Front lower panel rust repair

[AIR_CHILLED]

I have noticed significant rust at the lower edge of the front panel where it joins to the top of the deformation panel.
Generally what is the best method of repair, is it to replace the complete lower front panel?

For the top of the deformation panel, if rust has gone all the way through, would fabricating sections to replacing the top area considered a good repair.

Help would be much appreciated and with reference pictures if you have some.
For reference, here is the only picture I have of the van without the front bumper

Thanks,
Mike

[davidoft1]

Complete new panel is the best , easiest and quickest way , the deformation is pretty thick though I think they are unavailable so patching is or good used are your options

[AIR_CHILLED]

Thanks for your reply David.
I will have cut the left and right side seam joint with an angle grinder but how would I rejoin the new panel there?
I am assuming it was spot welded from the inside at factory?

[davidoft1]

Thanks for your reply David.
I will have cut the left and right side seam joint with an angle grinder but how would I rejoin the new panel there?
I am assuming it was spot welded from the inside at factory?

You can plug weld through the indicator hole

[AIR_CHILLED]

Ah right, that makes sense. Thanks for your help.

[Plasticman]

Most weve done even after blasting the defo panals are still suspect so we cut the tops out and let new 2.5-3mm steel back in then bond the lower panals too it
mm

[AIR_CHILLED]

Thanks for your reply plasticman.
When you say bond do you mean panel bond?

How are they originally joined at the bottom?

[multisi]

Lots of spot welds and there is the same again directly behind the lower edge so even more.

[AIR_CHILLED]

I don't have a spot welder so that's lots of puddle welds for me then!

[multisi]

You could save a lot of effort by bonding the lower edges as recommended by plasticman, weld the sides from behind.

[AIR_CHILLED]

Hi Multisi, I thought that is what Plasticman was suggesting.

What product do you recommend?
 

[Plasticman]

Purflex.keep it of skin .it takes some shifting

[AIR_CHILLED]

Thanks for sharing.

[scotttie]

I've got this job coming up and I like the suggestion of bonding the join to the deformation panel. Out of interest, do you think there would be any compromise in strength by bonding over spot/plug welding?

[Plasticman]

Bond it.easier and better solution.it has little to do with strutural integrity.
mm