Popped over to see blueToTango at Fletch's the other day.. Took some snapshots.. couldn't resist sorry Fletch they may not be as professional as your pictures The welding is progressing well tho great work dude The front panel needs attention: Heres a close up of the rot on the inner windscreen panel: Fletch is going to replace the inner panel and has a front panel to replace the cut out section.. The rear quarter has been replaced with the new, including the battery tray plus the pillar underneath did need a few repairs but all good now Rear valence is/has been replaced - the hinge panel is in poor shape but Fletch has found someone selling replacements so that is going to get fixed too: The passenger rear window needs attention: Sliding door side also needs work: Lots of welding completed looking at paint sometime in July - fingers crossed....
Fletch @brothernumerone you asked the other day about the engine shop I used it was: Owlesbury Crankshaft Services
Poor old David has resorted to popping over and taking his own pics to update his resto thread because I've been so tardy, apologies again Here's a few more. The rear corner needed to be replaced. God knows what we'll do if they stop making these, they're brilliant. The lower section below the bulge had been repaired a couple of times above the height of the klokerholm repair panels, the metal around the vents was perforated and the seam was swelling with rust, so it made sense to replace the whole thing in one go. With the corner cut off, I repaired a few other bits which needed attention. The tank breather pipe had perforated at the top where it's most exposed to the elements. The tank was dry and had been for a long while, so I welded the holes up. From the inside, you can see rust coming through where two panels are joined. It's caused by this bit of foam between the inner panel and the firewall panel which encloses the tank/pipes etc. Not VW's best idea, it must hold water against the metal, most 72>vans seem to rust here. Welded up from the inside. Not particularly neat, but will be ok with some seam sealer.
Also did a few repairs on the D pillar. Then I took advantage of the corner not being there, and prepped the area you see through the vents. Then I painted the D pillar with some Bonda and also sprayed the inside of the new corner with the stuff David had used elsewhere. The corner is sandwiched between the D pillar and the roof frame, so you have to trim the top of the corner down and weld the corner to the roof, then grind back the welds.
I'm almost finished now, so here's a few more pics. Corner on. Repair to the firewall panel next to the battery tray. Then the rear section of the rear arch can be repaired. With the corner in place, it was time for the engine lid hinge panel which was knackered. Autocraft now do this panel and it's top quality. You can see how much rot was inside the panel once it's been cut and pealed back. The panel behind it was ok, so I cleaned it up and painted it. With the panel off I soaked the hinge screws to give myself a better chance of undoing them. It didn't work of course, so I drilled them out instead.
The new hinge panel is a great fit, particularly compared to certain companies, but it was bowed slightly. Hopefully it's clear in this pic, the gap is good at either end where the panel meets the corners, but in the middle the gap is much bigger, so I welded the panel at each end, then jacked it up in the middle to close the gap up before I welded it into place. Finished the gap looks much better although I'm not sure it really shows up in the pic. Onto the front. It was a bit rotten round the windscreen, no suprise there, but the rest of the panel was ok, so I repaired a few sections at the bottom and replaced the area round the screen. It's already had some repairs to the front around the windscreen. Whoever repaired it last time must have blasted the rust because the section between the inner surround and outer panel was full of sand which probably accelerated the rot once water started to get in again.
Inner surround panel cut away. New one welded in. Painted the inside of the new front panel and inner suround. Then welded the new front into place. It takes a lot of jiggling and triming, but it fits well and shouldn't need too much filler. On the right side I joined it without disturbing the outer panel above the bulge which is an easier repair. On the left side, the rot had spread up a bit higher, so I used the full height of the new front panel.
Finished!! Here's a few more pics. I'd originally planned to keep the original lower rear corner and arch, but when I started digging, there was quite a bit of rot, particularly in the corner, so I replaced instead. Part way through welding the rear arch in. Rear end finished. Replaced the bottom of the window appertures. Welded and seam sealed the seat belt mounts in the rear wheel housings. Stonechipped the arches.
Lastly, I repaired the bottom of the sliding door. It had been done before, quite well, but had rusted through again.
The next stage is fast approaching... Paint!!!! Got the bus booked in for November so fingers crossed Ideally I'd like to replace the front section of my poptop - it has warped at the front down the sides. And is kind of unrepairable.. I might ask again if I can't get a replacement but it needs doing the new new prices are a bit too steep, so I am on the look out for a front hinged westy roof preloved... If anyone know of anyone.... Selling one.. It's been away for a good while now, and I was beginning to get used to life without it But now I feel excited again being only a few months away from getting it back
