So after a brew and a smoke, i decided to remove the wheel well, as i plan to have a full width bed the spare would be in the way, and as i dont like the wheel on the front panel i will just carry the spare lose in the back once on the road Wheel well removed So my plan to repair this area is to use some flat steel plate, so out with the grinder again and removed the rot in the corner and cleaned around the hole Needs cutting to fit but should look fine once in, along the side i will put a lip on it so i can weld it in as the original also i think i will put a couple a braces across the hole to make up for the extra strength the pressings give in the original metal Then all whats left is to repair on this side is the bit marked out but will need a body cut out a scrapper so that i can match the pressings, but if i can find an inspection hatch body cut i can use what i cut out to fit that I will do the same to the other side as well before I put the rear corners on as it makes access a lot easier
Looks good, the pics of the top hats with the floor out make it really tempting to pull the floor on mine...... MM
Cheers for comments Having sorted a engine inspection hatch (cheers bigrich) and a body cut with the corresponding hole (cheers sliver), i've made a start on fitting them This is what i started with Genuine vw hole Genuine vw hatch First job was to remove what i needed from the body cut Then made a similar sized hole in the van The body cut and hatch trial fitted Next after loads of trimming and trial fitting i was ready for a splash of weld through primer Then i set about it with the trusty welder and tacked it all in place Well pleased with how it's gone so far, but the kids going to bed but on end to my playtime Still got to repair where the wheel well was and a few other areas, but with what i have cut out and whats left on the body cut i have plenty spare to make some repair panels and do a proper job on the fuel sender cut out Untill next time Stu
Nice hatch mate thinking of doing something like this my self later on in the build , Was thinking of cutting the floor that's there and makeing that in to a hatch by welding a frame under it for it to sit on If that makes sense. And I wish my rear chassis rails were as nice as yours
Well i'm off work for the next week looking after the kids during half term so hoping to progress on the bus I managed to get a bit done today in-between breaking up fights, mopping up blood and making lunch and tea It's not a great deal but as a well known supermarket says "every little helps Having fitted the engine inspection hatch i now had to sort out where the spare wheel well once lived First off was to block off the part of the fire wall after a quick measure a plate was quickly knocked up and joggled the edges Then it was welded in Next was to sort out how i was going to attach the plain steel plate i was using to make a panel out of to fill the whole As it's just flat (not ribbed like original) i decided to fit some cross members that i cut off the body cut that i got the hatch from and along the side i plug welded some angle in so that i can get i nice clean finish once done thats it for today, but i'm hoping to have the back end finished by the time i go back to work a week on monday
Well got a bit more done tonight, made the new panels to fill my hole Cardboard template Copied on to a piece of steel and a small piece from the body cut i had Both bit fit a treat, but i want do paint the top of the inner wheel arch before i weld them in Also made a start on the other corner but will get some pics of that another day Stu
Well after a couple of good days i feel if i've made some real progress I have finished the floor area above the engine (just fuel sender hatch to make), seam sealed the welds etc, got some por 15 paint on the chassis legs and fuel tank area and finished a few little areas off that would be hard to do once all the rear panels are on Talking of the rear panels i've got them all on as well only clamped in place with the aid of some self trappers, pleased with the panel gaps and everything looks square and right which is good considering i have re-roofed her from the swage line up Next job is to take the panels off, prep them and get welding, then get the battery trays in etc, and make my mind up if to go down the subaru engine conversion or not
Looking good the more i view the more tempted i get to take alice apart and start work!! think other will go mad if i started while shes at work :'( and comes bk to see alice in bits...
Another update for you The back end is finished at last! Well apart from 5 little jobs Make and fit fuel sender hatch Weld up os corner on the swage line (cut it a bit to high) Repair the fuel tank straps Small repair in the ns inner wheel tub Fit the seat belt anchor point in the rear wheel tubs Anyway some pics enjoy All outer panels welded in and primed up for a bit of protection Battery trays fitted, i haven't fitted the tinware chassis top panels as i'm going down the subaru engine conversion route Some shots of the rear load floor and insides of the rear windows The engine bay just needs a good seam sealing and painting but will do that later, i still have front end to tackle yet Stu
Cheers for the comments guys, well pleased with myself how the back end has turned out Not done a great deal of late but i have made a better fuel of the PO's fuel sender access hatch (was a hole cut out with a spoon and some steel screwed over the top) Cleaned up the hole Made a frame for the hatch to sit on, welded it in with some nuts welded to the back Hatch cut and bolted in place Welds cleaned and a lick of paint
Also made a start on the sliding door using the large repair panel which is another quality panel supplied by the guys at autocraft Door and panel measured up and the original rusty dented skin cut off And new skin trial fitted The fit and curvature looks good just got to get it welded and and the edges folded over, but i'm in the process of building a new shed up the garden at the moment, so hope to get back on the bus next week
you have been busy ;D thats some great work going on at the back end, top job have you got much more metal work to do?