jiffies wrote: The van was bought in Oct & had been sat dormant for 8 years sat outside in all weather.
I think that's your problem right there, unless the vehicle had been dry stored subsequently and stripped back to empty bare shell and dried out for a few week properly before even starting on the prep then the residual damp inside will be finding it's way out
cutting up a van at the weekend it was suprising how much water ingress you find as you cut through what appears to be a sealed channel or the like, similarly the rust comes from inside out often till all that is left is the paint holding onto the primer with no steel left at all behind it
there is a real art to doing seems well especially to reapplying a bead which must be convex, ie a complete tube section, to maximise it's ability to expand and contract and the paint has to be flexible enough to do the same
my cheap £500 partial respray came through in 24 hours - I put virtually a whole can of very expensive rust cure paint, one of the american products from Frost all over the back of the affected seam and that pushed out more moisture and then seemed to cure in the seam and in the last 4 years it's been slow to get worse, problem there was damp in the filler and the crack because they'd moved the van out of the workshop into the yard while they did a nice little earner for a pretty woman so it rained on whilst unprepped but stripped back and then they trapped the moisture with the filler and new paint - it was a real shame the paint was excellent but the prep was woeful and the welding non existant - if they could prep like they paint I'd have been sending you all to them, but they'd rather do small insurance job work, I guess that's where the money is for those sorts of businesses; camper resprays would be a nightmare job really unless you love these vans
