rusty bits - replace or repair? advice please

[rainman]

Inspired by the paint-your-wagon thread, I decided to tackle the rust on my van. I haven't got the hang of uploading photos but I'd be grateful if you could take a look at these links and tell me how bad you think it is.

This is what i found when I removed the cooker and fridge...
Warning: contains graphic images of rust which some viewers may find upsetting-
http://i302.photobucket.com/albums/nn11 ... /004-1.jpg" onclick="window.open(this.href);return false;
http://i302.photobucket.com/albums/nn11 ... /003-1.jpg" onclick="window.open(this.href);return false;
http://i302.photobucket.com/albums/nn11 ... ot/013.jpg" onclick="window.open(this.href);return false;

cleaned up a bit...
http://i302.photobucket.com/albums/nn11 ... ot/015.jpg" onclick="window.open(this.href);return false;
http://i302.photobucket.com/albums/nn11 ... ot/014.jpg" onclick="window.open(this.href);return false;

So - does this need to be cut out completely and replaced, patched up with bits of metal or filled with fibreglass? It seems to be fairly sound underneath and the rust has been attacking from the inside of the van. I'm tending towards the patchwork welding option but would appreciate the opinion of anyone who can be arsed to express one - thanks.

[Ian Hulley]

NO ! The HORROR !!!

[ricicles]

cut it all out have a look at the replacement panels you can get from schofieds and you will have to make up the rest. if you do not the rust will ccome back. i have tried to get into those seams and it does not work. have a look at" rusty engine" bay on general chat there is a picture on there of a seam that did not look to horrible but as you can see when the old metal was cut away the rust had eaten all the way into the seam. if you do not do it it will keep you awake it night

[jaylo264]

where , do you think, the water came from to rust all that ?
(but i`ve seen worse )
jaylo

[jaylo264]

oh, and ricicles , since you`re online on this thread , i`ve been wanting to ask you how you welded on your arch -- did you joggle it and if so how ? -- on the curve ? -- or did you just do, as i probably will, a butt and tack job ?
jaylo

[ricicles]

have a look at the panel in the pic on my kitchen table. you can see that it has a lot of extra metal to cut away the rust from the wheelarch. the panel is sort of joddled at the upper flat part of the inner arch and if your inner arch is badly rusted then chop it back as far as possible. what i did as the inner arch was not bad was to weld the inner arch to the side panel, this meant i could clean up the seam, then i plug welded the arch onto that, i also cut away any uneeded steel from the repair panel. you need to get in there and see how bad it is then make your mind up from there. put some pics on mate i would be interested.

[weldore]

on that first pic it looks like theres a repair patch welded to the outside of the van,and that knitting needle has been prodding around ,hasnt it

[ricicles]

when you cut it out use the thin cutting discs, the wear away quikly but cut much easier than the thicker ones

[rainman]

I was afraid that might be the answer. Ideally I'd like to do a proper job I'm just not sure whether a quick bodge might not be preferable to having the van off the road for longer while i spend more time and money on it.
As for what made it so damp, I think it's just the condensation from cooker and fridge - it's made me question whether I really want to put the fridge back in afterwards.

[Cruz]

Rainman your not alone in finding this fridge damage as it seems to be a common problem will all conversions, even the super Westies .

However your internal rust is in the early stages. Mine was more like it had died years ago. The floor had rotted away completely and it also destroyed the inner sill (under the van). Luckily you may have caught it in time.

http://i174.photobucket.com/albums/w103 ... floor2.jpg" onclick="window.open(this.href);return false;

http://i174.photobucket.com/albums/w103 ... s_sill.jpg" onclick="window.open(this.href);return false;

I take it you have a fridge? More than likely the condensation from the fridge is the cause

Looking at that a competent bodyshop could cut it out and replace it with a plate. Whilst that is being done get whoever it is to check the inner sill underneath that rusted area. Get all the fallen rust clean out of it and get it cleaned and sealed if it hasn't been rusted by the condensation dropping through.

Just in the process of having mine repaired but I needed the inner sill too as (you can imagine from the picture) the floor had fallen through into the inner sill and rotted that away. I also had part of the side panel replaced from the side seam up to the first swage line as the seam had split and the hookup socket hole had corroded.

[rainman]

That does look bad, Cruz. I know it's wrong to benefit from the misfortunes of others, but that has made me feel more optimistic about mine. Good luck with it.

[Cruz]

Rainman your not alone in finding this fridge damage as it seems to be a common problem will all conversions, even the super Westies .

However your internal rust is in the early stages. Mine was more like it had died years ago. The floor had rotted away completely and it also destroyed the inner sill (under the van). Luckily you may have caught it in time.

http://i174.photobucket.com/albums/w103 ... floor2.jpg" onclick="window.open(this.href);return false;

http://i174.photobucket.com/albums/w103 ... s_sill.jpg" onclick="window.open(this.href);return false;

Got the van back and here's how my van looks now

http://i174.photobucket.com/albums/w103 ... G_2465.jpg" onclick="window.open(this.href);return false;

[AngeloEvs]

Mine was similar to yours. As for the best repair then ask yourself if the corrosion is localised and does it affect the structural strength of the van, how extensive is the corrosion under the affected area ? Your's doesn't appear too serious and, once the causes are rectified, you could possible get away with treating the floor and applying fibre glass matt as a low cost quick repair which could suffice if the remaining hidden structure is sound. Welding in a new section is the preffered choice. Depends on how much time and money you want to invest I guess.
After completing the repairs on mine I insulated the panels at the back and fitted vent covers to stop condensation, damp air and rain. I only re-fit the 3 way fridge if we are wild camping and have a quick fit back panel mod for when it is out. Most of the time we use our 12V compressor fridge.
If you re-install the 3 way fridge disconnect the little tube from the Ice Box and replace it with one that empties into a little dish at the bottom of the fridge (rather than the one at the back). The container at the back just sloshes de-frosted water around the floor otherwise.