The van formerly known as "Tootle"

Cheers! I'm really pleased it's been helpful. Top work there, looks really good.

 

Now the rear quarter is complete I've started on the outer sill/side repair panel, area chopped away and matched up to repair panel

Needed to repair this area first as the repair panel sits up tight against it

Knocked up a repair panel out of my favourite zintec sheet with a bench vice, cold chisel and persuader

Tacked in

Inside of new panel sprayed with high zinc cold galvanising spray

Slight repair of floor at c pillar, then middle sill coated in the same cold galvanising spray, hopefully nobody will have the need to open this up for another 38years

Floor repair section welded up and smothered in bonda primer!

Hope to get the repair panel welded in place during next week

 

Side repair panel all done


Next I started to repair the floor and wheel arch tub inside the van on the repaired good corner.

I always remember this area was the first place I found substantial rot when stripping the interior.



Cut out



Repairs tacked in



Welded up



Smoothed off and primed

 

looking good

 

Slowly slowly catchy monkey

 

I have moved around the other side of the van now, small repair to chassis where outrigger was removed

Outrigger/jacking points clean and painted

Mocked up inner sill and outrigger to measure up for tophat repair

Top hat repairs made up

Trial fitted

Rear tophat support removed from chassis, de rusted and painted in weld through primer

Welded back in

 

Rear slider track in rough condition

Outer sill mocked up and repairs to track carried out

Track end piece where seal sits made up

Welded up and surrounding area de rusted and treated

Inner sill being welded in

Middle sill repairs made and welded in

Inside of all repairs zinc painted

Welded in

 

Front outrigger/jacking point welded in and painted

Same for rear

Sill prepped and painted

Surrounding track area cleaned of old paint rust treated and painted up

Next up will be b and c pillars

 

Fantastic work

 

Great work!

 

Your metal work is very very tidy!
Keep the pics coming

 

New c pillar made up, not anatomically correct but is made from 2mm so nice and strong


I had to remove quite a bit of material around the b pillar to get rid of the dreaded rust

Low edge piece made up and welded to sill, outer skin tacked in and then painted inside with zinc primer

Template for lower part of the repair made up, I wanted to repair this part first then the part above seperate to ensure a good fit

Transferred onto metal

Upper half of the repair all welded up shown from the inside, it's covered in jenolite to remove any residual rust around the edges of the original material

All painted up

 

This is going to be a solid bus when finished

 

Thanks, that's my aim, one of my children is four and the other 8 weeks, I want it as structurally sound as when it was built!

Saying that they will probably both be teenagers by the time it's finished!

 

One of mine is a teenager and the van still isnt finished
Ive had it 8 years this month

 

this is a great thread to follow keep it coming

 

Cut out the seat belt mount on the passenger side, it was covered in bodges



Schofields repair panels are nice and solid, this one is marked up to be bent


Tacked in place



Piece made up to bridge the gap and then tacked in


With that section now rigid again I cut the rest of the rot out, there was plenty of it! Not sure if dormobile conversions have something added in this area as it looked pretty well done but was just a trap for rot over the years.