How best to repair this?

[tandemsandy]

While replacing the ARB bushes today, I found this hole in the drivers side inner wheel arch....


It goes into the cab just below the seat, in front of the battery box.

I've not done any bodywork before, but in an earlier life I was a sheet metal worker & welder making jet engine parts, so the practical side doesn't bother me. Not an expert on T25 construction though, so I'm wondering where would be good to cut back to, and where to make the joints.
And I'm guessing its about 18SWG or 16SWG here, or thicker?

Any advice welcome.

Thanks,
Rob & Sandy

[DavidPallister]

Mine's gone by there as well, both sides. the rust will be far worse than you can see by the time you dig through the under seal.

By the time i'd finished chasing the rust, I decided I needed to replace the complete seat box front panel, as the bottom edge where they weld to the little cross member / support thingy was totally shot as well. Panels are available from VWHeritage, about £30 each I think. Haven't actually gotten around to replacing mine yet, so can't tell you how much of a bitch it's gonna be

Dave

[Plasticman]

If you want to do it right? alsoi easiest i think , then if yopu van is petrol I would whip the tank out and remove the exp tank ,for derv just the exp will do. then clear both sides and get a woodbutchers chisel,well its the only thing im fit to do with one ,, and scrape the sealnt away,
it will have spread a fair bit so have a look and decide if your up for doing the whole panal. its easiest really and get one from £eritage, then its almost all puddle welding spots, if you up for it and want to do it the shorter way then cut out and 'let ' a piece in and butt weld it, but not as nice ,choice is all yours
mm

[tandemsandy]

Interesting reading, thanks guys.

Is this the panel you mean.....http://www.vwheritage.com/vw_spares_Rea ... tartPage=1

Will have a good look at the other side too, hadn't noticed a problem there but worth checking!

Cheers,
Rob

[Plasticman]

yes thats the flat bit that usually rusts out ,especially the oval reccess for the exp tank,its a fair bit of work to fit but nice and you have a good start to ad the other iffy bits to
mm