Keeping 1996 Mk5 alive

[maciejd]

Ok, it's time to post some progress on a little refresh.

My Tranny got a brake repair (adjusting hand brake, new pads, new step cylinder etc), brand new alternator to replace the original one, which started stealing energy from the battery etc.

It is also a time to do some work inside. I had some egg-foam so I thought it would be nice to try using it for soundproofing. As it definitely is hygroscopic, I used it only to the rear walls side panels. I don't want something what store water on the metal panles of the van the rust feels like at home without it

So.. let's get started. The foam needs to be cut. I had to be careful and leave some space in the places where panels stick to the body.



Some panels are ready.



The wall is much better I thought it will be. Only needs some cleaning to remove the dust.




Unfortunately the other side is much worse and needs complete rebuild.
I don't have any photos, but you have to believe me I could make a hole with a screwdriver. The very end of the van was rebuilt two years ago, but the middle section of the floor wasn't touched since it left factory.

The next thing was the windscreen washer. the original one was cracked, so I bought used tank/pump assembly 3 years ago. It was a plug and play, so I havent checked wires.
The washer went away, so I had to check what is wrong.

Starting with the power:



Removing some insulation - doesn't look good, but should be working (the donor van owner even didn't used soldering gun):



The pump - definitely I need a new one. Tomorrow I have to check the price of a Ford one. The replacement costs ca. 7 Euro but God knows how long it will work.



Next thing - extra carpet under the original one. I bought 2 square meters of 10mm foam-rubber which is quite lightweight but what is the most important - have closed bubbles so the water is not absorbed.



I have to remove front seats first...



... but I got stuck with two bolts of the driver's side. I sprayed them with WD40 and tomorrow will do another try.

And at the end - the rev counter. It seems to not show the true revs... but I wish it was the truth



Tomorrow next stage.

[BigMonty]

Great thread, lots of work going into this van. Its looking really good.

[maciejd]

Ok... so... after 5 years from the last re-spraying the van definitely needs it again. Front wheel arch and bottom of the body sides as well as driver/passenger step/floor cross members are getting rusty.

Because of the general condition of it and the fact I really like Ford Transit, I decided to invest into it. What will be done?
0. rip the white paint off the body to see "what" is under it
1. rust - eliminated - each an every panel that is rusted or the rust is appearing is to be replaced or welded, the same about cross members
2. complete (reasonably) respray - I will not remove the engine or complete dash; finally it is to be pepper red
3. it is now registered for 8 persons, I want to get a new row of 3 seats and make it officialy a 5-seat (2 + 3) van
4. mounting front fog lights
5. replacing windscreen as the current one has many scratches (the van will be reapinted so I need to cut it off anyway, new one is pretty cheap considering the total cost)
6. replacing side windows and mount sliding ones
7. maybe replacing front seats to match the ones I buy for the second row, don't know now
8. darken rear windows
9. getting new door seals (at least sliding and front, if I find rear door seals better than mine, I will get them)

If everything goes well, it will be finished by the end of May (2013, hahaha).

As for now I ripped the interior leaving only dash and driver's seat. The van was moved to the workshop and there further disassembling started.

Pepper red. The photo quality is not the best one (taken with mobile), but one thing is known - the rust wouldn't be so visible as it is on the white paint )



Ripping off the rear of the van:



And a short movie - driving to the workshop:
http://afol.pl/transit/2013_05_bodyrepa ... terior.mp4

More pictures to come.

[maciejd]

New toys are coming

Side sliding windows, in the garage I've got new side doors seals (20 meters).
I have to clean these windows and replace the foil. Same foil will be put on the rear windows to darken them a little.

[maciejd]

Sometimes I think if it was a good idea to start the whole thing. On the other hand I really want to keep it alive as long as I can.

The right front corner is already cut off, it doesn't look bad, but as always it could be better



Passenger step doesn't looks terrible as well. Always when I look at the van's underneth I wish to see picture like in the Haynes manual - clean and shiny. Over 0.5 million km did the job. The welding man said it looks really ok. I still do not know...



Sliding door step - as you can see the rust was cut out, still needs some cleaning but I belive can be kept.



On the back side the sliding door step looks pretty healthy and after some checks it occured it really is.



The driver's side step underneth was repaired 5 years ago and still looks solid. I just do not know if I should cut it away and put all new parts everywhere. I think even the best repair panel wont be so strong and solid as original one... even welded here and there.



The driver's side panels by the rear wheel... I hate the rust - when I look at it I'm never sure if this is only coverage or the panels / cross members are really rusted. Only hammer will tell the truth. Fortunately members need only some cleaning, panels are to be cut and welded.



Left side panels - need to be cut and welded, new parts arrived. I think they will be cut 10cm from the bottom, the rest looks healthy, want to keep original panels as much as I can.



Each and every screw need to be reviewed - the rust is everywhere! ...



... however it still looks pretty solid!



Rear doors were bought new in 2008, rear cross member was replaced in May 2010. Still looks fine.



Unfortunately it doesn't look it is electric windows / electric mirrors ready
I have to check the wires diagram, but I think it is not the "full option" loom.



More photos to come... Cannot wait when it's finished.

[maciejd]

And another pack of progress photos:
Rear cross member cleaned:


Passenger side wheel arch - cleaned:


Passenger side wheel arch (outter and inner) replaced:


Sliding doors step - cleaned:


And a bucked of pepper red paint

[screechowl]

Amazing what you can see in full light on a ramp wish I had one I've patched just the rusty bits I can get to when parked on a street with passing cars all the time, but I'm craving to get her on a ramp of someone's so i can have a real good look, maybe one day......

Good work mate

[maciejd]

Thank you

I'm leaving in a block of flats so I had to find a workshop where I can do the whole job. The one I found maybe is not a perfect one but yes, there is a possibility to do the underneth job as well as there is a closed space for painting tha whole van inside.
I wouldn't decide to change the colour without touching the bits under the floor. It is really a big investment for me and the operation will cost more than a typical Transit Mk5 is worth on the market. I cannot afford not doing complete bodywork on it.

Today next bits arrived - halogens and new light for the rear reg plate:

[maciejd]

And one more datail just arrived:

[screechowl]

They look spanking! Where d'you get them from

[maciejd]

From Ford dealer

They had to be ordered as for couple of years nobody wanted them brand new. But here they are after 7 days of waiting

[maciejd]

There is some progress.

Bottom of side panels is replaced now, rust protected and now covered with a little of filler to make the connection smooth.
Front cross member is replaced, lots of smaller and bigger fixes done to the body.

Next stage - cleaning the roof, final cleaning of the rest of body and paint it with primer. Then final check and... paint!

Now I know that the wheels should be much brighter than they are. I have to think what to do with them.

I really cannot wait when I wil start putting all the bits back together.



The windscreen will be replaced with green one with a blue strip/filter.






I cannot belive - rust free sliding doors




The battery mount will be painted in black.

[maciejd]

Another stage completed. Painted with primer, got wrinkles out. Now have to remove the windscreen and lasting side windows, remove any rust which for sure will be there and ready for the base paint.
First will be the roof and the interior - not everything inside but everything what is visible somehow is going to be pepper red - that's for sure

I think till the end of the week it will be ready to be for assembling. As soon as it will be ready for driving on public roads, so most probably Friday or Saturday I need to do the MOT which expired... today

As usual photos below.













And as always new toys - rear windows are black now (20% black film), new windscreen is here as well - green one with blue strip from Pilkington.





I a question for all of you. I want to refurbish the front bumper as well as rear bumper corners. There are two options: paint them in pepper red too or in original gray colour with structural paint (just to make them looking like a plastic, not a smooth finishing).
What do you think? Personally I think bumbers painted same color as body fits tourneo or smaller transits. LWB will - IMHO - look better with classic ones.
What's your choice?

[maciejd]

And here it is. 10 minutes after painting it in pepper red. I must say I love the color















Tomorrow polishing and assembling it back on Friday and most probably Saturday morning.

[JoeySully]

NICE color look great