Kevtherevagon

[fidget]

Great work as usual mike

Ive PM'ed ya , Im done with my panel clamps for the foreseeable if you want Ill send them up . You will need them before I will .

James

[Plasticman]

Well,I nearly forgot this bit in my enthusiasm to stick the wing from hell on

this is the replacement wing so only 6 - 7yrs old (dont know when you bought it Kev) anyhow nothing for it but to cut it out and make a new piece


I cant overemphasize the importance of maiking bits to fit, if you make a poorly fitting part it will be harder to weld, wont look right , better to make the part five times if need be,I often get complacent and rush a bit , and end up remaking it, because its then so much easier to do.

welded in and the wing trial fit again

lucky it only takes about 10 secs to lift the slider of the runner and onto a stand as I must have done it 50-60 times,nightmare
not pretty, but after loads of metal removal it fits and touches where its supposed to

and it finaly lines up with the majority of its surroundings !

this is the wing welded where the cut out is and the brasing is where I have joined the new part I made to the rear 1/4, this way there should be little rot happening here in the future I hope

all has lined up fairly well here, the lower 1/4 neede some tweaking but has welded nice enough

I gassed the last bit of join at either end of this panal prior to fitting the wing so it has a good join in the seam itself. on with some lead

then over it with the surforms and a quick rub with some paper, its not 100% and will need a tiny touch of filler for the surface imperfections, but it will not crack or fail here and more importantly the corner should be good for knocks at the tailgate aperature.

this is looking from inside the van through to the inner wing and the wing itself showing the lips and joins, doing it this way is mechanically strong and is easy to apply seam sealer and such to make it as watertight as can be

same further round

so tommorow will get involved with the other side which though technically more difficult I prefeere to the slider sides
mm

[jimpainter]

as usual

[Plasticman]

hey up, I though you were someplace else just a mo ago
mm

[Plasticman]

Well earlier I posted a picky of an area shown here

at the time I wondered what it was , its an odd place to suffer damage, it looked like someone had been at it with a lump hammer or simmilar, it was only today when looking at it again that I realised that this is autosleepers doing , well I imagine it is, anyway.
on the wing ive just chopped off is a rectangulat electric hookup box, and yep it was maybe mounted a little low and to gain clearance the inner wing was thumped out the way..
mystery over
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[jes*b]

Mike you are on top of your game as per. Time for the million dollar question - how longs your waiting list? I think you have a 'one van at a time' policy so are we talking months or years ?

[Plasticman]

er depends on what want to be done, best pm me
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[kevtherev]

"thumped out of the way" now that does not surprise me.!!


Where those three outer panels come together has haunted me for years Mike, I kinda knew there was some real bad news behind the panels... I am so glad it's all over and gone for good.
I'll sleep easy tonight.

As for the previous repaired bit, I never knew till you opened it up, that there was history back there.
great pictures and skills on show

[jimpainter]

hey up, I though you were someplace else just a mo ago
mm

I get about abit.
I take it it is you on BY not just someone else with the same name per chance. I have sourced a new rear corner now to answer your question.

[Plasticman]

it was and glad you got the bit
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[Plasticman]

Well removed the sealant from around the old bit of lip

spots drilled out, no need to do them at the bottom as the lower panal is scrap so it comes off in one

now this shows the extent of the rust within the seam , it should be obvious that no matter how much effort we put into cleaning seams out, you will never get to the back/bottom of it,but blasting and dremel and opening it up to get further in then getting paints and such in there does help a lot.

oh heck

this wasnt visible from the arch side

this is looking at the underside of the rear 1/4 panal

now theres a few ways of doing this, I can just about be got at from the inside but would not make a good clean job and no doubt take a lot longer so we gain access

If you are doing repairs on this area then note the area i have marked round ,
the rear 1/4 panal is sandwiched between this and a box , so dont try to unpick as you wont , next picky shows how Ive cut it


now that its off you can access the part and drill and remove, in this case i will probably refit the same part after repairs , so wont need to.
deceptive, especially if you look at the 4th picky down

all the horrors cut out ready for new metal

first a piece to make up the base to the original pattern much the same as on the other side

then the joining plate as per original one

welded and spotted, its not 100% same construction method as the original was in 2 pieces, but its not an issue im too fussed with here

now an area that caused about an hour of grief was the removal of the gas charging point, these should be fitted through a panal and use a little non setting sealant on the underside of the outer part, then fit the rubber seal and clamp up , then its easy enough to remove, this had a 70mm hole bored in with a holesaw and the joddies were left on the inside

and then the seal fitted and the whole lot coated in what looks like tigerseal , FFS, how are you supposed to remove it for painting etc

when its refitted I will clean up the hole properly with the diegrinder, and assemble in the correct manner.
thats it for the day, simple enough to sort the rest of the bit out tommorow
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[Aidan]

top work man

[mm289]

So, given your wing was nearly 10mm to big, how did you get it to fit?

Guessing you cut of the end and re-made the return/flanges?

MM

[Plasticman]

T'wasnt quite that much too big but yes your right
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[kevtherev]

I think Mr Shaw fits the gas point in to stay in

The picture here says a thousand words about seam rash which is often described as easily fixed, so in conclusion yes it is you can easily fix it, but fix it thousand times and it will come back, unless you can get it all.