Conrod's 2018 rebuild

[conrod]

I have a bit of spare time, as NZ is about to go into full lockdown across the country to try and control the spread of COVID-19, so I thought I would start a build thread on this, and detail the work so far.

I bought this van at a damaged vehicle auction last year. It is a 2018 L1H1, 170hp auto, with only 11,000 kms on the clock. It is a base model I think, with the added option of the large Sync 3 infotainment screen and heated seats. It has the barn rear doors, and LH side loading door (none on right) which happens to be the layout I like most. Most of the NZ specced vans seem to be similar to this.

Looks like it was struck at about 90° from the LF corner, which did a lot of dame to the LF corner. LH chassis rail was quite bent, as well as front bumper, bonnet, radiators, etc. Fortunately no suspension damage, and even though the coolers were bent they did not rupture, so I was able to take it for a drive before dismantling it, and it drove perfectly!

[conrod]

First job was to desticker it, and give it a good clean

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Before the stripdown, I had bought a set of projector Halogen lights, to replace the broken base halogens. Gave them a quick test to see if they would work, they did!

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Then the stripdown began. Everything forward of the bulkhead was removed, as well as the subframe and front suspension.

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You can see in this next pic the LH chassis rail is quite bent!

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[John webbo]

I think 'quite bent' is a bit of an understatement !
Will you be able to pull this back straight, or are new chassis legs available to replace it ?

[conrod]

I think 'quite bent' is a bit of an understatement !
Will you be able to pull this back straight, or are new chassis legs available to replace it ?

yes it has had a good nudge! New parts are available (bought them already as you will see shortly) The chassis leg has a join in it about a metre back from the front, so we will be replacing this entire section, as well as the inner wing and all supporting panels.

Basically anything that is bent gets replaced, pretty much no attempting to repair or fix damaged parts. As well as being the best way to repair a job like this, it is actually a requirement in NZ now that all work has to be certified by an independent engineer, who oversees the whole job, and signs it off, prior to the vehicle being put back on the road. While it adds to the cost and timeframe of repairs, the intent of the law is that it ensures that no bodgy and unsafe repairs are done on written off vehicles.

[conrod]

Okay I am going to fast forward this story a bit to two weeks ago, just before lockdown. I had completely stripped EVERYTHING out of the engine bay, and took a lot of pics. But my computer crashed and I lost everything, hence the fast fwd.
LH chassis rail was completely replaced, it ends at the subframe mount. This also required a new subframe mount, as you need to pick that off first. New inner wing and all of the various brackets, reinforcements etc. RH chassis rail just needed a new end cap welded on. Here are a few pics of it on the chassis machine, prior to heading off for paint. Which won't happen now until lockdown ends, and we can all get back to work!

[conrod]

front end has been painted now, and I refitted the suspension to make it mobile. Next stop is the paint booth, for a complete respray. Unfortunately whoever removed the stickers on the doors (before I purchased it) used some sort of sharp instrument, which gouged into the paint on the doors. It also had some auxiliary LED lights fitted on the rear quarters and rear doors. So these were removed, and the holes welded up. A few small dings here and there, and about the only thing which won't need painting is the roof!

[Altransit]

Nice work buddy

[Chug]

Great work, good to see skills like yours documented, keep em coming.

[S60r]

Huge respect for your work.


I removed some stickers and all the badges from my custom (I do it on every vehicle so I've done it lots without issue) This 2018 custom I now have left all its paint on the underside of the stickers... TERRIBLE paint job! I had to have it all blown back in and it looks good now... the paint and/or lacquer is not good on mine.

[conrod]

All finished from panel and paint, and I picked it up today

Now I just need to begin the reassembly process, and hope I can remember where everything went!

Got the old Mk2 still working hard

[Altransit]

[conrod]

a busy week! Got the engine bay refitted with everything, and installed engine/trans today. Will refit front suspension tomorrow, and should be able to fire it up

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[conrod]

Making good progress. All mechanical work done now, and I took it for a quick drive up the road, all seems okay, apart from a few warning lights on the dash which will need resetting.

Been fitting the 'bodywork" for the last week or two, it is a complete PITA to fit, but is starting to look quite good now

[karl]

nice work

[TallPaul]

I like those body moulding clamps, I've never seen them before, where did you get them and are they any good? Better than masking tape??