Hi all I feel the need to try to tackle some rust on my bus. I am pretty confident when it comes to sorting mechanical issues but haven't really done bodywork. My bus is in pretty good nick but has some rust coming through in some classic places e.g. where the inner and outer wheel arch panels join. The metal behind is good and solid though clearly water has got in between the panels and rusted through the outers. I did think about grinding out the rusty metal, using a rust treatment, then filler and then getting some paint mixed to try to finish it. I would prefer to do a decent job of it so thought I would see if I could get some tips from on here (hopefully not "buy a T5"). Here are some photos so you can see what I need to sort. Front left wheel arch Front right Th worst bit is above the left rear jacking point. Again the metal behind here and round the jacking point is solid and appears rust free. I suspect this bit is more likely to need a patch welding in. Like I say advice very welcome before I get the grinder/sander out. Cheers Phil
I'm afraid the rot is usually 10x worse under the paint and you are likely to find a few holes in the metal the worst bit will be the rear arch, as it will have rotted from inside, so likely that the end of the inner and middle sill will be pretty rusty behind it .....what does it look like underneath in those areas? depends on how you want to deal with it really, you could probably clean back to bare metal, treat the rust and filler/fibre glass any holes if you just wanted to patch up for a few years or grind back, have a look at what is under the paint and weld in new metal if needed. Make sure and bare metal gets protected as quickly as possible, and don't leave repairs in primer as it is porus
Unfortunately the only way you will know is to get the flap wheel or the grinder out. Get ready for tears. You might be lucky though.
Ta for the info. Ideally I would want to do a proper job which might mean a new repair panel for the rear arch I guess and any middle/inner sill repairs. Might need to pay someone to do that. The front arches look more doable as a first job by me. I think I will start with a couple of the smaller areas and get grinding, rust treat etc.
The holes will get bigger as you start to prod and poke at them Best repair is to take back to good steel and weld in fresh steel cut and shaped to fit the holes Fibreglass will do as a quick bodge
Front arch looks bodgable but will need sorting properly eventually. Rear is shot. Get a wire wheel on the angle grinder and show no mercy. I'm going through the same myself the mo, so am somewhat battle hardened.
