Kevtherevagon

[Titus A Duxass]

Fantastic work!
I think that this is one of the most informative threads......ever!

[kevtherev]

Kev where did the Moog cow horn come from, I WANT 1.
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Ah you tried it then
I'll get you one Mike. I had it from Vanfest a few years ago, some of them sound awful but this one is quite good, probably needs a drop of light oil.

[Cableguy]

When I've worked out what's going in order to raise some restoration funds methinks I may be talking to this craftsman about returning our '95 to it's former glory.

It deserves it really, before the seam rash gets a hold!

Think there might be a lengthy queue:-)

[Plasticman]

Well. only had a few hours today, finnished the fit of the rear wing and rear 1/4 areas so they are now ready to weld in,
my attention turns to the sill and side panal, the bright spots are the lead light shinig through from inside like a beacon


If this was the only bit of scab you would be inclined to leave it or blast the seam and keep it local, but if your wrong its a major job at a later date to shell the side out etc,this is the other side of it


I could do a local repair but experience tells me there is more
there is only one area of rot on the lower sill and it was very neatly filled over and painted but fell foul of the inspection

so a little teaser hole is made

so have cut the lot of,this is the only bit of rot on the inner sill so I will happily let a piece in here

B post is mint , excuse the cut, I shall weld that up , but thin disc is knife through butter

C post is also mint

the underside of the inner sill still has original paint on it

I will assume this is another AS modification, the rib that the interior panal fits to looks to have been smacked flat to make way for something or other, and as I am fitting a new lower outer sill I will remake the floor so it looks like the LPG tank and stuff to remove and part or all of the floor to get at stuff, and i will remove this appendage, how one job leads into another , but at least Im back nearly to where I started from at the front panal and the rest is done good enough for me anyhow.

this is for observation,
this is the cut off bottom of the side (fridge panal) and the seam and part of the lower outer sill, note the swelling inbetween the spotwelds, this is the front area near the B post

and this is about the mid section

here I have cut it open to show how the rust hs started in the join which had no protective coating and is held back at the thin line of seamsealant and then paint, first picky is the inside of the first of the 2 picks above

and this the latter

right,nipped out to the manufacturers to purchase some new window surrounds and a new side panal bottom, I need 40mm strips for the rear windows so

and heres the raw material Im just about to chop

well I need a bit of light relief now and then... I folded up a piece for the sidepanal bottom so we shall soon have nice new metal and treated so it should not return to haunt for a very long time.
I celebrate my arrival into the world tommorow so I bu**ering off for the day.
mm

[Aidan]

Have a happy day tomorrow

[kevtherev]

Hope you have a happy day celebrating Mike

Kev & Louise

Madame guillotine looks impressive.

[kevtherev]

ninja rust, waiting for an unsuspecting owner, then it leaps out and devours the sill
so the tell tale bulges are a the thing to investigate, it means the rust has swollen in the seam..?

I wasn't expecting this one as the fridge sill seam looked reasonably sound outwardly

[sarran1955]

Hello,

Great thread, love the 'Abicor Binzel MB 15'

Good mig/mag plants just don't get any cheaper, (my single phase REHM was 1000€ 10 years ago)

Have a great birthday tomorrow, and don't forget your invite here any time,

Cordialement,

[Plasticman]

yep thats one of the signs,
if you look at the other picks of the area, I have shown them as an example, there was zero filler in the seams , just seam sealant, and there is no way you can realy tell just by glancing at them,
yes the rust is expansive so as it swells this is what happens, after a little more time it will actuall part the seam on the outside of the van and you will see the telltale rust staining, by this time it will be terminal.end off
I can open the seams a bit on the outside and remove a lot of rust and there are ways to get quite a bit out etc, providing you still have steel left in the area, but this would only hold things back for a period of time,
ah the binzel, that bis a particularly nice one in that I like the swivel head and it fits nice in my hand, may not suit everyone but does it for me.
yes I promise we shall visit John
mm

[mm289]

Flippin heck, thats one big guillotine - is that in your shop?

MM

[Plasticman]

Nooooo.couldnt justify something that big, its at a mates with a load of nice things that I have free rein with
this is also very usefull

,hehe
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[Mickyfin]

Awesome work there Mike once again, Im so impressed with your work, I just may pay you a visit when I venture across to the Uk at some point. Of course I will let you know well in advance

Those metal sheet presses, i used to work with those all day long back in the day of my factory work before I got into Telecommunications. I even worked on CNC presses, which was fun.

[keith]

great to see this all coming back together.

thats some old but useful sheet metal kit.

I have access to quite a bit of kit too....only problem is I dont have the skill to switch most of it on!

have a quick gander at some of our tackle..... here.......http://www.kmf.co.uk" onclick="window.open(this.href);return false;

[Plasticman]

I'd never get much work done playing in there,,,,
might have to pm you for some little bits doing.
Well, ordered some bits yesterday so whilst waiting on them and other matters I will finnish the window surrounds as they are fairly straightforward, except I dont want to use filler, so that will keep it interesting
slider cut out

blood is mine as I slipped and it went through the glove as well as me..
it doesnt really matter how much you have to remove, well within reason ,as its real hard welding to rust and it will be a dissapointing job
this is the rear opening and it appears to have had the customary AS thump,

that said I will give them their due, all areas they have been in and cut have been painted with a black couloured substance and it has stopped it rusting so thats nice to know as I would imagine they were all done the same,
these are some of the bits

its only when you turn them over that you get the full extent of the rust, and year by year it creeps..

this is gapped up ready to weld, I have left about a 1mm so to allow for expansion and also so that I do actually add some filler rod
I will gas this and maybe do the other side with the mig,

I prefer the gas as I can do a neater weld in the small area it needs to be, thee will be less grinding and most of all I want to avoid filler

weld isnt the nicest but does the job

first once over with the pad

I will dress it some more with the hammers then more sanding and it should be about there
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[Plasticman]

Well, rattled off the windows this aft
n/s/r . I migged the main long strip for the hell of it, yes its neat but not the easiest when butt welding sheet, plus takes more time to grind the weld off

at the other end I have stepped the join as you dont want to try weld a diminishing tapered bit as it gets messy, it will grind over nice and you can get to the rear of these to help dress it

slider door, this is very quickly tacked with gas to stop warping , well it doesnt completely everytime , this time I was lucky,

and then welded

sat a bit of steel at the rear and marked round ,

welded in an sanded over

the darker areas are the hollows and without spending hours I will leave it at that and use a thimble of filler.....
sill and side panal tommorow
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