My '96 150 Custom LWB High Top

[MinorMatt]

She doesn't weld as well as me... but is much much much better at shaping the metal, attaching it in the right place and filling!

We both have slightly different - but complementary skills which helps a lot!

[kalkat]

Right then, after doing some more on the van, finding my camera lead (eventually) and working out the latest 'improved' Photobucket - here's an update

We start here just after tacking in the new inner arch panel so's to have some idea as to where all the other new bits go.

The first bit I wanted to survey was a hole through the return in the rear of the arch......




...... well I thought, seeing as the outer bit of the arch was poo .......



...... chop it off However this had the unfortunate result of showing even more rust, sooooooooo...........



........... I cut that out too!

At last - *fanfare* NEW METAL* ........



And ..................





There are a few more repairs I've not shown, mostly due to forgetting to photo them (or sucking burnt fingers) and the eagle eyed will notice I've recycled the sill outer although it has a new underside. Also in the pic, it's still to receive a patch in the top.

Tata for now .... I'm off to go and hit summat else

[MinorMatt]

Everyone should have a KalKat

[RustWidow]

Lol Matt, good job though. But don't you find that rust has that awful habit of sneaking up on you just as you think you've found the last of it?

[kalkat]

i have a small hammer that I use to 'tap' small areas that are suspect................. it's often 'quite interesting' just how many times it goes through!

[MinorMatt]

More work has happened....

I think it may be best if pics show whats happened? Nothing unexpected... except the strut tops are perfect







Previous step repair was just a nicely welded piece of metal over the rot...



so choppy choppy weldy weldy





(one more pic when it uploads, and probably more tomorrow!)

[MinorMatt]

Kalkat shaping the metal... me welding it in!

[RustWidow]

Nice job you two

[Reading Fan]

Looking good there Matt, nice to see it slowly coming together, so glad I never attempted to do any work, though if I had Kitkat I could have been tempted, coffee and biscuits for fuel I assume.

Away from the tranny now, picked up 54 reg Sprinter 4m yesterday, bodywork sweet as a nut, at first glance.

[kalkat]

Fuel... TEA ......and cakes, chocolate, doughnuts,battenburg, pot noodles ....... you get the idea

..... oh - and I EAT Kitkats.....

[kalkat]

....... oops! sorry RW, I forgot - fank'oo

[RustWidow]

No probs kalkat, but it is awesome work

[MinorMatt]

Grr having problems - lots of pics but this computer is playing up!

Kalkat might post them up from mmy photobucket though

In the mean time... it went to Billing (you can also see the purchase I made for it!)

[ake]

Grr having problems - lots of pics but this computer is playing up!

Kalkat might post them up from mmy photobucket though

In the mean time... it went to Billing (you can also see the purchase I made for it!)

The awning definately suits your van better than it suited mine

[MinorMatt]

Lets see if I can get this post sorted today...

Those of you who were at Billing might have noticed the van has progressed a bit from the pics posted so far...

I got on with doing the repairs to the inner sill and outriggers around the passenger side rear arch (but didn't take any pics ) whilst Kalkat got on with the temporary repair to the passenger arch (fibreglass & filler!)and finished tidying up the divers arch & step





Once I had done the welding underneath (well all that I could be bothered to do...) I painted up the drivers side inner arch with cold galvanising spray, and then chassis black



And I then moved on to the rusty patch which offended me most on the van - a hole in the B post above the fuel filler apature.







I gave the van a bit of a wash (with a plastic scouring pad!!!) - This photo shows the difference!



We then got everything masked up and put a coat of primer and then blue on... in the dark, and it rained in the night too

Kalkat rubbed back the runs, and we both poloshed it up with the buffer and a bit of G10.

I also fitted headlamp protectors, a glass headlight to replace the degraded plastic one and a few other bits too (ply lining etc)