Very rusty rear side seam - treat or cut out?

[dopplerhire]

Hi all,

Currently replacing osr panel and building wheel arch. In cutting out rear panel can see that the edge of the side panel that turns in to meet the pillar is really rusty and holy, barely even there in places. Question is whether I :

a) just leave as much as possible (brush off, vactan etc...)
b) cut it all flush so there's little to attach to pillar, other than top which looks ok
c) cut out patchy bits and weld in a whole new piece to form the section that attaches to pillar

obviously then the rear panel will need welding in too and seam sealing etc.

Likely that c) is the right answer...just wondering if there was at least one acceptable shortcut with repairs on these vans!!!
Also looking to buy rear replacement panels from aschofields unless other suggestions?

I'll try and upload a pic at some point if it helps but grateful to know how people dealt with this on their own.

Cheers

[Plasticman]

look through this one
https://club8090.co.uk/forum/viewtopic.php?f=38&t=93497" onclick="window.open(this.href);return false;
and to a lighter degree here
https://club8090.co.uk/forum/viewtopic.php?f=38&t=106511" onclick="window.open(this.href);return false;
picky would as you say be easist as no two jobs are exact the same
mm

[dopplerhire]

Cheers for getting back Mike. Unbelievably yet another digital camera died on me so haven't got a decent pic but working on this.

In the meantime was looking at some of your great work putting the rear panel on. Noticed that you used clico fasteners to hold the panel in place so you're lap joining the top of the new panel over the old one. With the cleco's in place do you spot weld the top of the panel, remove cleco's and then seam weld across the whole of the top panel?...or am I missing something?

[dopplerhire]

reading more...possibly joddling?

[Plasticman]

use your phone for pickies
er yes i joddle in this instance, the clico equivalents (mine are better )cos they was free, were used as you see, if you leave a slight gap between the top of the new panal and top of the jofddled bit on the existing panal then yes you can do some short tacks along there as when you grind them back they will be flush and yet have enough meat to hold
or drill through as ive just done on the ajitvagon sill and puddle through, either way you do not need to seam weld this.jsuy spot through every 1 1/2", or so.
mm

[dopplerhire]

not the best of pics but some idea of what's going on at least...

DSCF2688.jpg

DSCF2693.jpg

DSCF2695.jpg

[Plasticman]

I would try and add some metal in there, if you cant then as long as you can fit the new poanal in nice and close .then you can live with the void but you must have metal at least 3/16 turning in, none of this needs seam welding , tacks are more than good enough and mask of the reverse side and brush seam sealr on , 2 coats and remove the tape, this will leave it looking neat and will add strength to the join as well as waterproofing the inside aspect
mm

[dopplerhire]

Thanks for the advice - will take some time to get around to fix as only 1 day week on the van, plus a few other bits to sort first. Joggler/joddler on order now from Frosts. Cheers Mike - I know I speak for many in saying you're expertise on club 80-90 is a BIG confidence builder.