions of the roof structure and LH side of upper guard.

These areas were cleaned, assessed and prepared for future repairs.

Where possible, rust was removed mechanically before protective coatings and rust treatments were applied to prevent further deterioration while restoration planning continued.

Some small prep repairs were carried out.

To bend up the roof form i had to make bender, it was created using some 25mm x 30mm flat bar and some clamps. I was actually pretty happy with the results.

Cleaning, Preparation and Preservation

Significant effort was invested in cleaning and preserving components as they were removed.

Cab mounting points were cleaned and threaded holes restored using taps and dies. Rust inhibitors, primers and protective coatings were applied throughout the cab structure as work progressed.

The accelerator shaft assembly, roof structure, mounting points and various brackets were progressively cleaned, treated and prepared for final refinishing.

By addressing these smaller details early, future assembly work would be significantly easier.

Snorkel,air cleaner components removed, cleaned repaired and what could be reused. Reused.

Heater, Ventilation and Future Air Conditioning

With access improving, the heater, blower and demister assemblies were removed for inspection and refurbishment.

Years of dirt and debris were cleaned from behind the dashboard while measurements were taken to investigate future air-conditioning options.

The blower assemblies were dismantled, cleaned and restored, with mounting surfaces refurbished and new foam seals installed where required.

Power Steering

The power steering system was removed as part of the wider mechanical refurbishment to address several problems. The reservoir, pipework and mounting brackets were heavily contaminated with dirt, oil residue and surface rust, making inspection difficult.

The complete assembly was dismantled, sand blasted, pressure cleaned and treated with rust converter before being painted and reassembled. Particular attention was given to the steering box, where a leaking input seal was replaced to prevent future oil loss and contamination.

Once cleaned and painted, the reservoir, pipework and associated components were reinstalled. As a precaution, the power steering oil was later sampled, analysed and subsequently flushed and replaced to remove any contaminants and establish a known maintenance baseline for the future.

While no major defects were found, addressing these issues now provides confidence that the steering system is clean, leak-free and reliable for future operation.

Custom Cab Tilt

Access to the engine bay and engine bay area on a Unimog is limited with the cab in its normal position, so a custom cab tilt arrangement was fabricated to make future maintenance and restoration work far easier. With the cab tilted forward, critical components become readily accessible for inspection and repair.

Safety was a key consideration throughout the process. As well as the SHS stay once the cab is raised whenever the cab is being raised, timber blocks are placed between the cab and chassis to provide a mechanical support. This ensures the cab remains secure even in the unlikely event of a hydraulic cylinder or other failure.

A Better Foundation

By the conclusion of this stage, the cab was significantly cleaner, safer and better understood than when the project began.

Although considerable work still remained, major inspection tasks had been completed, safety equipment had been addressed and numerous hidden issues had been uncovered before they could develop into larger problems.

The cab was now ready for the next stages of restoration.

[INSERT IMAGE – Cab Progress Photo]