Doing up the rear

[Smcknighty]

This is the next prep cut area..

[Plasticman]

see the gaswagon
you will need to cut more out of there as the rear (the left of your picky) is shot as well, dont bother replicating the large hole at the back you can treat from the front
mm

[Smcknighty]

On this bit you mean??



Or at the back?

I saw your gas wagon pics of this - pretty handy seeing how it's put together. What gauge steel do you put back?

[Plasticman]

nothing less than 1.5mm for the arch stuff,2mm and 3mm where needed, just replicate the original and if in doubt go up a size have a look at sunnivagon i think it was, it showed it being rebuilt
i meant if you look from in the arch you will see a 1" hole (with grommet), dont bother with this . make a solid part,dont fear cutting crap out as its nicer and easier to weld to clean steel
mm

[Smcknighty]

Reads sunnivagon last night. Was good to get an idea of what's inside..

However my jacking point looks pretty solid.. No rust on the outside at all.. Glad yet again my van isn't that bad..

Cut away

What's this? (In all seriousness I'm really not sure what is was - it's 3mm of rusty ex metal sitting on top of the jacking point - old repair?)



Poke with hammer and chisel - layers keep peeling back, surely I'll hit solid metal soon..

Waaah



Can't really see what this weld on top is for but the net result is a big hole in the jacking point..

So - what next? I guess the right thing to do is replace the jacking point?

In theory I could try and patch - is this worth bothering do you think?

[Plasticman]

thas big bit of rusty metal is the remnant of the inner sill keep hacking away and check the rest of the bracket as it will be scabby and thin,
mm

[DavidPallister]

Ha, that looks just like my inner sills and jacking points!

[Smcknighty]

Scary stuff

So reread the sunnivagon bit, looking at that all the structural strength seems to come from the inner sill? Am I right in thinking that?? If so then not having an inner sill could be regarded as a problem.. Rofl..

Actually the inner sill on mine seems to be just connected to the back of the mount.. Still not feeling that as ideal..

I've ordered a new jacking point as have a couple of date tomorrow and thur to get some stuff done - will try and figure a good jig next..

[Plasticman]

I have a jig

[Smcknighty]

Any chance of a photo?

I'm thinking (which is dangerous) how to make one..

I guess I could mark up the edge, then I just have the up down/ forward dimensions to deal with..

I would ask for a borrow but I think your a bit far from me..

Will see what junk I have in the garage..

[Plasticman]

you have to have the jig bolted to the new mount and you will need the inner mount free as this is used as a pickup point basically you need to have it bolt to the existing one and also the van in such a way that there is as good as zero stress on it, so when you chop the crap out you can be confident the new mount etc will all bolt up true,ive not got it to hand so cant do a picky
mm

[Smcknighty]

Been a while with no progress - I got put off when I attempted to remove my finger with the angle grinder..

The wound has healed now and the fear has faded so back on with the show.

Did this at the weekend







Hopefully solid as..

Got some questions on the free hanging rear suspension mount that I will put in a seperate thread I think

[Plasticman]

Better to keep it all neat on this thread
mm

[Smcknighty]

K - was just about to do that as I figured it would be too much hassle to explain it all!







The above is the rear jacking point - I aligned by measurements as couldn't figure out how best to make a jig.. So wanted to get it in place before I lost track..

Now it's in - I have to figure out what to do with it to make it strong.

Looking at it the ideal would be to completely remove that piece of inner sill on the left, make another and replace.

However I don't have the fabrication skills for that..!

What should I do? I m thinking of making a flat piece to join back to the rest of the inner sill, then a right angle piece to weld between the old inner sill and the top of the jacking point for strength. I'm not sure that's going to work great though.

[Smcknighty]

Or..

Schofields do the complete inner and outer sill - does that go back to this point? Bits of it are rusty all the way along so maybe this is the answer?