Old journeys end, new journeys begin. 1981 Poptop Resto

[MrMet]

Here's some cleaning up I did on the passenger side rear panel. As you can see, it started off in a really bad way. Again, another bodged job from a previous "fix up". This was another case of a panel being put over an old rusty panel, and this was still cover in filler too! The whole window surround was rusty pretty much the whole way round too, so it's all had to go. At least with a bit of space opened up, I've been able to get in to some of the hard to get to seams and treat them with a dose of vactan. Looking at lot better now, even if i do still have a lot of work ahead of me welding it all back together again! At least doing it this way I feel like I winning the battle against the rust!

[MrMet]

You'll get nicer welds if you remove the primer at the edges. There won;t be as much spitting etc.
A bit of cellulose thinners on a rag should dissolve it. Its really only intended to be used on overlapped panels where you can't paint in between after welding. Are you going to butt weld or overlap the new panels?
If you're plug welding, you can just remove the bit of primer through the hole you've drilled for the weld. I use a rag dipped in thinners on the end of a flat bladed screwdriver to scrape/dissolve it.

Looks like you have your work cut out there but it looks great so far!

Thanks for the advice I've got a bottle of acetone that'll clean it off ok. I'd like to be able to butt weld the panels in, but I'm new to welding, so i'm practicing off the van at the moment. It's frustrating though, as sometimes i get good welds and other times, even though i feel like im doing the same thing, it all goes wrong and i'm left with a mess!

[MrMet]

More of the same with the front passenger pillar. Again, with all these holes everywhere, it's given me access to check what's going on behind panels and give it a clear up and treatment with vactan too.

[MrMet]

And the drivers pillar!

[MrMet]

And finally for today, the windscreen. This was another mess of filler, wire mesh and even some random piece of material stuffed in there too! Looking through the bottom corner and peering up into the pillar, I could see where water had come though and caused it to rust out, so I investigated further up and found holes up at the top too. The gutter had been completely filled with filler (again to cover rust throughout) but it looks like there are holes going through into the body.

Tomorrow, I'm going to focus on getting rid of more of the rust from the front of the van. I found a hole when I removed the number plate, so thats going to get investigated, along with both sides where the front bumper attaches. The steps on both sides are decidedly dodgy too, with the passenger side being badly welded on top of old rusty metal and the drivers side have a rusty replacement patch. The front wheel arches seem to actually be ok after an initial inspection, although the pillar and seam behind the drivers door will need looking at as it's showing visible rust and I was able to poke through from the inside of the wheel arch.

Not much to do then! At least it's sunny at the moment, I just hope it lasts...

[boatbuilder]

Wow, a lot of work there. I reckon you will need a lot of cuts from donor vehicles unless you want to spend many many many hours fabricating parts to fit.

[matt_pl]

Hi Guys,

what type and size of rims and tires have You got in Your bus?

Cheers,
Matt

[Plasticman]

has he/it been back .5 months have passed
mm