Tom's Mk5 (2000) 150s SWB 2.5L 76ps Project

[Van1968]

I got to work on and started knocking out the filler I put in the holes etc. I did mention earlier in the post that I would be sorting out this temporary fix once and for all. Here are some pictures of what I got up to.

[Van1968]

[Van1968]

[Van1968]

I worked on the front (near side). Lots of repair work to be done.

[Van1968]

[Van1968]

Come back to the front part later. I chopped out sections on the bed. Had some surprises waiting for me when I eventually opened up rear sections behind the rear wheels.

Repeated the same on the other side.

[Van1968]

Before introducing the hammer (MOT would have picked this up for certain)

After the hammer

[Van1968]

The other side before and after the hammer.


I’m on the understanding these sections can be bought off the shelf. I plan to have a look on the forum. If you know where to get them please drop me a link or name. I have to source them as soon as pos.

[Van1968]

Chopped out a little more on just to finish off.

Soon be ready for the welder. First I want to prep pieces of scrap ready for fitting.
Thanks for looking, tips advice always welcome.
Tom
I apologise for the amount of posts. Photo bucket have change their image link. For some reason I am unable to download as much as I like.
Thanks again for looking...

[Van1968]

Hello again
More chopping and head scratching today! I started by removing sections of rotten chassis. Bit of a pain getting access with the mini grinder. Hacksaw with blade turned 45 degrees helped out. Found more rot lower part of rear wheel arch inner/outer plus the small panel section adjacent internal/external. Looks like I will be spending money on panels to replace just got to make sure I go to the right place when sourcing them. Before I got to work on chopping out I hoovered between the chassis rail and then painted on VACTAN rust treatment. I primed up later with a generous coat of grey Hammerite. Here are a few pictures showing progress……….
VACTAN…Good stuff
Chopped out section on the nearside (Passenger side). Now labelled not so bad side!!!

A picture of the nearside section (Drivers side). What a headache this proved to be. Once I started on one piece more was uncovered. Oh well such is life. Welding practise and body repairs here we go!!!

What I’m up against, you can see the road!!

External view. The small rear panel is shot and other than what’s shown in the photo, the bumper mount fixing area has rotted out, you can just make out a thumb press test by yours truly. Bummer

I took my mind of things and did a little therapeutic painting…wish it could have been sunshine yellow instead of dull grey. Ironic really, weather was tosh where I was. Mustn’t grumble (I am at that age!!)


I then had this idea of I’m going to have a go at fabricating a chassis piece. So I got this sheet of steel. (Powder coated)

I did a bit of bashing using a section of chassis as a template and a piece of timber as an anvil. Pleased to say that I managed to knock up a decent piece. I don’t think it’s enough to do both sides.

Thanks for looking…all tips, links and advice most welcome………….
Tom

[oldyellar]

Nice work Tom keep it up

[Van1968]

Thanks Pal
Going to get hold of dieselhead123 Monday/Tuesday after work about panels being a club member should get a good discount.
Thanks again
Tom

[Van1968]

Hello again
Been busy cutting, fabricating and welding here are few pictures. I'm glad to say what needed to be done is done
A picture of some panel pieces I bought from Dieselhead123 (Thanks Tim). I didn't use them all, just one.

[Van1968]

Hello again
Started practicing on the holes I made for fitting the seats and others that I came across.

Got comfy so began on the sides (right side facing)

Left side

Manufacturing begin! Cardboard comes in handy, I cut these pieces out to help form the offside rear sections.

Wasn’t the easiest thing to do but having a jigsaw (Thanks Ali)

Nervous times here cutting out this section. No turning back now.

Fitted the new panel, I ended up blowing a few holes due to the breezy conditions. Tried a shelter but that didn’t work. No harm done I have since filled the small holes with Milliput putty.

One of the Pieces I manufactured fitted. Really chuffed with the result

The other piece welded in. Now ready to take the chassis piece.

Chassis piece fitted. Not easy welding upside down, I burnt myself a couple of times with dripping blobs!!

Underside view, a positive result

Now for the top section

Applied some Milliput putty to smooth things off. Cannot get a grinder in there!!

The other chassis piece fitted and milliputtied

Top section finished off. A total of 6 pieces were used.

Now to cover the chassis rail (offside). A total of 4 pieces

The other side

I used self-tappers to help prevent distortion. Pieces get really hot when you start welding on them. I fitted a piece directly on top of the chassis piece forming a box section, then welded a further two pieces side by side on top. I did the same for both sides. Nice and strong.





Once I finished welding the bed I moved onto the front passenger side. Here is a picture of the project!


Patch repaired the cill. I have bought x2 cills and wheel arch set from central panels. I decided not to use them. Time was against me and I felt a patch repair was good enough for now.

Pictures of the rest of the work I did.


Finished patch work result!

Overall I am happy with what I have done. The van is safe and ready for Wales this weekend. Off to Chepstow Castle for a reenactment weekend.
When I return I will be putting the van up for sale. Unfortunately my circumstances have changed (Beyond my control) and I cannot afford to keep it. It’s a shame, I do like the van and I have learned so much maintaining it. The new owner won’t be disappointed that’s for sure.
Tom

[Van1968]

Just a quick one to say a big thanks to all that have help with my van...
I have to stick it up for sale on EBay...
Can't afford to keep it any longer. Should be a good project for the new owner!
All the best for now and thanks again.
Tom