MK5 120 SWB Low roof with alloys

[AndyG]

I really don't know how much life is left in that engine, as at least 3/4 of those miles were all around town So that equates to about 6 or 7 hundred thousand miles

[MinorMatt]

It will be fine, if not I have the engine from my other van which can go in 182K of mainly motorway miles

Found parking tickets (not fines) from 2003 Andy

[AndyG]

Where abouts Might be bro's

Mmmmmm Might be mine if 2003

[MinorMatt]

Haven't posted here for a while because I haven't done much...

I have been told KalKat has been busy but I don't know quite what has happened yet.

North Weald is a possibility - the only problem I know about is that I can't afford windscreen + mot + tax until the day before

[kalkat]

Ok.... I was trying to keep my progress secret from Matt .......

................ but he guessed



This is how Matt left the rear of the van. Patches in the usual edges. When I came to weld new metal into the underside, there wasn't anything solid enough to glue to - so I cut it all out. More on this later.



this is one of the rear chassis rails. The whole area you can see was a latticework of rust I think the only thing holding the van together at this point was the underseal - by the way, the best way of removing it is a blowtorch



This is the inboard area of the chassis. As you can see, a lot of new material has been let in. I don't believe in simply plating up over holes, so this was all cut out using our plasma cutter. A wonderful tool this, cutting through all the rust as well as some patches previously bodged on.



Not so dramatic this one, but a lot of work has gone on here none the less - most of you will be familiar with this repair area Also while welding under here, I managed to set fire to myself!

There have also been other repairs - one of the most obvious being the replacement of the bottom part of the offside body. This involved rebuilding the sill areas before welding on the new panel. Unfortunately I don't seem to have any piccies of that, so maybe Matt can show you for me


I really CAN weld ... Emma

[MinorMatt]

Somewhat more than that has happened??? I will give more details and pics tomorrow

[MinorMatt]

Here are some more pics for you all

Kalkat had sorted the windscreen surround and painted it! Ringing the windscreen company tomorrow to come and fit one asap!



Inner wing repaired



Lower side panel chopped out and replaced...



This is the repair to the rear crossmember, a piece of channel section was let in to replace the really rusty base of the box section



Rust repairs in the floor



The channel that was let in and the repair below the bumper bolts



One of the chassis repairs... cut the whole side out and let in a piece of THICK glav...



Same on the other side



State of the front spring hanger this morning



and after attacking it with the plasma cutter



Drivers step/still/box section finished! (lots of weld!)



Most of the welding is done now, there are 3 small patches, the passenger step needs a few blobs of weld and the spring hanger needs finishing (metal cut to go in already, just needs welding in place)

Just a few trivial bits, an engine change, a windscreen, an exhaust and the "secret mod" and it will be ready for north weald (hopefully!)

[MinorMatt]

ALL the welding is now done, except for a piece on the front crossmember (about 6" worth of weld) which will be much easier with the exhaust off.

Both front wings are now on and so is the windscreen - £70 fitted from a local mobile man

Tomorrow I have to swap the engine and make an exhaust, Kalkat is doing the other mod and hopefully MOT on Friday...

[Luke]

whats this secret mod then matt

[MinorMatt]

errrm guess?

[Luke]

V6

[MinorMatt]

No, this one is staying diesel...

Nothing to worry about for weald though

[MinorMatt]

Had its MOT today... but it doesn't sound like anyone is interested?

[Altransit]

What engine is in there now?

[MinorMatt]

the one out of FLER