Sunnivagon

[LittleMissSunshine]

I bet you never look at a van without spotting work to be done

Great stuff

[Plasticman]

well i look at many vans that are very nice and dont need any immediate work ,that said none of them have to be done its up to you if you can be bothered, my own van needs work but it runs and is in use so not a chance of touching it....
carry on from last picks , this is with the inners coeated

darent leave bare metal exposed as thge rust is too quick to set in
right i have the issue of the lower rear 1/4, now there is a repair part available but I have not yet used it so cant speak for its fit or gauge of metal etc so back to self help

the trick is to get the very gentle constant curve into it

this is made out of 18g
this is the rear detail

now joined to the upper part, there is a bit missing this was a bit of rot on the return edge that joins to the arch/wing

made a small bit and added it

and lightly sanded off.ooops bit of home made birthday egg custard,,,,was a 10" square one

repaired 1/4 panal welded on and lower part trial fitted

tinned and lead on

wizzed over with a disc, my ex teacher would kill me for doing that

quick coat of product to keep things right

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[Plasticman]

Well welding about done,
small bit at the bottom of the rear valance, if you do this repair then make sure that the small fold/lip is welded to the valance as it gives it strength, and stops it bending about

with a quick coat

nsr lower panal from underneath

short bit of brake pipe and a few mech bits to finnish

then a sealing again under it all and the nice enjoyable front screen repair tomoz
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[LittleMissSunshine]

I want to see... please!!!! (stamps feet like Verucca Salt!)

Have you fixed the hitop bit yet? How did that seem?

[evilnoodle]

Amazing

[Plasticman]

Well. pried the support bits away from the arch and pumped some adhesive in so that will stiffen it up nicely
also applied some sealant to the rear seam internaly before refitting the lpg tank

same on the rest of it and here the inner sill top/floor, i tape the area to be neat as it does look a lot better and costs nothing

this sealing is usually done in as few goes as I can as the brushes are scrap after, ok only cheap 20p
all repairs have been painted and seamsealed now just a thin coat of liquid rubber and after paint it will all be dynaxed


so just the front area to attend to ,
I have never ever come a cross a washer jet that had been araldited in place

this screen corner looks fine so no fun to be had here

and the drivers side


But i found this

so all is not lost .also the screen apears to be in the early stages of delaminating
so chopping about in the morning
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[LittleMissSunshine]

Glad to hear the van is still surprising you - first for araldite

[lloydy]

Nice to see how it's all protected from the inside, looking forward to seeing it finished

[max and caddy]

What etch are you using mikey? Looks like the closterman stuff I'm squirting at present...

[Plasticman]

you mean the red stuff
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[Plasticman]

Well about the worst job there is to do ,well to me it is , I hate chopping lower fronts off,its tedious but its off

so a run over with a disdc then into this

its about as sharp as it comes....
so now a coat of vactan and will weld it all up in the morning

then its onto the best bit saved till last , lower screen..
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[Plasticman]

Well on with the lower front panal, I have used one of jk's taller ones to try out, its not something I will ever do again,anyhow set it into place and butted up the horizontal ends

this is on the flat surface just below the crease and wil sand back to be nice and flat,
the inward part that lives sort of behind the lower grill i have welded on the return edge after cutting a touch of the panal as its too big

both these welds have completely fused/joined the two parts so they are in effect one as opposed to a mig over them , this way I use the wled to form [art of the shape and so can sand it away to give the profile im after

a bit closer, will need more tweaking but ok for now

the lower seam i puddled welded through some 7 or 8mm holes and ground of and then ran over the lot with the belt sander, now nice and shiny

a quick coat to stop surface rust

and

so that concludes the lower panal .
Now , the upper , errr well screen of out the way and then the rest of the rubber away and more fun
dash now out

it looks worse than it is, so easy peasy repair

could have ;eft the dash in but fire and and, nope also i want to renew the washer pipes as the last fool or last but one has already cut them short , aslo need to deal with the rust around the orifice. this is the worst bit and its easy enough to sort

so thats tommorow all sorted then
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[LittleMissSunshine]

Fantastic pics, Mike

[Plasticman]

thank cruz for the camera, cant beat an old canon !
riight onwards with the best bit,
aerial area removed

and also the bad bit on the other side,when p**s bucket finaly churns into action.....

this is the bit that got removed surgicaly

new bit partially made, i will form the curve on the screen side once it welded in place, easier that way, the bit of rod (its thick rod not the thinner that i use for most welding)is on to hold it so i can move the piece around with out it dropping through

and this is the profile of the other bit, it has to be exact as the screen seals here

and this in place

happy with the weld in

buckets on a go slow so will post next bit in a few mins
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[Plasticman]

Well now got the ns corner to attend to,Im letting it into the frame surround as thisd is the least invasive and will be invisible i hope. i have made it in two parts as i want to have plenty of meat to grind away in the angle later to profile it

finished welding the main part of it

instead of spotting it to the inner frame i just ran a weld alonbg bthe top to join them, note tyhe two arrows,this shows the factory brazing, and mine just behind it, they do this in a few places that are not reachable to grind if they migged it, also they cant spot it here and it has to be joined, theres half a doz places where they do this

and sanded off

Got this waiting

little bit of lead added, i treat it like filler but instead of waiting for it to dry and sanding it and adding more its heat,add remove or reshape and its set in seconds, htis isnt perfect but good enough for the purpose and will only need a minor skim


and the other side

little tidying to do on the seal lip itself
quick coat of product to prevent surface rusting on adjacent areas

so just a tiny bit of filling to do and other small bits then we paint
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