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Ex John Lewis MK5, 2.5TDi 85ps Automatic & Air Con.

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Re: Ex John Lewis MK5, 2.5TDi 85ps Automatic & Air Con.

Postby RustWidow » Tue Aug 06, 2013 9:18 pm

NAD!!!! Soo good to see you back, only just stumbled on this thread - wicked cakes - puts me well to shame - but then, I don't do it as a living and am busy studying... not telling you for what on here! I'll get lynched! (no, not a car parking attendent/traffic warden) hehehhee

Would be good to see you at 'mania - haven't seen you for ages - well, not since you had that bump that has obviously turned into a sprog (kid) :lol:

If you can make a gluten-free cake for 'mania that would be AWESOME... I'll just stick to making some bbq sauce yeah.. i know, not quite the same!

Well done on keeping Lewis running... fingers crossed for the MOT, Delilah passed hers today but only just because she needs new brake pads - which have been bought.... just waiting on that clever old so and so of a husband to fit them!

Keep in touch hun
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Re: Ex John Lewis MK5, 2.5TDi 85ps Automatic & Air Con.

Postby Nadjenka » Sat Aug 10, 2013 11:00 pm

RustWidow wrote:NAD!!!! Soo good to see you back...


Hellooo right back!!! :mrgreen: Yeah, the little one is out and about, running, talking and messing everything up, yet I kept my bum lolol :lol: Times goes fast when you're... errrm, how does it go... don't get to sleep?? :? :lol: :lol: :roll: Oh well, we might see you and catch up at Transitmania, would be lovely to see you! 8) :mrgreen:
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1999 Mk5 190 LWB 2.5TDi, automatic, story has started :twisted:
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Re: Ex John Lewis MK5, 2.5TDi 85ps Automatic & Air Con.

Postby Nadjenka » Sat Aug 10, 2013 11:06 pm

The time has come to meet the welder 8) MOT runs out this week, jeees where did the year go again?? :?

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Some new metal surely will please the MOT man :mrgreen: :lol:
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Hmmm, didn't expect THAT... :o
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Well loads to do, lucky it's not me doing the hard work, it might actually look presentable this time round :lol: :lol: :mrgreen:
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1995 Mk5 150 LWB Minibus - camper-to-be - Lola's story :mrgreen:
1999 Mk5 190 LWB 2.5TDi, automatic, story has started :twisted:
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Re: Ex John Lewis MK5, 2.5TDi 85ps Automatic & Air Con.

Postby AlanN » Sat Aug 10, 2013 11:13 pm

Great to see some being done, look forward to seeing you and the family :wink:
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Re: Ex John Lewis MK5, 2.5TDi 85ps Automatic & Air Con.

Postby MinorMatt » Sun Jan 26, 2014 8:58 pm

Stuff has happened...

That is all :P
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Re: Ex John Lewis MK5, 2.5TDi 85ps Automatic & Air Con.

Postby Muttley » Sun Jan 26, 2014 11:01 pm

Oh yeah, like we are going to leave it at that :lol:
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Re: Ex John Lewis MK5, 2.5TDi 85ps Automatic & Air Con.

Postby kalkat » Sun Jan 26, 2014 11:30 pm

............. you'll have to wait for Nada to post :wink:
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Re: Ex John Lewis MK5, 2.5TDi 85ps Automatic & Air Con.

Postby transitandy » Mon Jan 27, 2014 12:42 am

8) 8) 8)
TRANSIT M8, SAY NO MORE YOUR IN...... FORD THROUGH TO THE BONE......
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Re: Ex John Lewis MK5, 2.5TDi 85ps Automatic & Air Con.

Postby Nadjenka » Mon Jan 27, 2014 1:56 am

Well I wish I could work out how to make these pictures bigger, but seems to be more stubborn and definitely less sleepy than me lol, so we'll just have to carry on teasing for now... magnifying glasses at the ready... 8)

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I'll see if I can persuade photobucket to let me see larger images when I'm on computer tomorrow, but for sure you can appreciate the magnitude of the task undertaken by Kalkat and Matt even without the magnifying glass 8) Things are finally happening for sure :mrgreen: :mrgreen:
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Re: Ex John Lewis MK5, 2.5TDi 85ps Automatic & Air Con.

Postby MinorMatt » Mon Jan 27, 2014 9:04 am

Arrgh - just wrote this up, pressed the wrong button and lost it :twisted:

Anyway... last Sunday (19th) Nada delivered the John Lewis van to my workshop for Kalkat to give it a spruce up...

Up until friday, Kalkat had stripped the van of most of its trim, lights etc - but was waiting for a 2nd person to do the doors (me!)

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I got there before Kalkat on Friday and got to work with the welder.

I haven't looked closely, but a quick glance suugests the rear of the van (up to the cab) is 100% solid to the mudflap (only the 1!). I started by attacking the side that looked worst underneath, cut out the rot and welded in a repair to the mudflap mount

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At which point Kalkat turned up... and it was decided I should look at the other side, to make the body side as stiff as possible, and get datums fixed for what she needed to do. At this point the rear floor liner was removed (the proper plastic ford one) and the floor pan assessed. Other than it looks like an elephant has been dancing over the axle, on the whole its not too bad, just a few repairs to make on the rear floorpan section.

Starting on the drivers side... I cut away the floorpan where it was rotton above the mudflap, and found the top return on the sill was perforated in lots of places, and the end of the chassis outrigger was also iffy...

So it was all cut out, a repair section made and welded in to place.

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The metalwork around the wheel arch, up to the join with the next floor pan section was distinctly frilly, so this was also cut out and replaced and the floor replaced over the inner sill/chassis repair

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At this point it was decided to conserve the welding gas until I can get the 2nd bottle refilled - and that Kalkat should start the outer panelwork!

I got on with prepping iffy areas for welding

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Caught in time :) - The chassis needs one small localised repair on the top hat, but other than that its in remarkably good condition

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Passenger side

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This has been cut out and prepped (but forgot the pic)

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and there are 2 small holes (1.5 x 3") on the rear cross member to do, and an area in front of the wheelarch. There is no readily identifyable corrosion in the join between the wheel arch and the majority of the floorpan on this side - so no full length repairs required...

Oh look... Kalkats done it again.... :shock:

Before:

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After:

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Theres not a huge amount of space around the van (3-4 ft on one side, 1-2 ft on the other) so this is very much a one side at a time job!
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96 P 150 TD 100PS LWB Hi-Top

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Re: Ex John Lewis MK5, 2.5TDi 85ps Automatic & Air Con.

Postby Muttley » Mon Jan 27, 2014 9:38 pm

She do like a rusty van, that Nada :shock:
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Re: Ex John Lewis MK5, 2.5TDi 85ps Automatic & Air Con.

Postby kalkat » Mon Jan 27, 2014 9:49 pm

It's not only the rust - of which there's not as much as many - it's the way previous owners have tried driving THROUGH bollards and gateposts :shock:
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Re: Ex John Lewis MK5, 2.5TDi 85ps Automatic & Air Con.

Postby Mr RVM » Mon Jan 27, 2014 11:03 pm

Muttley wrote:She do like a rusty van, that Nada :shock:


We ALL do :!: otherwise this forum would be a very quiet place :!: :lol: :lol: :lol:

And all those grinders and mig welders are doing my shares in the national grid a power of good (no pun intended) :lol: :lol: :lol:
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Re: Ex John Lewis MK5, 2.5TDi 85ps Automatic & Air Con.

Postby kalkat » Mon Jan 27, 2014 11:22 pm

And all those grinders and mig welders are doing my shares in the national grid a power of good


......... and those who have shares in angle grinders. I kill at least three a year :twisted:
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Re: Ex John Lewis MK5, 2.5TDi 85ps Automatic & Air Con.

Postby Mr RVM » Mon Jan 27, 2014 11:45 pm

Ive got about half a dozen now each set up with a different "wheel" flapwheel, twisted knot wire brush, slitting disc etc so i dont have to keep changing them :!: amongst them is the first one I ever bought when i was 18 its a black and decker professional and it cost 2 weeks wages at the time (about £70/80 if i remember) its still working well and I'm nearly 52 now :)
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