My '96 150 Custom LWB High Top

[MinorMatt]

Yup... what he has done is great

I had a minor incident when I went to the transit center in Dudley on Friday to pillage bits of a tourneo... the gate closed on me and needless to say I didn't stop in time and its put a crease in the passenger door (taking the handle with it), sld and rear panel

So I changed the handle today (it pulled one of the bolts through and nearly pulled the other one through) and it opens the door much more nicely now! I've also stuck a new backbox on, changed the clock for one that works (including backlight!).

I have also made a start on changing both propshaft bearings (rubber knackered on both). All went well until the propshaft fell apart... one of the bolts/lock washer etc was missing very lucky it hadn't fallen apart! Hoping I can get the bits tomorrow!

[MinorMatt]

Long time no update!

Next to nothing done except changing the clutch (fitting the big SVO type) and fitting an LED light bar and strobes.

But its MOT time... so I've started looking at some of the rot...







Not too horrendous...





Looking promising!



Hmm maybe not







My grinder slipped a bit...



Just as well I have a few bits in stock...



Spot the difference... guess which one is going on??

[BROWNYS V6]

id say the one on the left is genuine and that pile of new panels looks like it will keep you busy for a bit

[captain hook]

It's threads like this that make me so happy that there's been no rust or welding to be sorted on my van for the last seven years.
Oh the joys of owning a good Mk5
Just a shame I've got to let it go this year

[MinorMatt]

Yes its a genuine inner wing at first glance the pattern one is pretty close - but then you start looking and its all over the place!

I have the pattern one in case the inner needed a little bit of patching... and if I didn't have the genuine one it would have done the job... but as I do have the genuine one it make sense to fit the whole thing!

I guess it will be an evening of drilling out spot welds tonight!

[MinorMatt]

A bit more cutting and thinking today...

Remains of inner arch removed



Cut a little bit more rot out



Cardboard template...



I suspect tomorrow will be yet more cutting, with metal starting to go back later in the week.

I am debating whether to replace the complete bottom of the step at the moment, but whats left is good, so I need to have a think!

[kalkat]

Is that one of my screwdrivers I spy? ............ don't bugger it up please!

I'm surprised the bodging lasted as well as it did, espesh as it was raining (and dark by the time it was painted) when it was done

[MinorMatt]

Yes you did well!

[MinorMatt]

I've spent a couple of hours fabricating a new front step outrigger this evening. Not quite the same as the factory one - but should fit properly!

Its a suprisingly odd shaped part!




The old one isn't out yet... but it looks like it will fit!

[BROWNYS V6]

nice work matt

[kalkat]

Aaah! ....... but will it fit as well as the cardboard and F/G one did?

[MinorMatt]

Given the cardboard distorts to fit.... I doubt it.

This is what seam sealer is for!!

[MinorMatt]

My fabricated panel didn't fit at all... the angle at the front of the step was completely wrong - so I'm just using the plain simple box section bit now!

But a few more bits cut out and a few more bits put on!

Old outrigger removed



A bit more rust removed



And... some new metal going in

[kalkat]

That's a shame - that were a nice bit of fabbing

[MinorMatt]

Most of it will be reused - just needs modification