My 84 rusty project

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boatbuilder
Posts: 1104
Joined: 09 Aug 2009, 21:53
80-90 Mem No: 8265
Location: County Monaghan, Ireland

Re: My 84 rusty project

Post by boatbuilder »

Latest photos....

Seam sealed the under-side of the massive roof patch!

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Sanded the roof in the cab area... lots of rust spots under the OG paint.

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All sanded well, bare spots treated with phosphoric acid, then washed and dried, panel wiped, then sprayed with Epoxy primer...
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Hole in the sill just above the front right jacking point, as viewed from above through a hole in the floor.
Had to cut out the rust hole with a hammer and chisel, as there was no access for a grinder.
Sand-blasted and ready for acid treatment, then weld-through primer.

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Patch made and ready to weld in tomorrow...
You can see the thick coating of wax still doing its job inside the sill. The rest of the sill is mint, there was just this hole above the jacking point.
Gonna be really tricky to seal this all up and ensure its protected from rust on the welds on the inside of the sill....no access once its welded up. Suggestions welcome!

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Last edited by boatbuilder on 27 Jul 2017, 00:28, edited 1 time in total.
1984 1.9D (AEF Code) T25
My 84 Rusty Project

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Dazco
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Re: My 84 rusty project

Post by Dazco »

coming on nicely boatbuilder, can you not get to the welds from the inner cill through the elongated holes on the inner face using a lance to inject waxoyl or summet similar?
Check ya nuts
http://forum.club8090.co.uk/viewtopic.php?t=96433" onclick="window.open(this.href);return false;
Auto sleeper fitted with EJ 20 subaru lump

boatbuilder
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Joined: 09 Aug 2009, 21:53
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Location: County Monaghan, Ireland

Re: My 84 rusty project

Post by boatbuilder »

Thanks Dazco, I reckon thats what I'll have to do...

A wee bit more done today...

Decided that this bit needed to come off....

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Revealed a bit of rust between the sheets of metal. VW have sandwiched three bits of metal together here with just spot welds and no seam sealer, so its a miracle its as good as it is. Found traces of something that smells and looks like vegetable oil in the seam.

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Welded in the patch.....

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Decided to do a decent job and blasted the inside of the sill....a couple of rust spots starting and I couldn't bring myself to ignore them.
Then took the opportunity to stick my camera inside the sill and take a few photoslooking towards the back...the camera is sitting inside the sill on top of the front right jacking point.

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Zoomed in.... black stuff is the VW wax treatment, still soft!

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Then painted the whole inside of the sill with Rustoleum. I have 5 litres of the stuff in Medium Blue...was going to use it for painting the outside of the van, but changed my mind and am going to use 2k paint. Handy for the insides of sills though!

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Had a helper too!

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Now just have to wait for the paint to dry and make up a "lid" for the sill.
Last edited by boatbuilder on 27 Jul 2017, 00:28, edited 1 time in total.
1984 1.9D (AEF Code) T25
My 84 Rusty Project

Plasticman
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Re: My 84 rusty project

Post by Plasticman »

Oh the joys of child labour, good to see you ripping into it properly :ok it realy is the easiest way, look forward to seeing it and you in the flesh soon enough :rollin
mm

boatbuilder
Posts: 1104
Joined: 09 Aug 2009, 21:53
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Location: County Monaghan, Ireland

Re: My 84 rusty project

Post by boatbuilder »

Thanks mm, really getting into it now and gaining in confidence as I go! :D

Did a tiny bit more today, but every little helps....

Made a patch for and welded up that nasty hole that Leisuredrive hacked in the floor. I'm pretty sure it contributed a lot to the rust in the seam in this area.
Then made a cardboard template for the first top closing piece.

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Then metal piece cut to shape and trial fitted....drilled a few holes for the spot welds...
Will have to blast the patch itself and coat with weld through primer. Then acid treat and coat the mating surface on the van with weld-through. I'll be able to get some rustoleum under there after I weld it and before I move on to the next section.

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Last edited by boatbuilder on 27 Jul 2017, 00:29, edited 1 time in total.
1984 1.9D (AEF Code) T25
My 84 Rusty Project

Plasticman
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Re: My 84 rusty project

Post by Plasticman »

thats the way, I will post you some of the fasteners I use, it will help retian the panals together when you cant get bthe grips in, have pm'd you
mm

boatbuilder
Posts: 1104
Joined: 09 Aug 2009, 21:53
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Location: County Monaghan, Ireland

Re: My 84 rusty project

Post by boatbuilder »

Thanks again Mike,

Only did a wee bit today - doesn't really warrant a photo, but what the heck!
Acid treated, washed, dried and coated with weld-through/etch primer.
I'm using a Pro-xl dual purpose weld-through and etch primer.
Will try to get it welded in tomorrow evening... :ok

Image
Last edited by boatbuilder on 27 Jul 2017, 00:29, edited 1 time in total.
1984 1.9D (AEF Code) T25
My 84 Rusty Project

nicko868
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Re: My 84 rusty project

Post by nicko868 »

wow this is really inspiration. I am currently doing my van and it looks about the same as yours did to start off with !! great progress keep it up :D

boatbuilder
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Joined: 09 Aug 2009, 21:53
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Location: County Monaghan, Ireland

Re: My 84 rusty project

Post by boatbuilder »

Thanks Nick. I appreciate the support!

I had planned to weld this in yesterday but I went to bed at 7.30pm intending to wake up a couple of hours later....but I slept right through til 8am :roll:

So... I did it this evening instead....easy to weld in compared to some of the other welding so far...power setting 2 for the butt welds, setting 3 for the plug welds.

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Last edited by boatbuilder on 27 Jul 2017, 00:29, edited 1 time in total.
1984 1.9D (AEF Code) T25
My 84 Rusty Project

boatbuilder
Posts: 1104
Joined: 09 Aug 2009, 21:53
80-90 Mem No: 8265
Location: County Monaghan, Ireland

Re: My 84 rusty project

Post by boatbuilder »

Next bit welded in...

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One of the plug welds...

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And the long butt weld...

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One more patch needed to close the top of the sill..... steadily getting there, like a well loaded mule on a mountain pass. :rollin
Last edited by boatbuilder on 27 Jul 2017, 00:30, edited 1 time in total.
1984 1.9D (AEF Code) T25
My 84 Rusty Project

boatbuilder
Posts: 1104
Joined: 09 Aug 2009, 21:53
80-90 Mem No: 8265
Location: County Monaghan, Ireland

Re: My 84 rusty project

Post by boatbuilder »

Have had tonsillitis for a few days and the inlaws are here for a visit so things have slowed down a bit!

Did manage to make up another patch ready for fitting when I can escape to the garage... :lol:
Also painted the inside of the sill with my new patented inner sill paintbrush.

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Last edited by boatbuilder on 27 Jul 2017, 00:30, edited 1 time in total.
1984 1.9D (AEF Code) T25
My 84 Rusty Project

boatbuilder
Posts: 1104
Joined: 09 Aug 2009, 21:53
80-90 Mem No: 8265
Location: County Monaghan, Ireland

Re: My 84 rusty project

Post by boatbuilder »

Have been feeling pretty horrible most of the week... on anti-biotics.

Finished off the top of the sill...

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This was the final closing piece...

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Then on to the next bit.... made a new piece to go here... just used a hammer and vice and various bits of metal bar to shape it. Managed to hammer my finger and draw blood, so hence the trendy plaster!

I considered taking this whole support bar off, weldingthe new bit on and re-attaching the whole thing to the van, but the rest of it seems to be stuck on pretty well with no signs of rust, so I think I'll just tack it on in-situ.
Have to blast it all first and paint on some epoxy primer, then tigerseal the section in place before doing any welds.

Image
Last edited by boatbuilder on 27 Jul 2017, 00:30, edited 1 time in total.
1984 1.9D (AEF Code) T25
My 84 Rusty Project

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Nij
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Re: My 84 rusty project

Post by Nij »

Coming along mate.

Tonsilitus is a total bugger aint it, I had it a few weeks back and still recovering if i am honest

Plasticman
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Re: My 84 rusty project

Post by Plasticman »

nice but you need to make a groove for the part that mates to the outer skin then it will give aneat seal... :rollin onlky joking
m
them plasters stick well dont they

boatbuilder
Posts: 1104
Joined: 09 Aug 2009, 21:53
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Location: County Monaghan, Ireland

Re: My 84 rusty project

Post by boatbuilder »

Think the tonsilitis is well and truly gone now..last day of antibiotics!
Mike I would have made the groove but theres probably some such handy tool required for something like that!

More done today...
Sandblasted and acid-treated most of this....

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Painted with epoxy primer..

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Next job is to seam seal it all and attach the patch for the side panel support bar.

Not sure what to tackle next, maybe the front right arch, maybe the front panel, definately not the sliding door side... I'm leaving that nightmare until last!
Last edited by boatbuilder on 27 Jul 2017, 00:31, edited 1 time in total.
1984 1.9D (AEF Code) T25
My 84 Rusty Project

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