My latest project mk2 CI Travelhome LWB

[davev6newman]

i think i must have had beer goggles when i bought it.

[transitandy]

Yeah but when its all done just imagen how its going to be

[davev6newman]

I can see an end in sight for the welding now!!

Bottoms of both doors were rotting out quite badly so i decided to cut out and replace rather than fill it.

I marked out a straight edge and used a really thin cutting disc to remove rotten bit on the drivers side, leaving just enough metal at both sides and bottom to give me something to weld to.



Using the piece i just cut out as a template i marked up the new steel and cut out using electric shears so as to not bend the pattern.

Offered it up and it fitted a treat.



Spot welded some more and ground flush



Some filler



Rubbed down and some primer



The other side was a bit more gone than drivers side



Same principle of cutting out and making a template, except this time i had to weld new metal to bottom of door frame as it had nearly all rusted away.







Run out of filler so do that another day.

[bezzabsa]

jUST ONE WORD COVERS THIS POST.....FAN-BLOODY-TASTIC.


Hat goes off to you mate, buy it for and engine, then rebuild it.....Class job at that too....sooooooo jealous!!

[plasterman]

that van will look smart m8 well done on all the hard work ! keep us posted cant wait to see it finished.

[transitandy]

nice work im enjoying this thread

[davev6newman]

Cheers Guys, Cant wait myself to see it finished.

[irishtransit]

i've just read this from start to finish and i'm amazed.to think you were only gonna tidy her up to sell on in the first place.if i wasn't working on a couple of mk5 cortinas at the moment i'd go out and start on the mk2 camper which is rusting away at an alarming rate.i shall keep an eye out now for the next episode in this great thread.WELL DONE.

[davev6newman]

Not much done this week due to my daughters car needing urgent care and heavy showers on sunday.

The original dash panel was all cut about


So i got another one from a phase 2 and sprayed it with vinyl paint. whilst i had the glovebox and heater out i gave them a good scrubbing with Mr muscle before i put them back along with the rest of the dash panels and updated the silver trim along the front of the dash with woodgrain sticky back plastic.

Also i replace the phase 2 steering wheel with an original phase 1 one i had lurking in the garage, i think the later one is a better wheel as its slightly bigger and heavier, but the grey doesnt look right.

i took all the firewall sound deadening out and the wheel arch covers and painted them with tyre black before refitting.




The roof lining and sunvisors were filthy with mould, so Mr muscle again and a nailbrush and they come up a treat



On the drivers side the lower skirt was always in bad condition with a broken wheel arch and a crease right along the side



Well it didnt help that i reversed into a low pile of pallets and bent the rear skirt back like a sardine tin, so i took the whole lot off.



a fella on ebay was breaking a LWB CI so i bought the whole side skirt inc the wheel arch for 50 quid, so im in the process of rubbing them down and painting in stone chip.

[BigMonty]

One of my favorite threads on this forum. Keep up the good work

[davev6newman]

Im enjoying writing it as well!

[davev6newman]

The wheel arch always looked rusty, so once the wire brush had been at it i wasnt surprised as to what i found, but an easy enough fix.







So welded a piece of metal in and filler



Bottom of wing is coming along





The rear fibreglass light panels were quite damaged so i took them off for repair



The more damaged one was full of filler and the other was my fault when i baked into some pallets





Some fibreglass matting on the back and some filler and they look loads better





One of the first things i ever dod was take this window moulding off as it was quite damaged





Trouble was, it was so brittle every time i picked it up it broke, so ever since i been coming back to it when i got a minute.



Trouble is it weighs twice as much now
Still some filling and rubbing down to do, but at least it stopped breaking.

[Trickie Dickie]

Just read the thread from the start to now.
Amazing work Dave, you must have the patience of a saint.
Can't wait to see it finished you must be very proud of all the work you've put in.

[deankdx]

great project, got your fair share of rust too

How did you seal the rust repair under the left wing(mudguard)
mine has rust in there that i will be tackling soon, i was planning to cut a section of the guard off to access it.

[davev6newman]

Well as you can see it was made much easier with the scuttle panel removed, access was good, i just welded another plate over the original mud guard and welded a return up the a post, finished of with plenty of seam sealer.

Somebody did suggest that you cut the top of the wing off to access that point, then weld it back on again, which didnt sound too difficult.