Rustoration

For documenting and technical details of T25 restorations and major repairs
This section is for major restorations only.where to buy a panel or where to buy window rubbers belong in the bodywork seats and glass section.
Also please note,we need pictures of the restorations,without them posts are pretty useless.[\b]
Picture heavy and detailed threads , not for general banter or advertising
Traders welcome to post but not to advertise blatently
Threads will be cleaned of chit chat.

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RogerT
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Location: Central Scotland

Re: Rustoration

Post by RogerT »

Putting right earlier mistakes today.

Taking you back, I’d made a pigs ear of removing the panel over the rear arch, so thought trimming the edges and inserting this strip…Image
… would be the solution.

But I realised I was introducing new probs, specifically creating the inner fold along that weld line, and the potential for warping as the slightly uneven gap closes on welding.

So I cut it out, and then made a broader strip,…
Image

…clamped it to the panel and scribed along the top edge so I can get a good, tight, even, join. Carefully cut along the scribed line, and offered up the strip to fine tune it.
Then cut it into three sections so it fits my folder (cut with snips so I don’t lose any material and create more gaps), and folded it
Image

See how well it fits?
Image

Chuffed. Just have to avoid making a horlicks of welding it in…
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
Registered user
Posts: 1800
Joined: 10 May 2013, 11:59
80-90 Mem No: 13706
Location: Central Scotland

Re: Rustoration

Post by RogerT »

Tacked in the angled strips
ImageImage

Offered up the panel to check the fit
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Scribed along the edge, then used a straight edge and cut it.

Then filed down the top edge of panel to match
Image

Here’s how it fits together
Image
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

Nasic
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Re: Rustoration

Post by Nasic »

Much respect for the work you are taking care of, keep up the good work! These reparation take much time!

RogerT
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Posts: 1800
Joined: 10 May 2013, 11:59
80-90 Mem No: 13706
Location: Central Scotland

Re: Rustoration

Post by RogerT »

Nasic wrote: 12 Apr 2022, 05:58 Much respect for the work you are taking care of, keep up the good work! These reparation take much time!

:ok
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
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Posts: 1800
Joined: 10 May 2013, 11:59
80-90 Mem No: 13706
Location: Central Scotland

Re: Rustoration

Post by RogerT »

Welding in the edge flanges. Not quite finished, and nothing dressed back yet. But it all went together much as it should.
ImageImage
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
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Posts: 1800
Joined: 10 May 2013, 11:59
80-90 Mem No: 13706
Location: Central Scotland

Re: Rustoration

Post by RogerT »

This isn’t as straight as I would like
Image

Wasn’t careful enough. Cut at the top and pull out
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Messily welded again (3 times!)
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Ready for the panel, must admit I wasn’t looking forward to it. Bonding sealant first.
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Tack along top edge, and start the puddle welds.
Image
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More puddles
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Start the butt, penetration good after a blow-through!
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Pleased with this, got my settings pretty nice
ImageImage

Then top edge of the angled strip…. and my gas ran out.
Image

So, grinding and power-filing.
Image
Image

Didn’t completely escape warping… but could be worse.
Image
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
Registered user
Posts: 1800
Joined: 10 May 2013, 11:59
80-90 Mem No: 13706
Location: Central Scotland

Re: Rustoration

Post by RogerT »

That last photo was taken before I started the top edge of the angled strip, and the first warp popped out, so you never know, I might be lucky after I get more gas…
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
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Posts: 1800
Joined: 10 May 2013, 11:59
80-90 Mem No: 13706
Location: Central Scotland

Re: Rustoration

Post by RogerT »

Starting on the next bit
ImageImage

The ends are ok
ImageImage

Bit rubbish at this end, and the brackets are ropey
ImageImageImage
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
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Posts: 1800
Joined: 10 May 2013, 11:59
80-90 Mem No: 13706
Location: Central Scotland

Re: Rustoration

Post by RogerT »

My Lidl auto darkening helmet provided good service for 5 years or so, but it’s head band has failed in multiple places. Banjaxed.

New helmet arrived, tried it today - it’s like night and day! So much easier to see, more comfortable, more adjustable. I could see that the arc was blue!

https://www.weldingsuppliesdirect.co.uk ... elmet.html
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
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Posts: 1800
Joined: 10 May 2013, 11:59
80-90 Mem No: 13706
Location: Central Scotland

Re: Rustoration

Post by RogerT »

Cleaned off that last weld and stuck some primer on
Image

Took off the cover strip, and marked out for cutting
Image
Image

A sorry state…
Image
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
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Posts: 1800
Joined: 10 May 2013, 11:59
80-90 Mem No: 13706
Location: Central Scotland

Re: Rustoration

Post by RogerT »

Cut out section, and in an effort to get good butt joints, trimmed the edge with a flap disc to a line scribed off a straight edge. I just can’t cut straight first time!
Image

ImageImage

Then cut a section of new metal, divided into 3 so it fits my bender, and cut out a profile to match to.
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
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Posts: 1800
Joined: 10 May 2013, 11:59
80-90 Mem No: 13706
Location: Central Scotland

Re: Rustoration

Post by RogerT »

Bender failed, so repaired it.
Fabricated the three strips, and tacked them together.

Image

Pondered how to accurately cut the lower edge for a bit joint, couldn’t actually get the piece onto the inside of the hole for scribing. Then remembered I still have the scrap piece, so used that.

Image

Came out pretty good after a bit of filing.

ImageImage

Laid aside now while I do the bracket area at the rear. Looks like it’s tricky as there’s a joint there.

ImageImage

Fortunately the rot does not extend noticeably internally, but it’ll be in the joint.Image
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
Registered user
Posts: 1800
Joined: 10 May 2013, 11:59
80-90 Mem No: 13706
Location: Central Scotland

Re: Rustoration

Post by RogerT »

Duplicate post
Last edited by RogerT on 30 Apr 2022, 10:07, edited 2 times in total.
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
Registered user
Posts: 1800
Joined: 10 May 2013, 11:59
80-90 Mem No: 13706
Location: Central Scotland

Re: Rustoration

Post by RogerT »

But when you get an itch, you just have got to scratch it…

Image

Image

Image

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And you end up with a bigger hole.

Needs a plaster, made of 1.6mm for easier welding. Cleco pin just for handling purposes, to help make sure I don’t drop it somewhere awkward.

Image
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

RogerT
Registered user
Posts: 1800
Joined: 10 May 2013, 11:59
80-90 Mem No: 13706
Location: Central Scotland

Re: Rustoration

Post by RogerT »

Welded in one patch, then started putting in the flange over it.
Image

Realised I needed to prime under it, so cut it off again…Image
Have you ever seen an unhappy fool?

88 Transporter with hitop camper conversion, 1.6td.

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