My T25 restoration

For documenting and technical details of T25 restorations and major repairs
This section is for major restorations only.where to buy a panel or where to buy window rubbers belong in the bodywork seats and glass section.
Also please note,we need pictures of the restorations,without them posts are pretty useless.[\b]
Picture heavy and detailed threads , not for general banter or advertising
Traders welcome to post but not to advertise blatently
Threads will be cleaned of chit chat.

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mshaw1980
Posts: 553
Joined: 10 Aug 2015, 06:50
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Location: Peel, Isle of Man

Re: My T25 restoration

Post by mshaw1980 »

Been a while since I last updated this thread but there hasnt been that much to tell. My original 33 year old radiator however corroded through a few weeks back and so I decided that now might be a good time to replace the lower front panel as this was the last majorly rusty panel on the van:

ImageFront lower panel by Mark Shaw, on Flickr

ImageFront lower panel by Mark Shaw, on Flickr

So the cutting, die grinding, air chiseling and flap disking began:

ImageFront lower panel by Mark Shaw, on Flickr

Until it was more or less removed and then the cleanup of the steel began:

ImageRemnants of panel nearly off. Started cleaning up the metal. by Mark Shaw, on Flickr
1987 VW T25: Subaru EJ20 using RJES parts (If it was meant to go fast it wouldn't be brick shaped!)

mshaw1980
Posts: 553
Joined: 10 Aug 2015, 06:50
80-90 Mem No: 14800
Location: Peel, Isle of Man

Re: My T25 restoration

Post by mshaw1980 »

So after some advice from good ol Plasticman I cut out the rusty metal on which the front lower panel sits and made some new pieces from 2mm steel which I am in the process of tacking in...
Image
Not done any welding for a while so decided to make my own land rover mirror brackets out of 3mm angle iron I had lying around.
Here's the first one whilst trial fitting before painting...
ImageImageImage
From the drivers seat the land rover mirror gives a much better field of view. Hopefully help with my crap reverse parking :-)
1987 VW T25: Subaru EJ20 using RJES parts (If it was meant to go fast it wouldn't be brick shaped!)

mshaw1980
Posts: 553
Joined: 10 Aug 2015, 06:50
80-90 Mem No: 14800
Location: Peel, Isle of Man

Re: My T25 restoration

Post by mshaw1980 »

So finally started the stitch welding in of my repair pieces in preparation for primer and paint before the front lower panel goes on...
Image
Image

Only problem is my flap disks are worn out so need to buy some more to grind my final welds flat. Stay tuned for more new panel escapades ☺️
1987 VW T25: Subaru EJ20 using RJES parts (If it was meant to go fast it wouldn't be brick shaped!)

mshaw1980
Posts: 553
Joined: 10 Aug 2015, 06:50
80-90 Mem No: 14800
Location: Peel, Isle of Man

Re: My T25 restoration

Post by mshaw1980 »

So my repair panels are welded in and primed ready for paint. Dont need to perfectly grind down the repairs as I will be bonding the bottom of the panel with polyurethane sealant and the bumper will cover the other welding. Will spot weld the top and sides though.

ImageImageImage

Also like the look of the land rover mirrors :-)
1987 VW T25: Subaru EJ20 using RJES parts (If it was meant to go fast it wouldn't be brick shaped!)

mshaw1980
Posts: 553
Joined: 10 Aug 2015, 06:50
80-90 Mem No: 14800
Location: Peel, Isle of Man

Re: My T25 restoration

Post by mshaw1980 »

Finally got the panel tacked in...
ImageImageImage
Used polyurethane sealant instead of spot welding the bottom lip as it should hopefully keep the moisture out and not disintegrate to rust anytime soon.

Got tired so will grind the spot welds off the front tomorrow and then prime and paint 😁

ImageFront Lower Panel Replacement by Mark Shaw, on Flickr

So after paint, looks pretty good I think!
Last edited by mshaw1980 on 21 Aug 2020, 15:31, edited 1 time in total.
1987 VW T25: Subaru EJ20 using RJES parts (If it was meant to go fast it wouldn't be brick shaped!)

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sarran1955
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Joined: 11 Mar 2009, 18:51
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Location: 6, les Hauts de Sarran 19800, Sarran ,Limousin ,FRANCE

Re: My T25 restoration

Post by sarran1955 »

Hello,
mshaw1980 wrote: 06 Jul 2020, 21:09 Finally got the panel tacked in...
Image
Used polyurethane sealant instead of spot welding the bottom lip as it should hopefully keep the moisture out and not disintegrate to rust anytime soon.

Got tired so will grind the spot welds off the front tomorrow and then prime and paint 😁
Oooh........Avdel porn... :)

Cordialement,

:ok
 
Help and advice on Aircooled engines here:
http://www.youtube.com/user/sarran1955/videos?view=0" onclick="window.open(this.href);return false;

mshaw1980
Posts: 553
Joined: 10 Aug 2015, 06:50
80-90 Mem No: 14800
Location: Peel, Isle of Man

Re: My T25 restoration

Post by mshaw1980 »

Yeah avdel pins make bodywork so much easier. Another great tool purchase.
1987 VW T25: Subaru EJ20 using RJES parts (If it was meant to go fast it wouldn't be brick shaped!)

T25boy71
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Joined: 21 Jun 2019, 20:56
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Location: Surrey
Contact:

Re: My T25 restoration

Post by T25boy71 »

Hi I’m in the process of doing the front lower panel, panel supplied from JK dansak panel.
My question is how good a fit was your panel at the bottom where you glued it and who made the panel?
I’m still in the process of cleaning up the rust but did do a quick fit and the gap bottom middle is 3/4 cm I didn’t clamp it in just poped it in position to see.ImageImageImageImageImageImageImageImageImageImageImage
Vw T25 1.9 TD Z1 hightop rusty but Less rusty than when I got it. lol: 😊

mshaw1980
Posts: 553
Joined: 10 Aug 2015, 06:50
80-90 Mem No: 14800
Location: Peel, Isle of Man

Re: My T25 restoration

Post by mshaw1980 »

Hi

I cut the lip off the back of my panel on the recommendation of Plasticman on this forum who is a metalwork master. It took a little bit of fettling to get it to fit but once welded and bonded looks fine. There was a gap under the middle of the panel where it bonds to the bumper slam panel but the polyurethane sealant took away the gap and then you can seal the seam up.
1987 VW T25: Subaru EJ20 using RJES parts (If it was meant to go fast it wouldn't be brick shaped!)

glennyboy2
Posts: 25
Joined: 16 Oct 2005, 13:00
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Location: newquay,cornwall

Re: My T25 restoration

Post by glennyboy2 »

Fantastic work mate. It’s inspired me. Going to start in one corner and work my way around.

Thanks
glennyboy2

member 1838

I hope this van lasts longer than me.

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