The Rust Bucket unrusting...

[Rust Bucket]

So where to begin..

the rear valance was really corroded
Before




After


need to get that bumper painted!

forgot to take pics before i put the bumper back on

hightop removed
before


after



front of the roof was badly rusted due to water leaking in from the skylight in the hightop forgot to take pics.

next big job is the n/s inner



sliding door track wil need replacing




jacking point collapsed


n/s front wheel arch wil need replacing.

and thats just the passenger side...

[boatbuilder]

Quite a bit of work to be done there!
Did you put a whole new roof on?

[Rust Bucket]

I couldn't get a roof cut so I had to plug weld a section of sheet steel in. I started to weld in the middle and worked towards the edge to get the curve then seamsealed. Had to fab the two front corners above the windscreen which was an absolute nightmare, I used the bits that were cut out as a template and worked from there, hardest part was getting the curves, used a little bit of filler to tidy up.

i'll try to dig out the photos.

[Rust Bucket]

small update

repaired a little hole next to the tailgate



rust cut out



repair panel made and sprayed with weld primer



lining up



welded in



ground down with flap disk



light skim of filler



sanded down and painted



just need this bloody rain to stop now

Michael

[rustbucket]

I'm afraid you've stolen my name. Please post me £499 in pound coins.

Yea, quite a bit of work, keep at it.

[Rust Bucket]

I'm afraid you've stolen my name. Please post me £499 in pound coins.

Yea, quite a bit of work, keep at it.

I think you'll find you've stolen my name

started on the n/s front wheel arch







cutting the rot out




 Repaired the bottom of the jacking point all nice and solid (I hope)



welding in the new panel



still got the inner arch to finish, but it's getting there slowly

Michael

[Rust Bucket]

Inner wheel arch welded and seam sealed.





just need to get the n/s filled, sanded and painted and thats one side of the van finished

[Rust Bucket]

B post and wheel arch sanded and filled.





Good rust free second had door arrived from ebay. Started filling and sanding ready for painting. Just waiting for a sliding window to arrive so i can fit the door on the van.



Hopefully i'll get the n/s of the van painted this weekend

Michael

[JPC1]

Hi mate, nice work.

just wondering with the b pillar panel, did you get a cut from another van or did you make up the replacement panel?

have a similar problem meself and was going to have a go at making a replacement panel, i'm pretty new at bodywork though and the b pillar looks like a tough fix.

thanks

[Rust Bucket]

Thanks, yes got a the complete arch and b post chopped out of another van and welded it all in together. Got the cut from a company on ebay called vw-camper-shop.

[Rust Bucket]

Few little patches done

Small hole in the passenger side floor


patch welded in and seamsealed


what was a tiny patch of rust turned into this


patches made up and welded in



not very interesting to look at I know

does anyone know what the rubbery stuff is in the last picture is it some sort of sound deadening?

Michael

[Rust Bucket]

start to inspect the driver's side sill on the surface it look ok until...

poked around with the screwdriver to uncover this




cut the rot off the bottom part of the sill


im really not looking forward to doing this as i have no idea where to start

as they say on top gear "how hard can it be"

[Rust Bucket]

Been a while since i added anything

got all the driver's side sill rebuild, decent second hand middle panel fitted (thanks to mark.bilsborough for the panel), new front wheel arch and a rear quaterpanel. All three side are finished just need to sort the dreaded windscreen corners. Had tons of pictures to i seem to misplaced the memory card with them on

thought i would make a start on the rattling interior started with some flashband









foil insulation over the top









finish the rest off next week

Michael

[Bestwick84]

Grate work