Baz has a new home!

[BigMonty]

His BBQ skills aint half bad either

[RustWidow]

His BBQ skills aint half bad either

Lol it's always food with you guys isn't it? Lol but I agree...

[dieselhead123]

Fitted the rear lower corner repair parts a few days ago, a bit of filler to hide the join and some primer;


Now we will be moving around to the rear valence.

TIM

[ColinJack]

Fitted the rear lower corner repair parts a few days ago, a bit of filler to hide the join and some primer;


Now we will be moving around to the rear valence.

TIM

Almost like new!

[RustWidow]

Lovely job. Ty for sharing

[transitandy]

Great work as usual Tim

[dieselhead123]

Bit more progress to report, continuing around to the rear valence, we found a fair amount of rot!
This is with part of the outer panel removed;

We can see that the inner valence requires a repair part and the intermediate panel needs to be replaced;


The intermediate panel was removed, this is spot welded to the outer panel, the drill holes where the spot welds were removed can be seen in this photo. Part of the inner panel has also been removed at this point;


The corroded part of the inner panel can be seen here;


The corroded intermediate panel was used as a pattern to produce a replacement;



The intermediate panel features two recesses to provide clearance for the rear of the number plate lamps, these were produced as separate parts then welded to the panel. Although the panel won't be visible once the repair is complete, it is important to retain the factory structure as this area needs to provide a solid mount for the tailgate catch.

TIM

[ColinJack]

Bit more progress to report, continuing around to the rear valence, we found a fair amount of rot!
TIM

Sh*t you are good (but you probably know that already!).

[dieselhead123]

Bit more progress to report, a repair panel for the inner rear valence has been produced. This spot welds to the underside of the rear floor but features a recess to provide clearance for the tailgate catch plate, the recess can be seen here;


This panel also has a return flange at it's lower edge, this provides some additional strength;



Here we see this repair panel in place, screws have been used to temporarily secure the panel. As it was not possible to gain access for spot welding along the full length, (due to part of the outer panel still being in place), 'plunge welding' will be employed;


Here we see the panel in place viewed from below;


Once the inner repair panel was welded in place we moved to the intermediate panel shown earlier. This part required the addition of a return flange at it's lower edge. This was folded from sheet and then, to minimize heat distortion, spot welded to the part.
Here we see the part viewed from below, the added return flange at the lower edge can be seen, this will eventually be welded to the outer panel;


Here we see the intermediate panel viewed from above, screws used as temporary fixings. Again, no access for spot welding so 'plunge welding' will be employed;


More later,
TIM

[ColinJack]

Bit more progress to report, a repair panel for the inner rear valence has been produced. This spot welds to the underside of the rear floor but features a recess to provide clearance for the tailgate catch plate, the recess can be seen here;

Here we see the panel in place viewed from below;


More later,
TIM

A work of art!

[dieselhead123]

A bit more progress to report!

We manufactured a repair panel for the centre part of the rear valence, care was taken to correctly position the holes for the installation of the number plate lamps;


The panel was then clamped in place. Pre-drilled holes were provided for 'plunge welding', self-tapping screws were fitted in some of these holes to assist with panel location;


This panel was 'plunge welded' to the step of the rear valence inside the van, spot welded to the replacement inner rear valence and then 'plunge welded' the the lower edge of the inner valence reinforcing panel. Originally, the reinforcing panel would have been spot welded to the outer valence prior to the outer valence being fitted.

The repair panel was then welded in place and the welds cleaned off;



Filler and paint application then followed, more pictures later.

TIM

[Mad machinist]

You been in my bloody workshop again Tim, lol

[ColinJack]

Looking good Tim. Lucky to have a nice warm workshop to work in!

[dieselhead123]

Looking good Tim. Lucky to have a nice warm workshop to work in!

Getting there Colin

[dieselhead123]

Bit more on this chaps.

Light skim of filler to hide the 'joins';


Holes drilled for re-fitting the reversing lamp;


Primer and 'stone chip' applied to the rear valence;


Then some top coat applied to the rear valence and rear quarter area;



TIM