Rustoration

[RogerT]

Rebuilt the base of the C pillar.


Took an initial look at the base of the B pillar inner section


Not much left to go off.

Fashioned the beginnings of what it might be?


Took a wee photo up inside the pillar


Has there already been a repair? New part with no paint or rustproofing applied? Hence loads of rust…

[RogerT]

Found a photo on adie’s thread, very handy

[RogerT]

More photos on here
viewtopic.php?p=8228046#p8228046

[RogerT]

And here’s BigBlueVan’s original and fixed


Thanks folks, big help!

[RogerT]

Continued making up the base of B pillar with a template taken off the outer so the inner matches up




Need to get some phosphoric acid

[mike the van]

This is pretty amazing, not sure if it scares or inspires me to dive in with my reto over the winter, I willl be positive and say inspire, but the photos are brilliant shwing whats happeneing ing those seams!  Keep it coming !

Mike

[RogerT]

[mshaw1980]

Brings back memories. Massive job taking the whole big fridge panel off and doing the inner sill. Hopefully never again

[RogerT]

It’s a bugger isn’t it? How’re you keeping? I’m still plugging away at this, retirement is helping somewhat but I’ve a job interview on Tuesday given the cost of living. Hope to get it as a job share for a few extra pennies.

Did you replace your fridge panel with new, or just stick it back on? I’m planning on the latter, probably with new seam flanges fabricated and joined to panel with puddle welds. Really struggling with warp if I butt weld(as you’ll have seen). Likely to be the last job on this side…

[RogerT]

Here’s a reminder of what the base of my B pillar looked like, with the wee bit of expanded polystyrene reinforcement…

[RogerT]

Next step, form the rear flange of the inner B pillar.

(Apologies, I can’t really see what that is!) It’s meant to be a photo of the new flange formed against the flange of the outer B pillar…

Then cut the side section of the B - half done here.

I’ll probably stitch these two pieces together while the flange is clamped to the outer B pillar, so it retains its shape, then add it to that back plate. This should ensure the two halves of the pillar match up in a half decent way.

Meanwhile, thought I would check the remains of the inner B is roughly the right shape, and no it isn’t.


This photo shows a straight edge up against it, showing that it has splayed open at the bottom. Cue some persuasion to get it lined up again. Measurements of inner and outer confirm success.

[RogerT]

Completed fabricating the inner B repair section

Flange clamped to outer B, then side section tacked on


Held in place on van and tacked to rear section


Removed from position to finish welding up in an easier orientation


Cleaned up and applied some weld-thru on the faces.

[RogerT]

Piece of the outrigger patched in, in 3mm sheet


Then the base of the inner B welded in, good penetration (then blow thru on the corners - should have turned it down)




Reinforcement ready to be fitted

[RogerT]

Welded the jp to the rear part of the outrigger. There’s a cavernous gap to the front of the outrigger though, need a sliver of thick metal to fill that. E D I T. I can just cut some from a bit of angle iron I have lying around

Unzipped the outer B





Gordon Bennett

Put an axle stand under the outrigger and removed the front wheel to give more access.

Now the cab door doesn’t shut, dropped a few mm at the rear.

My old mate, Gordon Bennett again.

[RogerT]

Would the door be aligned if I stuck the Jack under the lower arm? I’m guessing yes. What is going on? Is it due to the lack of rigidity in the B pillar structure, so it’s just bowing out? And how much of that outer B is knackered?