Panel replacement work underway !

[rover]

Best to do it from inside

Besides, if you dont remove the ply lining you WILL set fire to it

Rover.

[fmr]

Ohh I was going to get the wife to sit in the corner of the van in her leather trousers, holding a watering can, just in case it got too hot
Ply-lining out then

Phil

[rover]

Ohh I was going to get the wife to sit in the corner of the van in her leather trousers, holding a watering can, just in case it got too hot
Ply-lining out then

Phil

If my other half was sat in the corner of the van with leather trousers on there wouldnt be much welding getting done

Rover.

[Retrohowla]

I have done both, from inside and underside, ply may take a bit of effort to get out but you will have a much better finnished product if you weld it inside

[fmr]

Rover you rude man !!!!

I have done both, from inside and underside, ply may take a bit of effort to get out but you will have a much better finnished product if you weld it inside

Looks like the ply-lining kit was put in by a pro some years ago Problem is every joint has mastic in it

Phil

[Retrohowla]

Do you have a skill saw?

this needs allot of care and skill but.............

set saw cutting depth to 1 mm less than floor ply thickness, now gust rip straight up the middle from back doors to seats, then adjust saw about another half mm deeper and repeat (if you havent already gone through ply)
then crowbar under cut at back doors and prise up ply one side all way allong, then you can take out one side without disturbing the side pannels

only adviseable if your S**t hot on the tools though!!!!!!!!!!!!!!

if unsure start first cut at half depth and work deeper mm at a time untill almost through

best to leave very thin bit joining two halves still and just break it with the bar, minimal mess that sands down after

[fmr]

Nice idea but being a little heavy handed I can see myself slicing the van in half

Phil

[Retrohowla]

If it makes you feel any better i found this on the mk2 when i went to pull out the motor today..........




we all have to deal with it

[djswampy]

Oh my goodness.

[fmr]

Good grief retrohowla, the old metal mites have been busy there

I really don't know where I would start. Get busy mate then you can come round and make a start on mine

Found my own solution to removing that corner of ply-lined floor........ANGLE GRINDER Took a while for the smoke to clear but gained access from above and below

Will add more photos soon.

Phil

[Retrohowla]

I think i might start on the off side somewhere........................

ita not all bad, the chassis rails are ok still just the front cross member and front panel are near on non existant, was patched up with all sorts and filled and spayed to hide it, then i came allong and thought i would start poking only to find the horrorshow beneath.....



looks like i am gonna be a busy boy

[fmr]

Pictures of progress as promised.

After cutting out a section of ply-lined floor I managed to get access to the rotten floor from above here you see the extent of the rust cut out.


A picture from further away showing the ply-lined cut out floor.


Made a cardboard template of section, drew around this on the steel plate below.


Here we see the section cut out of steel using the angle grinder.


Steel section in place, now all we need is a decent welder.


More to follow as I progress.

Phil

[MarkM]

Personally I would call a halt right now and remove the rest of the ply floor to see what else it is hiding...just because the rot isn't showing through underneath doesn't mean it isn't all paper thin on the plyside.

[OxtonyxO]

yep i know that feeling

[Retrohowla]

I live in fear of what i might find under my ply floor, it wont be comming up untill i have the engine driving the damn thing allong!!!!