My 75' Panel Restoration (my first bus!!!)

Ordered a left hand chassis rail top repair panel as it's rusted out by the chassis number. Would it be worthwhile filling the chassis rails with anti-rust stuff before I weld the valance on? Also painting the inside of the valance before putting the outer on? Has anyone done the outer and chassis top as I need tips for welding these bits on, nudge nudge Zed!

 

I've replaced the lot ;D

I painted the insides of all my panels including the inner rear valance and the inner face of the outer rear valance...gave it a good coat of epoxy mastic

did the same with the chassis tops, painted the top of the chassis legs and the bottom of the chassis tops, I then made holes for plug welding the 2 together and cleaned of the paint in these areas back to bright metal for welding (about a 50p size area around where the welds would be) some of the other paint probably burned back a bit but at least there is a lot of extra rust protection from the paint inbetween the panels now.

I wouldnt fill your chassis rails with any anti rust wax (waxoyl etc) just yet as it is flamable so you risk starting a fire from the heat of the welding ....but make sure you use plenty of cavity wax once your welding and painting has finished

I've got a feeling the repro chassis tops are not a great fit and may need some fettling which is why I opted to repair mine ....try and save the chassis number if you can and weld it on to the new panel

 

What he said^, but to be pedantic, rust starts at the welds whether you paint it before or not. I don't cavity wax until the paintings done. It's spirit based and my painter would go ape. ;D

 

The van isn't being ignored, combination of money, weather and time. I have managed a few bits. Just need to learn to measure and cut straight!

Roof cut coming together





Rear valance going and new one being roughly offered up

 

Old valance plus rusty contents

 

The place where I keep it has cleared up the garage and it is now stored inside after spending nearly two years outside and having cats live in it. At least I can work on it if its raining now!

 

I have managed to get some sheet steel at last so I can make a start on repairing the inside of the roof before putting the skin on. Has anyone got any tips for when I need to weld the complete corner on? Will I need to remove the inner corner skin to be able to weld inside the side panel?

 

Nice to hear its indoors now and your back on it dude

 

Will I need to weld a small brace on the passenger side where the PO has removed the bulkhead for a captains chair? It's great to finally have it indoors, means the local cats can't hide in it anymore!

 

Good to see you're cracking on with it now,

For the roof corner, if I'm understanding what you mean, I'd weld from the above in the gutter and then grind the top of welds if need be with a narrow belt sander, but if you need to cut a flap from the inside to get access, its no issue to weld it back up afterwards.

I've done the same, in the grand scheme of things its a small job, so just do it, as it might* help, VW obviously put them there as an afterthought!

 

The bit in red shouldn't be a problem, it's how to weld the yellow area?

 

Fair play mate, your on it! Did you find the welding course helped alot?

 

I'd misunderstood you before, but seeing it now, you will as you'd anticipated have to cut the inner panel away to weld the left and upper edge of the corner.

 

Yes it did. I wouldn't have known about prep, different welding methods and how to weld such thin metal!

Kruger, thought it best to pop a pick up so it made sense. Going up to the van after work to do a few bits. Need to crack on as this wife wants to go away.

 

Peeking out of it's new home



The to do list......



Had to re-hang the tailgate and engine lid to make sure everything lines up. More valance work tonight, nearly at the welding stage!

 

Tonight's efforts, bit of cleaning up of various parts to check for holes and a start on the arch.




Yay, another hole to repair...



Inner arch




Welding is a bit rusty as its been a while since the course, need to cut straighter!



£8 from tool station, now I can see under the van!


Me in my battle gear

 

When I refitted the engine lid I noticed there was a gap in the middle as if the lid was bent. I changed it for one Kruger gave me but it was the same. I think the hinge panel maybe out of shape, but it's got a couple of holes in it anyway. Best to chop it out and replace?

 

Kenzie dude
If your using a grinder whilst wearing that top it would be a good idea to remove the cord that runs through the neck
You wouldent want it dangling down and getting caught up in the grinder

 

paradox
Thanks for the heads up, hadn't considered that!
Been up the van again this afternoon to do more prep work. Had noticed that the striker plate for the engine lid is not central so I think the chassis rails may have moved. Will need to brace them before welding. Pics to follow.

 

Fella You Am 1 Brave Dude!!! Ive just read the whole of Your Thread Hats off to Ya Big Time I Mean that Sincerly!!!

Well Done and Keep up the Good Work