Panel Van side repair

[silver surfer]

Well I am about to start the most ambitious repair of my panel van resto and am a little nervous to say the least. I have been bringing this van back to life on and off or about 6 years. In this time I have learned to weld, learned how a T25 is put together and stripped most of the mechanical bits and bobs and refitted them. I have one real big repair left which is the replacement of the nearside rear arch, sliding door runner panel and repair the wheel arch.

I have had so much help on here with the pics people post that I thought I will record and post this one properly. So here goes.

This is what this side of the van looks like now



This is a close up of what the rear panel looks like now



This is the sort of finish I am looking to get after having repaired (no where near as much) and painted the rear corner



This is what the inner arch looks like now



What I need to decide really is the sequence. I need to replace or repair the following:

Rear tall arch panel
Sliding door runner panel (many thanks in advance mm )
Replace the sliding door runner cover lip
Remove and refurbish the sliding door runner (unless someone has one I can purchase)
Repair / remake the innner arch

I only have my drive to do this so my thoughts were do as much as possible before taking the rear panel off (i.e repair the arch). If I do this I will have guide to fit the new arch panel to.

Anyway that's the start. Will post more good or bad as I go

[silver surfer]

well started to get my fabrication skills (I use skills in the loosest of terms) going again with a repair to the drivers side step. Got home from work last night and had a bit of time so thought I know I will prep the side step. Anyway on inspection things were a bit worse than I thought

6pm - Started with this and thought I have got to take door off to do this



6.30pm - found that the side piece was also shot so followed the guidance on here (thanks mm) of "don't be afraid to cut metal out". I made a template and cut out a new side peice



7.30pm - another template and made the new step. looks a bit rough on the curves as i only have a claw hammer and the corner of my wall to use Anyway started to get it welded back in



8.30 pm - got it welded in and started to treat the new metal. Dinitrol 900 first then Waxoil underseal (underneath) and weldthru on the top

9pm - found out that putting door back on late in the evening after a day at work and then three hours van fixing is about the limit of my strength but in the end i have this.



Maybe not the best in the world but I am happy with it and I know it is solid

[Plasticman]

nothing wrong with that..
im collecting the new side panals Ive had made in the morning so youve no excuse now, will post a picky up as well
mm

[silver surfer]

Nice one.......I think

[max and caddy]

If you put the door on by yourself and put the bolts in you must be related to Geoff capes...

[silver surfer]

Rested it on my knee then got one bolt in. Had the ratchet in my teeth. Not too slick but it worked and needs must when it looks like rain

[silver surfer]

In conducting said repair and as a last f**k you too me for trying to fix it the van also appears to have deposited a chunk of rusty van in my left eye even though I had a visor on for the cutting. Didn't notice until the morning after at work

Anyway cut a long story short I was in A&E at 6.15 this morning with orange dye in my eye and very skilled doctor pocking about with a needle

[silver surfer]

Well finally got going on the side of the van. Took a few measurments before taking anything off then removed the door slider and the cover seal lip.



Then started cutting you can see from the pics the reason for the new metal



Bit of ups and downs really after taking the wing off. I found the side of the post rotted out but to my suprise the bottom of the post and the jacking point were really good



Only thing I can think is that water has got in the seam and rotted it. Anyway got this repaired with some new metal. Really am suprised how my attitude to rot has changed with a bit of practice. Just stuck to the same advice from mm. Cut out the rot back to good metal so you have something good to work to. Made a template then cut the pieces and welded in. Won't win any prizes but it won't be on show and it's solid. Finally got to test fit the arch before I cut out the upper section. I wanted to do this so I could see how it sat before I only had the new panel to work to.



Tomorrow will be the real test. I have got a replacement panel to replace the metal under the sliding door runner. This is one that mm has made up and I must say it is the dogs doodars I am going to join this in about 2" up from the upper swage line as this is where the clean metal starts. I am going to butt weld this in but thought I might put in a backing plate onto the existing panel to stiffen it and help me align the new panel. Any thoughts most appreciated

[silver surfer]

Well got another good day in today Mother Nature smiled on me.

Started cutting out the old sliding door runner panel ready to fit the new one from Metalmick8y. I have to say it was one of those "sit in the corner and tell yourself to stop being such a pansy and GET ON WITH IT!!!" moments. Whilst cutting out I found a few more holes so had cut some more out an repair



Once I got these bits repaired I trial fitted the new panel. I have to say the new panel was a dream to fit. I welded a backing piece to the new panel to help keep the but weld aligned and to try to stop the panel warping. The panel is great metal and very accurate shape, Mike you have done a great job



Next up was to start to tack the new piece in.



Then fully welded and a bit of filler to finish off



Finally fitted the sliding door runner and gave it bit of paint on the bits that won't be on show.



All in all I am pretty happy with it

[fidget]

Thats some great work there mate keep it up

James

[silver surfer]

Cheers for the encoragment

I have to say I was very jittery starting this as it seemed a bit of a step too far but am really pleased how it's turned out

[weimarbus]

that's looking really good, you must be delighted,well done

[silver surfer]

Thanks, more relieved than anything else. I really, really wasn't looking forward to this. Thought I might have bitten off way more than I could chew

Think this was more good fortune than skill to be honest

[silver surfer]

Well after yesterday's success today was a mixed bag really. Started really well with final prep to fit the new arch panel but then started repairing the battery tray on the nearside whilst the wing was off. Lots of rot!!!!!!!!!!! Anyway have a question does anyone know what the right angled tapered peice in the pic below is for



Started to make a new one but can/t see what it's for other than to funnel air in. Maybe a hangover from the Aircooled days? Anyway I can't see that it's structural as it sits on the battery tray base plate but any thoughts most welcome. Here is where it is missing from.



Pic is looking from inside the arch backwards up through where the tray needs replaced. The line at the top is where I was going to cut to fit the new one but won't bother if it's not needed. If I am going to have to do this I think the lower back panel will have to come off so not too keen.

[Plasticman]

debatabler if you replace it or not. leaving aside any airflow requirements we have aa enough hoiles for that. but if you look at the picks in particular kev the revs, then you will see how it fits together as there is a pick of the body cut as well, may be a bit to wade through though. but it does give support to the whole corner area, that said i dont think IMHO it would cause any issues if you ommiterd it, but do try to neaten any cut and make it look like it was meant to be,
this is a common area and only you can decide where to draw the line
mm
oh and good work done so far and keep the pickies cvoming