Rustoration

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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Funkyoid
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Location: Dumfries, Scotland

Re: Rustoration

Post by Funkyoid »

Wish I was as talented. I’m not looking forward to really tackling mine.
‘81 2.0ltr air cooled automatic Devon Camper - Gladys
‘81 2.0ltr air cooled manual Doka - Basma

RogerT
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Location: Central Scotland

Re: Rustoration

Post by RogerT »

Talent? Don’t make me laugh! Dogged determination, tho my family have other words for it. I started this at the end of 2017, and I’m starting to get the hang of it. No talent, but a willingness to learn from mistakes.
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
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Location: Central Scotland

Re: Rustoration

Post by RogerT »

Last time I was at the van was mid-July. Other jobs intervened, but that did mean I missed the hottest of the weather. Back to it now though.

Filled in this section
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with that compound curve I was so proud of
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Started to stitch together the pieces at the bottom of that corner, having done so much prep and fettling previously.
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I don’t get why the junction between the lower corner and the infill piece has that scalloped edge. But that’s what it has, and ignorance isn’t a good reason to argue against something. I’ve decided to put these three pieces together out of the van, then attach them to the van in a one-er. First I used cleco pins to fit the lower corner to the repair section above, welded them together, then cleco pins to hold it in place (old photo but you get the idea).
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Then trimmed the scallop-edged infill to fit, and fixed it with butt clamps to the edge of the internal corner I had built earlier (old photo, showing edge of that section, which Schofields call a rear corner tray)
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Then reached in the rear light opening to tack the infill at the scallops to the rear corner.

Next step will be to butt weld the infill to the rear corner along the scallops, while it’s separate from the van, for ease of access, then refit the constructed corner leaving me with the butt joint of the infill to the tray, which can be mostly done through the rear light opening, and only a bit of upside down welding. And puddle welds to connect the rear corner at the locations where I used cleco pins. And butt weld in the repair section above the lower corner.
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
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Location: Central Scotland

Re: Rustoration

Post by RogerT »

That failed attempt at a folding brake finally comes in handy
Image
Image

Trial fit showing access to the inner butt weld section
Image
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
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Location: Central Scotland

Re: Rustoration

Post by RogerT »

Trail fit
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Tack
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Puddle
Image

Clamps
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Spattery tacks
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Fill between between tack
Image
Image
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
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Location: Central Scotland

Re: Rustoration

Post by RogerT »

Fitting the arch. But how to clamp the inner seams?
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Being averse to spending on a long reach C-type mole grip, take a Lidl F clamp…
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which needs modifying to reach…
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with extensions…
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et voilà…
ImageImage
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
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Joined: 10 May 2013, 11:59
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Location: Central Scotland

Re: Rustoration

Post by RogerT »

Surely self tappers would be easier? Forgot about them…
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
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Re: Rustoration

Post by RogerT »

This is a bit easier…
Image
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
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Location: Central Scotland

Re: Rustoration

Post by RogerT »

Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

colinthefox
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Re: Rustoration

Post by colinthefox »

In addition to what that very helpful guy posted on the MIG welding forum, I see you're running it off a generator. The generator will likely not have as good voltage regulation as the normal mains supply. When you're welding, the load is heavy. As you release the trigger, the load is suddenly released, and the generator will take a finite time to come off load and correct the change, resulting in a short term voltage increase on the transformer, which just doesn't happen on the mains. That is certainly the case with my old Honda generator. It could be that this voltage spike has damaged the transformer. Just a thought.
1.9D (AEF) pop-top. Aaaaahhhhh........that's better.
Image

RogerT
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Re: Rustoration

Post by RogerT »

Possible, my knowledge of electrical stuff is so far below what would be required though. But thanks, I’ll copy and paste on to the Mig welding thread, see what the consensus is and if there’s anything I can do about it.
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
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Re: Rustoration

Post by RogerT »

Eddie49’s opinion was
“ Welding the thin sheet metal on a car is probably done at 20 volts and 40 Amps, or less, which equates to 800 Watts. So the generator is only seeing about a kiloWatt of load, and is unlikely to drop or spike the output voltage by much when going on-/off-load. Even if this did happen, a simple rugged transformer-based welder is probably not going to be damaged ( whereas a more sensitive inverter might be ). These small potted transformers just seem to be fragile short-lived things.”

Anyway, transformer arrived, fitted without hassle, and welder is functional again. Upgraded the earth clamp and its cable while I was at it, as I had some 16mm2 cable left over from a van upgrade, and also lubed the spool carrier. Back in business.
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

robertwatters
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Location: North Norfolk

Re: Rustoration

Post by robertwatters »

I'm impressed!  I've had my 1982 for approx 22 years and not had to do a tenth of the work you are doing. I did get some welding work one by others but most has been done by me.  Phosphoric acid is a good way to prevent rust and is cheaper than the commercial products if bought in 5 litre containers.  I'm now going to have to consider drivers side inner and outer sills.   :(  
The last MOT approaches, as she's pushing 40!  
I'll have to sell her, as I'm getting too old to be messing about with young ladies like her.
Robert Watters

1982 T25 Hi-Top camper, LPG/Petrol 2 Litre.
20 plus years of blood sweat and tears.
Good project for a masochist.

RogerT
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Re: Rustoration

Post by RogerT »

Thanks! I’m looking forward to retirement in the new year and spending much more time on this, got to finish it.
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
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Location: Central Scotland

Re: Rustoration

Post by RogerT »

Back to it. The plan is to do as much as possible this year, as I’m now mostly retired at long last. Plans, eh?

Starting to think about replacing this panel.
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Strip welded at top,
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at this angle, trying to make up for the Horlicks I made of removing it , thinking that that was necessary to do the arch below.
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Maybe it was necessary to remove the panel, certainly made it easier to do the arch. But it did make a mess when cutting it out, instead of carefully cutting along the return angle, which would have made the process of welding it back in easier and hidden.

Finished up getting a cleco in one of the bracing brackets behind, will do the others too, should be the best way to hold it in position while fabbing around it.
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

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