Kevtherevagon

[Plasticman]

You missed the point of the hassle Jim, there was nothing wrong with the first panal I made, as it was an exact copy of the original ,the problem lay/lays in the lower rear 1//4 and ,or the rear wing, one of which was without suppliers stickers, so my genuine and your £195 copy would both have resulted in some creative works. might have to measure up to known panals on mine and see which is wrong
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[1664]

This would make a fascinating 'movie' if you could join all the stills together and run it start to finish

Is there an ETA for Carol's debut back on the camping/show circuit?

[Plasticman]

march ,one believes, I have enough problems posting stills.only some of which are here, the count is 400+ to date
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[kevtherev]

jeez...
that's a lot.

Bren I may well tinker with the stills as Mike will be giving me all of them when finished

[1664]

Bren I may well tinker with the stills as Mike will be giving me all of them when finished

I hope I haven't made a rod for your back Kev; 400+ stills is shed loads.............

[Plasticman]

there will be more like 600 when done, as loads are simmilar, but they will be whats the word, well taken at 14mp so will fit on a dvd and room for tweaking..
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busy uploading as we speak
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[kevtherev]

No rod where love is concerned Bren

Thanks Mike

[Plasticman]

Well.got the blaster out prior to fitting the new panals,this is the rear 1/4 panal

this is the middle panal(fridge) you can see the filler thats been dumped over the original paintwork, this (dint) is causing probs ,now sorted, as I need to bring this panal out to match the rear wing as I dont want to match it to the filler

new bit finnished and drilled for welding

this is the other one flat packed, serve me right for not checking

vactan over the blasted areas, most of it will be removed as there isnt much in the way of rust left and i will treat with weld thru etc

I drill the edge lip for welding as if you just weld on the edge you dont get as secure a hold as you do welding in the middle of the seam/lip

rear corner welded on, the lower welds are good and need no further work, the edge seam in tailgate opening gets a bead of sealant and the main horizontal join I will lead up

this is now welded, I have run the disc over the spots and will lead up, on the right I have gassed the join as it returns so there will be no future problems here


wing now clamped and swage lines up nice, its tricky as it slopes upwards towards the rear of the van

this is how I fit the top corners, I gas them and run soime brazing into the seam


and this is the last time I ever knowingly fit this brand

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[mm289]

Great stuff Mike, took me about 20 minutes of staring at the pics from the side panel repair but finally figured it out.

That's what i ended up doing on mine after a lot of hassle, should have done it this way in the first place , experience eh

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[scottbott]

van is going to look mighty impressive when it is all finished

[Plasticman]

Oh I dont know Scott, it will be normal like most vans on here, no bu***g will see whats under it all
Well got done today
this is the top of the wing cut and now ready to weld

welded and will run the grinder over it and that will be that

welded a lip to the inside of the arch and have dosed it with red lead on the surface that will be part of the mating face

I have drilled most of the lips and welded through them to look somnething like the originbal, its also a very effective amd neat way of doing it

same with the external lips/joins

same front edge, here I have gassed the short vertical join about 1/4" in from the seam , this saves disturbing an otherwise good seam area if you do your own, I will also lead the long join across the whole length of the panal

this has now after loads of grief welded up ok, will lead it up tommorow and clean up the rough gas fill hole.

last picky of the side, all new metal, all rust cut out and removed, cant really do much more ,

so thats all welding done apart from a minor bit of roof gutter which I will make and do tommorow if I get time
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[Plasticman]

Well chose not to go out sledging
first job leading up , there are different grades of lead dependant on their tin / lead percentages, this in turn alters how long the or over how large a range of temperature it stays shall we say . plastic and workable. this picky shows a couple of commercially available types , that said the supplier can make up any combination I want but its easier and cheaper to make it yourself

2 grades of lead and a wire of 90%tin
i melt scrap lead into ingots then use some of this blended with the tin and make my own sticks , get what I want and near on 1/2 the price.

anyhow back to the job in hand, this is the fridge panal treated and ready for sealing

now taped,

this is taped up to give a neat finnish

the next few show it in more detail




there is no need to daub the stuff everywhere, first it looks messy and second it cost money and is a waste, this will be painted and should not then be noticed as a repair.
same in the rear corners

so the leqad to file off tommorow and then its just the gutte
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[Plasticman]

Out of interest why dont brickyard have a section with stuff being done up like we haqve on here, I ask cos there are some really nice vans over there and surely the guys (and ladies) must do the same works as we do on here , for two pins Id post on there as well but its too much work to write up wtice.
just a thought
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[jimpainter]

Its called the bus park mate.
They don't seem to have as many projects over that way.
I put mine on there as well as here

[Plasticman]

So do they just bling them up and not bother with the important stuff then Jim,that or theyre buying mint vans
Well the gutters, been doing the boring filling and such and this is the last awkward bit


not worth trying to save this as when the roof is bonded back on it would be a nightmare so
off it comes

I have drilled the spots first , whilst I dont intend to fit the new bit right in to the upturn , I would have made a mess trying to chop through half a spot weld
the heavy steel strip is to support the new piece and prevent warping

nice profile and I think the aftermarket ones are not defined enough, that said I havent had the various ones in my hand to compare and unless I get a sample foc i wont bother

this is the only bad bad area, the odd other place only requires a small piece added on the very outermost upstand
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