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mk5 rotten a?s! - MOT: IT PASSED!!

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mk5 rotten a?s! - MOT: IT PASSED!!

Postby Breakdown Biker » Sat May 09, 2009 8:57 pm

I've been cracking on with my camper conversion as I'm determined to get it ready for Slippy's Do. The interior is basically finished and I thought I just needed to do a wee bit of welding before finishing it off.
Wrong :!:
The weather here is rotten and so is my campers ar?e end :( So, since I can't get anything done I thought I'd see if you guys can pass on any advise to help me get it sorted out :?: :?
The story so far : viewtopic.php?f=58&t=43816&start=0
When I bought my van the only welding needed was to the r/o/s inner wheel arch, which I got done before starting the camper conversion,everywhere else was solid enough.
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However during the build I'd noticed damp patches on the plywood under the bed/seat I'd built at the rear. I eventually traced it to be coming in the window seal and had formed a puddle exactly where I'd had it welded. So I tried removing the solid bead from the window, pulled back the rubber to clean it out then ran some sealer behind the rubber, which made a right mess when I replcaed the bead. To back this up I used expanding foam in the crevices around the window inside.
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After all that the b@?t!*d's still leaking. :evil:

So the window has to come out :(
I've done windscreens before so thought it should be simple enough to remove, seal and replace the window...
Wrong :!:
Getting it out was indeed quite simple, but getting it back in was a nightmare because the rust around the window frame acted like sharks teeth on the string no matter how much fairy liq I used. I'd read on here that somebody used speaker wire and (my favourite tipple) WD40 so tried that too. Still snapped,so back to string and try again
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All in it took me and three mates 2 hours to get the bugger back in :oops: :lol: :lol:

Thankfully it is now sealed and staying dry, so tetra-sealed the panels again and replaced the damp insulation. also had to make a new inner panel as the old one was damp and rotting.
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Tought I'd better check the other side and Oh sh1t!

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The near-side window was leaking too, but thankfully the window frame wasn't as bad as the o/s one so I got it sealed ok. The puddle wasn't there only because it had rotted a drain hole in the floor and was now working it's way through the inner rear over hang!
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Just for good measure, I checked the n/s/r wheel arch and more oh.......!
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And yes, the other side had gone too!
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Had enough? cause there's more.......

The rear cross-member,which I'd noted a couple of 10p sized holes in decided to show it's true colours when I got pssd off and wacked everywhere with a hammer :oops:
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What a difference from last year when I parked her up to start the conversion. I'd been so busy with the build that I hadn't washed off last winters salt and I'm paying for it now.
I've been quoted 400 QUID to put it right by an arrogant tosser of a welder, to whom my reply began and ended with an "F".
So I pit the word out to my mates that I was looking for a welder and in the proccess ended up buying a wee mig for 50 quid-and it dosen't f'in work :twisted: :cry: Image
Thankfully, the bloke that sold it likes his knee-caps where they are and is sorting it out with a new liner, etc. :lol:
At this stage I'm thinking about just maxing out my credit card to get it done, but the Mrs just reminded me that divorces cost even more!!! :(
Is 400 takin the mick for this amount of work, I've bought a length of chassis to use on the rear cross-member
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My welding skills are very much "under development", so do any of you think I'll be able to do it myself :?:
It's still p1ssn down outside so Ahm away to get p1ssd :wink: :D :( :lol:
By the way, If you've got any ideas (other than weighing it in) I'd be glad to hear them.
Last edited by Breakdown Biker on Tue Jun 16, 2009 6:07 pm, edited 3 times in total.
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Re: mk5 rotten a?s! - Deadline Slippys Do (help!)

Postby neilc5023 » Sat May 09, 2009 9:49 pm

dig in pal pick up some scraps that are clean and practice weldings patience and setting up your mig and patience it will be fine divorces are dear but holes cost nothing just a mate and a couple of spades. :lol:
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Re: mk5 rotten a?s! - Deadline Slippys Do (help!)

Postby rover » Sat May 09, 2009 11:46 pm

Take the rear bumper off, you will find more holes I can assure you, but dont worry! You dont need chassis section, just plate it up with sheet steel :wink:

In fact from whet I can see there's no major chassis issues, its all plate work :D

As has already been said, get some practice in before you attack the van, take your time, its actually quite satisfiying to repair it yourself in the end.

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Re: mk5 rotten a?s! - Deadline Slippys Do (help!)

Postby noobrider » Sun May 10, 2009 8:12 am

A minor set back Colin, At least you know about it now so you can crack on. Shouldn't cost much to repair all yourself just a bit of time. Make sure they all get a good covering of sealant or rust proofing paint when you done though
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Re: mk5 rotten a?s! - Deadline Slippys Do (help!)

Postby gardener68 » Sun May 10, 2009 9:51 pm

been there and done that ect :roll:

my so called tidy looking van had nightmare sections of rust just like yours.
no choice but to cut all the crap out and weld in clean metal, takes ages but nice when its done.

look on the bright side with that much to do you will soon learn the basics of welding and probably get pretty good at it

get yourself a selection of wire cup brushes that go in a power drill to clean up the rust from edges that you cut out (safer than angle grinder wire knot brushes)
weld it up to the best of your ability then primer paint and waxoyl the hell out of it so you dont have to do it again :wink:
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Re: mk5 rotten a?s! - Deadline Slippys Do (help!)

Postby Breakdown Biker » Tue May 12, 2009 1:55 am

Thanks for the encouragement and advise lads :D I've got over my initial downer and gettin' at it again. I discovered ages ago that building a camper can be a roller coaster of a project, so I'm lookin forward to the high of gaining another skill and completing another part of my build.

The parts for my gas mig are on their way but meantime, a mate turned up with a wee gasless one and an old mini bonnet for me to practice with. I've also been swotting upon mig welding at this site http://www.mig-welding.co.uk/ which I saw mentioned here.

At first my welds were like a bunch of snotters, but eventually I got it by using techniques I developed when I was younger, as a chef :shock: :!: Honestly, the way you hold a piping bag is very similar to how you have to hold the mig torch. So I got some good practice in and I managed to weld a dod of the chassis section I'd bought onto the mini bonnet, it looked all right and when I skelped it wi a hammer it stayed put 8) So well chuffed :D I'm off on thur and fri so I'm gonna have a go at the van.
I've also booked an extra few days holiday before Slippy's Do, as it might go to the wire on my deadline!
Thanks for your help again and I'll keep you'se posted on my progress.
This site's the dugs danglies 8) :D
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Mk5 hicube minibus camper conversion
viewtopic.php?f=58&t=43816
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Re: mk5 rotten a?s! - Deadline Slippys Do (Progress made so far)

Postby Breakdown Biker » Sat May 23, 2009 9:19 pm

Finally managed to get a space on the ramps at work, so progress has been made :D
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Unforunately I didn't make my deadline, just took longer than I thought it would to get where we are now. I say we because I managed to persuade a fellow biker (and Transit owner), to help me with it as he has some welding experience.
The main problem we had was finding good enough metal to weld onto, it would look okay and even take a hammer blow, but it disintegrated under the weld. I'm glad Ray knew what was happening as I'd have been messing about with the mig settings. :?
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Ended up using larger plates than first thought needed, but getting better results :) though it meant having to lift some of the wooden floor, which we'd hoped we wouldn't have to do.
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Inner wheelarches were a pain but it's coming on :)
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While the van was up on the ramps, I got the chance to thoroughly check it, and found that the cross members at the back of the front wheel arches are starting to go, so they'll get done as well.
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I'm glad to say the van is absolutely solid everywhere else :D , and to help keep it that way, I took the opportunity to tetroseal every-where, but on the new welds. Apparently the MOT inspector needs to be able to inspect new welds, and will fail a van if it has any more than a light coat of primer on them.
Don't fancy trying to remove tetroseal once it's on :shock: So I'll do the back end after the MOT
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The rest looks great now and I made sure an extra thick coating was put on known vulnerable places
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Imagees.

Also took the chance to check all the brake pipes, grease up the handbrake, and check all the bushes, all seems fine.
Just a few wee bits of welding left to do now and some "tidying" but might not get the ramps again till next weekend.
Still, I'm happy with the progress so far :D

I'll keep you posted, but right now I'm off to see if I can get a lift to Slippy's......... :wink:
Last edited by Breakdown Biker on Sun May 24, 2009 3:21 pm, edited 1 time in total.
Where would ya be without a can of W.D?

Mk5 hicube minibus camper conversion
viewtopic.php?f=58&t=43816
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Re: mk5 rotten a?s! - Deadline Slippys Do (help!)

Postby Luke » Sat May 23, 2009 9:25 pm

well done for seeing it through 8) 8)
good job with the underseal too but you could do with waxoil on the insides of the box sections aswell as it can still rot from the inside out :(
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Re: mk5 rotten a?s! - Deadline Slippys Do (help!)

Postby Breakdown Biker » Sat May 23, 2009 9:32 pm

Thanks mate,
Luke wrote:good job with the underseal too but you could do with waxoil on the insides of the box sections aswell as it can still rot from the inside out :(

Yeh gonna do that too, before sealing everything up
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Mk5 hicube minibus camper conversion
viewtopic.php?f=58&t=43816
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Re: mk5 rotten a?s! - Deadline Slippys Do (help!)

Postby Luke » Sat May 23, 2009 9:38 pm

nice one 8) should keep it at bay for years :D

i've got one of theses shultz guns with a pipe attachment for wax so you can get the wax right down into the channels :idea:
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you might aswell do the rest of it while your at it - its a crap job but beats laying on your back welding :lol: :lol:
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Re: mk5 rotten a?s! - Deadline Slippys Do (help!)

Postby Breakdown Biker » Sun May 24, 2009 10:35 am

One of the guys at work has a waxoil gun too, so I just have to buy the tins. :) Any idea how much it will need?
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Mk5 hicube minibus camper conversion
viewtopic.php?f=58&t=43816
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Re: mk5 rotten a?s! - Deadline Slippys Do (Progress + pics)

Postby Luke » Sun May 24, 2009 10:47 am

i think on my swb i used 5 tins of wax - i got dinitrol coromax 3125 from frost - its more expensive than the normal finningans stuff but has much better reviews - any type of wax is a million times better than none tho :!: :lol:

i went mad with mine - working on the theory you can put too much in but you can put not enough :lol:
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Re: mk5 rotten a?s! - Deadline Slippys Do (Progress + pics)

Postby Breakdown Biker » Sun May 24, 2009 3:19 pm

Thanks Luke, I'll get as much as my pocket (and Mrs) allows :lol:
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Mk5 hicube minibus camper conversion
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Re: mk5 rotten a?s! - Deadline Slippys Do (Progress + pics)

Postby Breakdown Biker » Sun May 31, 2009 8:58 am

campervan06 wrote:nice work mines the same

Cheers mate. Yeh yours looks as bad as mine, :( but at least you know it can be sorted out :? I've just got the two wee bits on the front wheel arches to do today, and the MOT a week on Monday, so here's hoping :) Good luck with your repairs
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Mk5 hicube minibus camper conversion
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