Rustoration

For documenting and technical details of T25 restorations and major repairs
This section is for major restorations only.where to buy a panel or where to buy window rubbers belong in the bodywork seats and glass section.
Also please note,we need pictures of the restorations,without them posts are pretty useless.[\b]
Picture heavy and detailed threads , not for general banter or advertising
Traders welcome to post but not to advertise blatently
Threads will be cleaned of chit chat.

Moderators: User administrators, Moderators

RogerT
Registered user
Posts: 1798
Joined: 10 May 2013, 11:59
80-90 Mem No: 13706
Location: Central Scotland

Re: Rustoration

Post by RogerT »

Put the flange on, and then the piece under the cover bracket.

Image

Image
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

User avatar
BigBlueVan
Registered user
Posts: 137
Joined: 21 Dec 2020, 20:45
80-90 Mem No: 0

Re: Rustoration

Post by BigBlueVan »

That area you attacked today is a right pig to get in after its all welded to clean it back, the cover hides most of the area so it doesn't have to be as perfect as an external skin.
But it's looking good and heading in the right direction 👍

RogerT
Registered user
Posts: 1798
Joined: 10 May 2013, 11:59
80-90 Mem No: 13706
Location: Central Scotland

Re: Rustoration

Post by RogerT »

Aye, I’m glad it’s going to be covered up. Still not happy with the weld in the corner (didn’t bother replicating the flange internally), think I’ll use a grinding disc on it and have another go tomorrow or the day after.

Then another hiatus as we’ve spent the lump sum from my pension on a deposit on a flat to rent out to supplement the pension, so a few weeks of intensive DIY to get it fit. Pick up the keys Friday, and there’s such a shortage of rental accommodation that we’ve got tenants waiting!
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
Registered user
Posts: 1798
Joined: 10 May 2013, 11:59
80-90 Mem No: 13706
Location: Central Scotland

Re: Rustoration

Post by RogerT »

Back to it

Heath Robinson to push a panel straight for welding

E D I T
Oct 2022. Discovered that it was a mistake to try to get this straight. When it was all welded up, I offered up the cover plate, to find it had a gentle curve which probably matched what I assiduously tried to get rid of. FFS.

ImageImage

Then welded in the strip below the cover rail

Image

All pretty straight

ImageImage

Then ran out of welding wire…
Last edited by RogerT on 17 Oct 2022, 21:33, edited 1 time in total.
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
Registered user
Posts: 1798
Joined: 10 May 2013, 11:59
80-90 Mem No: 13706
Location: Central Scotland

Re: Rustoration

Post by RogerT »

Threaded in the new reel of wire trouble free, and finished welding in that panel. Warp city!! I’d better be good with the filler…. I’ll be looking for tips.

No photo.
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
Registered user
Posts: 1798
Joined: 10 May 2013, 11:59
80-90 Mem No: 13706
Location: Central Scotland

Re: Rustoration

Post by RogerT »

After forced delays, decided I couldn’t live with warp city, so cut out a section encompassing the top of that bit.

Image

Made up a section with my new-to-me Rolastep,

Image

Top edge flanged for puddle welding, bottom edge flanges for location of side cover channel, and that will be butt welded.

Lengthy process to remove flashband from the rear…

Image

Drilling for cleco pins

ImageImage
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
Registered user
Posts: 1798
Joined: 10 May 2013, 11:59
80-90 Mem No: 13706
Location: Central Scotland

Re: Rustoration

Post by RogerT »

Tacked in, didn’t go too badly but my first puddle welds were a bit pants until I got the settings right. Would have been easier with slightly larger holes to weld through but I just went with 5mm punched holes rather than drilling out to 6 or 7.

Image

Image

Better control of warping this time, I think flanges help as well as puddle welding one edge, rather than butt welding both edges.
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
Registered user
Posts: 1798
Joined: 10 May 2013, 11:59
80-90 Mem No: 13706
Location: Central Scotland

Re: Rustoration

Post by RogerT »

Welded and ground down , no photos but I’m not happy with the penetration, but sure it’ll be good enough for that location. Just forgot the best settings. Ought to make a wee label…
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
Registered user
Posts: 1798
Joined: 10 May 2013, 11:59
80-90 Mem No: 13706
Location: Central Scotland

Re: Rustoration

Post by RogerT »

ImageImage
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
Registered user
Posts: 1798
Joined: 10 May 2013, 11:59
80-90 Mem No: 13706
Location: Central Scotland

Re: Rustoration

Post by RogerT »

I’m going to have problems fitting the non-sliding-rail cover on this (drivers) side, but not the kind of problems that won’t be solved by a gentle bend. A useful learning experience prior to doing the sliding door side, where fit and alignment are critical! Should have held up the cover at the start and maintained the correct shape…
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
Registered user
Posts: 1798
Joined: 10 May 2013, 11:59
80-90 Mem No: 13706
Location: Central Scotland

Re: Rustoration

Post by RogerT »

A proposed remedy for it being so out of shape. Useful experiments…

ImageImage
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
Registered user
Posts: 1798
Joined: 10 May 2013, 11:59
80-90 Mem No: 13706
Location: Central Scotland

Re: Rustoration

Post by RogerT »

Et voila

Image
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
Registered user
Posts: 1798
Joined: 10 May 2013, 11:59
80-90 Mem No: 13706
Location: Central Scotland

Re: Rustoration

Post by RogerT »

Cutting that slit and using it to pull in on rewelding worked ok, that and some bending…

Not the prettiest welds, but it cleans up, and most of it will be hidden. Started to shape the brackets for the lower edge of the cover, but they’ll not be welded on til later, to avoid catching on them, and cos I’d probably put them in the wrong place until I’ve got the long strip bracket welded on… which I’ve not bought yet. I’ll get that when I’m buying gutter strips.

Next is finish the base of the C pillar, base of B pillar inner and replace a section of B pillar outer, and finally the outer sill and fridge panel.
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
Registered user
Posts: 1798
Joined: 10 May 2013, 11:59
80-90 Mem No: 13706
Location: Central Scotland

Re: Rustoration

Post by RogerT »

Made up a couple of brackets

ImageImage

Took my angle grinder apart, all in good nick. Took my powerfile (Lidl’s) apart, about to catastrophically fail. Need to make a part…

ImageImage

Plate that prevents the belt chewing into the fan on the end of the motor, nearly ground through to leave a chunk of metal loose to do who knows what! Easy enough to make another and just in time.
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
Registered user
Posts: 1798
Joined: 10 May 2013, 11:59
80-90 Mem No: 13706
Location: Central Scotland

Re: Rustoration

Post by RogerT »

Powerfile back together with a 1.6mm plate replacing the 1.2mm.

Tidied up the tool mess in the back of the vanImage

…as when I start work on the fridge panel I’ll need to access the inside of the van at times - via the tailgate opening as the garage is so tight for space.

So I did what I should have done ages ago and put up a tool storage boardImage

Bit more tidying to do tho’
Image
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

Post Reply