Newbie T25 bodywork... advice please.

[rustbucket]

Hello good people of club 80-90

about 2 years ago I bought myself a 1981 t25 westfalia. I knew nothing about looking after a camper or restoring it, and still know very little. I spent the last 2 years using it without worrying too much about doing any bodywork, but now I want to get stuck in and learn how to fix it up myself. I'm keen to learn and want to do as much of this myself as I can, whilst spending as little as possible. My last MOT I was told that it was completely structurally sound, so hopefully nothing major to do.

I would just like some advice on where to start, how to save some cash, and what you guys think are the most important issues to address first because I have limited funds.

The forum isn't letting me upload photos, it's saying 'It was not possible to determine the dimensions of the image.' - anybody know why? Just click the links to view them.

So here she is. Today was spent just getting everything out of the way and stripping back the interior (because I plan on redoing the interior after the main bodywork is done). She looks a bit worse for wear, partly because she's been sat on my driveway for 5 months when I was travelling, partly because I started stripping it before I took any photos.

I am currently back at home in Essex, near Chelmsford, so I plan on going to a guy called Dr Stew in Battlesbridge, unless you can recommend me someone else near me? I will get him to reattach the roof, and sort the rusting in the footwells, cab floor and sliding door rails. I guess I won't really know the extent of that damage until it's all been sanded back to metal. Then I will fix any smaller rust holes myself, with some p38 or p40 (which one is best). Then I plan on repainting the van using the £50 roller method on here (i've purchased the DVD). Then I will reupholster and repaint the interior and maybe fix in a swivelling chair if I can afford it. Let's hope nothing structural gets found when it gets looked at.

I just need advice on where to begin, and how to keep costs down. I'm keen to do things myself, and have confidence I can do most of it myself except anything that requires welding.

http://www.leeburnett.co.uk/uploads/berty/001.jpg

http://www.leeburnett.co.uk/uploads/berty/001-1.jpg

http://www.leeburnett.co.uk/uploads/berty/001-4.jpg

http://www.leeburnett.co.uk/uploads/berty/001-2.jpg

http://www.leeburnett.co.uk/uploads/berty/001-3.jpg

Rusting to the passenger door - I'm trying to find a new one from somewhere.

http://www.leeburnett.co.uk/uploads/berty/002.jpg

http://www.leeburnett.co.uk/uploads/berty/003.jpg

The sliding door rails - a lot has been eaten away here, including the whole underside of the door. Buying a new sliding door too.

http://www.leeburnett.co.uk/uploads/berty/006.jpg

After stripping away the cab mats and footwell mats I found this lovely surprise. I don't know how much damage has been done. It's similar on the passenger side but not as bad.

http://www.leeburnett.co.uk/uploads/berty/009.jpg

This happened when my roof decided to pop open on the M25 a few months ago. It's twisted the roof out of alignment, but I'm hoping it's as simple as getting a new patch welded in and reattaching the hinge.

http://www.leeburnett.co.uk/uploads/berty/005.jpg

http://www.leeburnett.co.uk/uploads/berty/006.jpg

Rusting at the back.

http://www.leeburnett.co.uk/uploads/berty/010.jpg

http://www.leeburnett.co.uk/uploads/berty/011.jpg

[nevill3]

Edited for you to show the photos, you need to use the img not the url button for your links

Hello good people of club 80-90

about 2 years ago I bought myself a 1981 t25 westfalia. I knew nothing about looking after a camper or restoring it, and still know very little. I spent the last 2 years using it without worrying too much about doing any bodywork, but now I want to get stuck in and learn how to fix it up myself. I'm keen to learn and want to do as much of this myself as I can, whilst spending as little as possible. My last MOT I was told that it was completely structurally sound, so hopefully nothing major to do.

I would just like some advice on where to start, how to save some cash, and what you guys think are the most important issues to address first because I have limited funds.

The forum isn't letting me upload photos, it's saying 'It was not possible to determine the dimensions of the image.' - anybody know why? Just click the links to view them.

So here she is. Today was spent just getting everything out of the way and stripping back the interior (because I plan on redoing the interior after the main bodywork is done). She looks a bit worse for wear, partly because she's been sat on my driveway for 5 months when I was travelling, partly because I started stripping it before I took any photos.

I am currently back at home in Essex, near Chelmsford, so I plan on going to a guy called Dr Stew in Battlesbridge, unless you can recommend me someone else near me? I will get him to reattach the roof, and sort the rusting in the footwells, cab floor and sliding door rails. I guess I won't really know the extent of that damage until it's all been sanded back to metal. Then I will fix any smaller rust holes myself, with some p38 or p40 (which one is best). Then I plan on repainting the van using the £50 roller method on here (i've purchased the DVD). Then I will reupholster and repaint the interior and maybe fix in a swivelling chair if I can afford it. Let's hope nothing structural gets found when it gets looked at.

I just need advice on where to begin, and how to keep costs down. I'm keen to do things myself, and have confidence I can do most of it myself except anything that requires welding.











Rusting to the passenger door - I'm trying to find a new one from somewhere.





The sliding door rails - a lot has been eaten away here, including the whole underside of the door. Buying a new sliding door too.



After stripping away the cab mats and footwell mats I found this lovely surprise. I don't know how much damage has been done. It's similar on the passenger side but not as bad.



This happened when my roof decided to pop open on the M25 a few months ago. It's twisted the roof out of alignment, but I'm hoping it's as simple as getting a new patch welded in and reattaching the hinge.





Rusting at the back.

[rustbucket]

Strange, I tried it with the img tag and it came up with that warning and wouldn't let me post. Thanks.

[CovKid]

Fair bit of work there fella. See what Dr Stew says. I posted your DVD out today - Lee isn't it? Should be with you tomorrow then you can sit back and watch how its done.

Might pay you to get yourself a mig welder as it'll pay you back several times.

[rustbucket]

Yea, I'm very very new to doing even the smallest amount of bodywork, but today I realised there's a fair bit more work than I thought there was. I just hope I have the funds.

I'm gona be heading back to Cornwall in a couple of weeks to someone who has a welder and said he would help out, but I'm still unsure what to get professionally done and what to try and do myself... I like a challenge but I don't want to make it worse.

Great, look forward to watching it, although it might be a couple of weeks before I can start painting!

[rustbucket]

Also, do you have any advice on what to look for in a MIG welder? They vary in price so much, but are the cheaper ones a no-go?

[CovKid]

https://club8090.co.uk/forum/viewtopic.p ... s#p7727990" onclick="window.open(this.href);return false;

[New Kentish Campers]

Yea, I'm very very new to doing even the smallest amount of bodywork, but today I realised there's a fair bit more work than I thought there was. I just hope I have the funds.

I'm gona be heading back to Cornwall in a couple of weeks to someone who has a welder and said he would help out, but I'm still unsure what to get professionally done and what to try and do myself... I like a challenge but I don't want to make it worse.

Great, look forward to watching it, although it might be a couple of weeks before I can start painting!

There's a fair bit of work to do there fella, but with time and patience you can get it done to a decent standard. Much of what you have there is pretty typical of the rust issues with these vans.

I would suggest that you begin by looking through the Schofield's repair panel guide to see what parts are available; you can also get a reasonable club discount from them too: http://www.ahschofield.co.uk/ to you can get a good idea of what parts will cost you, and put an advert in the 'wanted' section on this site for the doors that you need as theres always somebody who will have one or point you to the right area.

And as for welders, get the best you can afford. Dont go for the 'gasless' ones or those that use disposable gas cylinders as they will cost you a fortune to run. Better to get one that has a reasonable wire feed set-up in it and that it will take small argon gas cylinders. Also, if you can run to it, a welding helmet that automatically darkens as you begin to weld, as against the hand-held ones [it leaves you with two hands to work with]

And remember to take plenty of photos while you work so you can show us here what you are up to, and they will help you remember where everything needs to go back on, afterwards.

Good luck

[rustbucket]

Thanks for all the help guys. I'm going to take it to the guy near me today, and see how much he will charge for the big areas that need work. Never had any welding done before so I don't know how much this sort of stuff costs. Then I will compare it to the price of getting a welder and the parts etc.

I'd really like to spend the time doing it all myself, my problem is that I was going to go down to Cornwall in a couple of weeks and stay in the van for a few months whilst I worked on it, so it really needs to be a rolling project if I'm doing that. Obviously that's not possible with the bigger areas of rust.

[rustbucket]

Having a real quick look through Schofields, I'm looking at roughly £200 - for one inner sill, outer sill and both wheel arch doorsteps. I just don't know how extensive the rust damage is so I hope it's contained to those parts, although the rust in the floor of the cab might not be great. Then I think both doors will cost roughly £150.

My plan is to get it to Dr Stew today and get the roof reattached so that it's safe to drive, and see if he thinks there's any major welding needed. I've got a 9 hour drive back to Cornwall, so I want to be safe. Then as for the rest I will do them myself with my mates welder when I'm down in Cornwall. How long do you think I should realistically spend practicing with a welder before I attack my own van? I want to learn it thoroughly, but also want to get working on it asap.

Cheers for all the help guys.

[neil3965]

If you'rte going for a MIG welder, check this out for the gas - have only used the small disposable bottles so far (very expensive), but plan to give this a try next - looks a lot cheaper!

http://www.hobbyweld.co.uk/

[rustbucket]

Thanks Neil, will have a look into it. Just weighing up my options about the welder, but I'm pretty sure I will get one. Just took it down to VW Surgery and the quote for just the roof is £300, although just to attach a plate in and reattach the hinges I think that's a bit of a rip off. So after seeing how steep just that single job is, I think I'm going to try and get it all done myself over the next few months. Where the **** do I begin?

[neil3965]

It's easy to be overwhelmed - just break it down into smaller jobs. My priorities for the bodywork/welding would be:

1. anything structural that might affect the safety of the van, and fail MOT (sills, jacking points, front wheel arches etc)

2. once that's done, sort anything that affects the watertight integrity of the van, and will therefore be helping to cause more rust (window surrounds etc)

3. then you can move on to the cosmetic stuff that just affects appearance

Give the van a thorough inspection, and make a list of the bits that need welding, and put them in categories 1, 2, or 3. then rank them within those categories, then work your way through.

I was a complete newbie at welding three years ago, got a MIG, practiced on scrap metal for a total of 8 to 10 hours before touching the van, but my first job (repair to front wheel arch and seatbelt anchor) passed MOT no problem. The Mig Welding DIY Guide is a huge help - read it through and get practicing!

[rustbucket]

Amazing, thanks so much for all this help guys. I never really considered doing welding myself, I always thought it took huge amounts of practice (and I'm sure it does for professional quality). But now you've given me a bit of confidence to get stuck in, I think I'm going to rent a welder from BOC as bmouthboyo said I could get one for £40 a year. I got myself an angle grinder today as well. Now I'm off to assess the damage and get a list together of exactly what needs doing.

Thanks again.

[rustbucket]

My bad, I thought £40 was too cheap, that's just for the gas bottle haha.