The Pock-Holed van

[Plasticman]

gave up on the complexities of flikr for now and grabbed another peebucket acc, well the devil you know
well so.
I have labeled the wing up in the order and method of removal , (cos Ive been asked to a few times and forgot)
so

no1 is the first cut to remove the bulk, no 2 is the cut that will be made after the wing is of, there is reason for doing it this way as i hope will become apparant.apparent ??

this is it off,
next i have tagged the 2 parts,

the XXXX's are the remains of the wing itself and the squares are part of the arch which exstens into the main load bed. now if i was just removing the arch to change out, which keeps the factory seam then i woiuld drill out the spots in xxxx fro underneath to leave the wing intact, its a bit more time consuming but makes a nice job, BUT only if whats left is in good order,, this isnt so of with it

see all the rust, this is within the seam and cant be reached or dealt with unless you split the seam
Now that i have removerd the remnants of the old upper wing i can cut down the inner arch and get rid of the arch itself and some rot and get back to a workable area

i forgot to mention that when chopping off the old wing make sure you cut the tops like this

on the slider side just the rear end but on single sliders/fridge side do both ends
next we make a simple cut up the rear opf the lower 1/4 and errrrrr, lift it

then a waggle and its off
with part of the floor and rear 1/4 attatched with sealant like a tendon hanging in for dear life

then we make a cut up the 1/4 panal itself and drill out the spots on the inner edge (tailgate closure)

and we are left holding this bit of scrap

t'other side

so some work to be done in here i thinks

easy and methodical, start inside and work back out as per OE

and peebucket is being a gem and instant acceptance of instructions on this new account.
mm

[Wychall]

Now I can see the area that I was having bodged last weekend! Get plenty of practice in, Mike.

[Plasticman]

yopu didnt get it bodged, it looked a decent repair for what was required and the welding was quite neat too.....
mm

[silver surfer]

mm,

Thanks for the posts. This is exactly what i need to do so it's great to have a step by step guide.

Just got to work out how to get the van undercover to do this repair

[halfbakedpixels]

This post is awesome, Marks going to be well stoked when he gets it back.
Its exactly what i need to do on my new camper.

[pocolow]

Eeek.... Some radical weight loss there Mike....Very happy you're doing it and great step by step photo's.

Mark

[halfbakedpixels]

bet you hope its ready for that there camper Jam?

[lloydy]

Was the van grey in it's first life? I quite like that colour..
Looking forward to seeing this metamorphosis, means the queue is getting shorter

[kevtherev]

Oh boy
I bet Mark is swallowing hard seeing this sort of porn
Nowt like seeing your own vans striptease.

Chin up Mark..

[pocolow]

Oh boy
I bet Mark is swallowing hard seeing this sort of porn
Nowt like seeing your own vans striptease.

Chin up Mark..

Phwoarrr .. I love it really Kev...nearly as good as watching your van get "stripped" Kev and it was white originally Lloyd...

Mark

[Plasticman]

hmm will be done by the end of the week at the latest. it would worry the hell out of me seeing my van hacked up and zero possibility of having a real hands on peek tomoz is more cutting out and putting back , got the sill to investigate further too may do the window first then the rear 1/4,then sill and C post then arch and finaly wing
mm

[pocolow]

hmm will be done by the end of the week at the latest. it would worry the hell out of me seeing my van hacked up and zero possibility of having a real hands on peek tomoz is more cutting out and putting back , got the sill to investigate further too may do the window first then the rear 1/4,then sill and C post then arch and finaly wing
mm

[weldore]

yeah...


why do they leave that bit ?

it caught me out twice when I did mine

[Plasticman]

dont think it stamps well in the mold more than likely but i would cut them this way anyhow as it gives a cleaner easier fit,
mm

[Plasticman]

Well had to spend the morning down the paintshop attending to Mally
so a bit more digging

that does it for me so out with the lot

and the rest of the iffy stuff out, it really is the easiest way to do this job,

this is what you are then left with

so out with the snips and here is the basic part ,i have marked the points for adding the swages, they are deep so i dont miss them and run them too long

and here it is sat in place, I have drilled for spotting etc and am fairly happy with it

from under

this is the first part that has to be fitted and then alkl the subsequent panals simply fit to and around it, the hardest job is cutting the old stuff out
you will see the rust in the seam here,

this is why its so hard to sort seam rust, its the bit you cant see that causes the problems, note i have sheared the spots off to avoid grinding as i dont like removing good metal for no reason. will get the blaster out for sorting it.
mm