Sunnivagon

[LittleMissSunshine]

Lovely

[kevtherev]

It is nice to fit new.. But new these days does not mean it will last, with certain items they will be vastly inferior
I cleaned up a lot of the interior stuff.
Just soap and water, in some cases a lick of paint or polish.
I fitted new rear lights and end caps.
Nice tidy clean wheels make big difference.
If mike is leaving the interior out like mine, now is the time to renew the floor, pipework ,wiring and renovate/refinish the cupboardry. All these little things inside make for a calmer camping experience knowing its all sorted... Like the body

[LittleMissSunshine]

Great advice thanks Kev, we have having the interior put back in but I am sure if there is anything suspect Mike with let me know.

One done my list is...

Interior re-upholstered - two front seats, bed, curtains if the fabric is different.
Price getting the carpet-type wall covering renewed
Nice wheels
New dash tidy as this is cracked

The cupboards etc are ok, I think!

Lets hope OH doesn't see this

[Plasticman]

well if he does then add a new bike rack to the list
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[LittleMissSunshine]

He just has.

In fact ill be selling the old (perfectly functioning) one on here as soon as I get a description/price!

[Dr. B.]

Yep, new bike rack all ready to go! I can get three bikes on this one too .....

[Plasticman]

you wanting the tailgate ladder refitting or the holes blanked
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[LittleMissSunshine]

Yes please, handy for shackling bikes too.

[ZsZ]

Nice progress here.
MM, do you have special tricks to remove the thick sikaflex?

[Plasticman]

sikaflex ah, you mean the sealant that vw thankfully coated everything in , yes i buy cheap sets of woodbutchers chisels and cut it straight off to metal , dont take that long ,oh and i use a wooden mallet too.
bout as low tech as you can get
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[Plasticman]

Well this builds up the base of the floor to where it originally was

at this stage its still sort of floppy and why the original joins almost all have swaged lips to give rigidity as will be shown later.
next part is the rear upright of the inner arch, this is diagonaly folded to align as shown

and it fits here, this is just roughly clamped in place to test fit

welded in place, this should also be one piece with the next follow on part, , whilst i could make it in one piece it would take a lot longer and not really necessary in this instance

this is the bit that should be part of it the swage is giving it great stiffness and help alighn it to the outer lower panal as well as the rear 1/4, it is only welded to the bottom lip of ther rear 1/4 ,not the outer lower panal as will also become clear later

clamped in place foir adjustment

nice clean fit

this is now puddle welded on

upload probs so I will do this in 2 parts
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[Plasticman]

a small weld joins it to the earlier upright part

confirmation of fit again, most important this as if its too far out it will cause grief when i redo the rear 1/4 panal

from the inside it looks about how i wanted it to

and im 100% happy with the line up now and its all flat as should be

so on to the next bit here,

technically it should be in 2 parts as well but im cutting a slight corner and doing it in one
there is an innternal fold as well which is welded to the base

if you look to the rear you can see that i have continued this to the rear panal to make good the rotten corner which i also cut off

a quick weld round

and seamed it down the rear panal

then a few tacks to the internal lips i made, this now gives very good rigidity to the whole floor which is importand for joining to the rear 1/4 etc

like so

and the rear bit sanded off

more in a min
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[Plasticman]

I have drilled the arch to spot through to the 1/4 panal when fitted, you will see the dots on the adjacent part, this is where the rear 1/4 will be drilled to puddle through to this item from the wheel side onto the extented lip i will add to the 1/4 panal .

im having to do it this way as normally the arch would be off at this stage so a slightly different method would be used, but needs must and all that and it wont be detectable when done
so that concludes this area, i have sanded it over and coated it, picks tomoz,
next job is to remake this

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[kevtherev]

amazing...and without these pictures you will never see this inside work, it's all hidden
I get my DVD out now and again just to remind me

[Plasticman]

well you sort of see it when you look behind the rear lights and also under the steps and such but at least it looks like its meant to be so shouldnt stick out like a sore thumb and to be honest how else could you repair it, i mean easy to dab a new panal on but what about the rest that it fastens to ?
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