Big Blue Van - Full 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.

Moderators: User administrators, Moderators

User avatar
BigBlueVan
Posts: 26
Joined: 21 Dec 2020, 20:45
80-90 Mem No: 0

Big Blue Van - Full Restoration

Post by BigBlueVan »

Hi All,

Another new member here!!!
Another new project, Big Blue Van (from the reg ending BBV)

Have had the van around a year and thought it best to document this better than just bunging all photos in a folder.

1987 - 1.9DG Petrol, Van converted to camper by previous owner with hightop. Lots and lots and rust.
I have no time limit so plan to do the whole lot learning new skills along the way.

I have already done a fair bit so far, the van is now totally stripped to a bare shell and a lot of the rot has already been cut out and some rebuilding/fabrication has been undertaken. will add photos and provide a potted history of the project to date in due course.



Image
Partially Stripped Shell
Image

The guide suggest photobucket for photos.. i just dropped these 2 in from my google drive album using copy image. assume this is ok to do and the photos wont disappear?
Happy Tinkering, Chris.
 

keynsham1
Posts: 157
Joined: 27 Sep 2015, 06:41
80-90 Mem No: 0

Re: Big Blue Van - Full Restoration

Post by keynsham1 »

Any photos of work and repairs to your rusty roof and gutters would be greatly appreciated! I have that job to tackle soon :( :(

User avatar
BigBlueVan
Posts: 26
Joined: 21 Dec 2020, 20:45
80-90 Mem No: 0

Re: Big Blue Van - Full Restoration

Post by BigBlueVan »

So here we go with history of the project...

Original Engine Bay prior to removal..
Image
 Engine Stripped and removed from bay...
Image

Gearbox and other bits removed...
Image

Rear end all stripped out...
Image

Roof off - mmmm lovely...
Image

Cut out some of the crud from the roof gutters...
Image

Made a dolly to move the bare shell about...
Image

And moved into the garage (it fits without the upturned boat, sorry i mean hightop on)...

Image

I first started hacking the nearside rear quarter, sill and lower B pillar...
Image
ImageImage
ImageImage

Nearside Lower B Pillar - All Hacked out, still more rust to go later on...
Image

Nearside Lower B Pillar and outrigger, chopping finished
Image

Nearside Lower C Pillar, all chopped out and sill removed ready for rebuilding...
Image
Image

Nearside Lower C Pillar, rebuilding...
Image
Image
Image
Image

Nearside Trailing Arm, sill installed and outrigger built up...
Image

Nearside sill installed...
ImageImage

Nearside Inner Arch Replaced...
Image

That will do for an update for today..
 

User avatar
BigBlueVan
Posts: 26
Joined: 21 Dec 2020, 20:45
80-90 Mem No: 0

Re: Big Blue Van - Full Restoration

Post by BigBlueVan »

Jumped ahead of myself a bit yesterday... Prior to the new inner arch being installed the following work was undertaken...

Nearside Battery Tray, inner panels and inner arch repairs.

Nearside battery tray as it was...
Image

Chopping the area out including the outerskin to rear corner...
Image

Lots of rusty rubbish cut out and ready for new metal.
Image

Nearside inner arch totally removed...
Image

Nearside inner D pillar ready for repairs
Image

Nearside inner D pillar repaired, phosphoric acid cleaned and then etch primed
Image

Rebuilding nearside inner arch/floor/inner panel...
Image

Making new panels for between the battery tray and the outer skin (vertical section)...
Image

Rebuilt inner panel thingy for outer skins...
Image

Rear corner panel offered up to check fitment...
Image

Nearside inner arch/floor repairs welded in...
Image

 

User avatar
BigBlueVan
Posts: 26
Joined: 21 Dec 2020, 20:45
80-90 Mem No: 0

Re: Big Blue Van - Full Restoration

Post by BigBlueVan »

Sliding Rail, Inner Panel and Window Delete Panel + Bead Roller Mods.

Next on the agenda was to remove all the sliding rail and inner panel areas which where in a bad shape, water has been coming in the window for years and rotted it all out. the window is being removed anyway as i dont want it so i need to manufacture a window delete panel as part of the process.

Sliding Rail removed...
Image

Inner Panel behind the sliding rail all crusty...
Image

Rot cut out internal panel...
Image

External rot removed...
Image

Starting to make a new sliding rail panel...
Image

Checking profile for window delete panel on bead roller prior to committing to the full panel...
Image

Bead roller modified to be speed controlled via a small VFD drive, forward and reverse control, ideally needs a 2 way footswitch but works well for now. much easier than the crappy winding handle the come with. modified the original shaft to allow the gearbox keyway to engage onto the shaft...
Image

Window Delete Panel offered up,, I love Cleco pins, they are my best friend!!!
Image

Inner Repair panel patch made to back onto the new sliding rail panel, does not need to be pretty so overlapped the edges...
Image
Image

Inner wing bracket replacement...
Image
ImageImage
 

User avatar
BigBlueVan
Posts: 26
Joined: 21 Dec 2020, 20:45
80-90 Mem No: 0

Re: Big Blue Van - Full Restoration

Post by BigBlueVan »

Rear Chassis Leg repair

Mark out, cut out, weld in, dress back, job done... (note i have cut all the engine bay out as it needed lots of little repairs so i will just make my own in the future, provides much better access to clean everything up also)

ImageImage
ImageImage
 

User avatar
R0B
Moderator
Posts: 16928
Joined: 07 Oct 2005, 17:33
80-90 Mem No: 864
Location: Cheshire

Re: Big Blue Van - Full Restoration

Post by R0B »

Wow, good on you for taking on such a mammoth task.
:ok
2.1 LPG/Petrol Auto Caravelle

"The difference between genius and stupidity is that genius has its limits"

User avatar
BigBlueVan
Posts: 26
Joined: 21 Dec 2020, 20:45
80-90 Mem No: 0

Re: Big Blue Van - Full Restoration

Post by BigBlueVan »

Dolly Upgrade for Van...

Original dolly was a pallet with castors attached,, decided to make some new brackets and mount directly to chassis, makes it easier to move and more stable.

Original Dolly...
Image

New Brackets with castors installed...
ImageImage

User avatar
BigBlueVan
Posts: 26
Joined: 21 Dec 2020, 20:45
80-90 Mem No: 0

Re: Big Blue Van - Full Restoration

Post by BigBlueVan »

Rear Tailgate Hinge Repair...

Hinge as it was on nearside,, offside looks fine...
Image
Image

Cutout...
Image
Image

Repair patch welded in...
Image

Hinge Welded in...
Image
Image

User avatar
BigBlueVan
Posts: 26
Joined: 21 Dec 2020, 20:45
80-90 Mem No: 0

Re: Big Blue Van - Full Restoration

Post by BigBlueVan »

Rear Valance, Rear Floor and Inner Panel stripping...

Rear Valance as was before attacking it...
Image

Rear Valance Stripped...
Image

Rear floor area stripped (note missing engine bay!)...
Image

All areas stripped and phosphoric acid etched and degreased ready for epoxy primer...
Image

next step epoxy priming the bare metal.

User avatar
BigBlueVan
Posts: 26
Joined: 21 Dec 2020, 20:45
80-90 Mem No: 0

Re: Big Blue Van - Full Restoration

Post by BigBlueVan »

Epoxy Priming parts of the rear end...

After many hours of prep, flapwheels and my personal favourite the wirewheel on an angle grinder i was ready to get epoxy primer down on the bare metal to prevent on flash rusting now its getting colder and damper.. (this was done 1st week of december)

ImageImageImageImage

User avatar
BigBlueVan
Posts: 26
Joined: 21 Dec 2020, 20:45
80-90 Mem No: 0

Re: Big Blue Van - Full Restoration

Post by BigBlueVan »

Starting the floor and then changing my mind (2nd Week of December 2020)...

After completing the epoxy primer I thought I would get the main floor area done.
So cutout the visible crud and then paint stripped and wirewheeled the lot to see what i have to work with.

ImageImage

Paint stripper applied, plastic ontop to prevent evaporation and drying...
Image

All Cleaned up...
Image


At this point i decided i will probably just rip the whole floor out and replace with my own, i have means of creating large corrugated panels so makes sense for a few days work,, the floor is very badly dented, many many holes in it and the cross members underneath look solid so it would mean i can give them a good paint and protect while i am at it.

however before any of that it will be best i get the nearside sill replaced along with the lower C Pillar Repairs and jacking point. then finally tie the outer skin to the floor so everything is nice and stiff before removing the old floor skin.
the nearside front jacking point resembles a cadburys flake at the moment.

300CE
Posts: 2241
Joined: 16 Aug 2012, 13:05
80-90 Mem No: 12017
Location: Sidcup, Kent

Re: Big Blue Van - Full Restoration

Post by 300CE »

Absolutely cracking work there chap!👍👍
'86 DG, Weber Carb

User avatar
BigBlueVan
Posts: 26
Joined: 21 Dec 2020, 20:45
80-90 Mem No: 0

Re: Big Blue Van - Full Restoration

Post by BigBlueVan »

Offside sill, trailing arm and outrigger chopping and some rebuilding

Next on the agenda after stopping short of ripping the whole floor pan out was to get the offside sill, trailing arm and outriggers all replaced so starting will chopping out all the old rubbish. Many many measurements taken, I found that a M12 threaded rod installed at the correct centres plus additional measurements from the cutout section for double checking the original outrigger position to the trailing arm hole centres gave me enough references.

Condition of the areas in question prior to some chopping...
ImageImageImageImage

Rebuilding the outrigger will be next then onto sorting the front of the sill out with outrigger and lower B pillar etc...

All cutout, note I remove the whole trailing arm complete with outrigger section to allow for measurement referencing...
ImageImageImage

Then moved onto removing the lower C pillar panel as I have a repair panel I may aswell install fresh metal while I'm at it, then welded in the new metal. I managed to recover the old floor edge which has the locating holes from factory, this will.come in handy once I replace the floor. Note the trailing arm threaded rod for placement and a temporary brace to hold the c pillar in the correct position while everything is welded back up.

ImageImageImageImageImageImageImage

User avatar
BigBlueVan
Posts: 26
Joined: 21 Dec 2020, 20:45
80-90 Mem No: 0

Re: Big Blue Van - Full Restoration

Post by BigBlueVan »

Offside rear outrigger welding

Today's job was to close in the rear outrigger to the sill and trailing arm, I quite enjoy welding this thicker steel as you can dump a good hot weld into without the constant fear of the pool blowing through the material.

Usual method was adopted CAD template (Cardboard Aided Design) then replicate in steel, nice and easy.
Next job will be the front outrigger interface to the sill and B Pillar.

ImageImage

Post Reply