My '96 150 Custom LWB High Top

[derv23]

Looking good MM

[MinorMatt]

Thanks

The front wing isn't the best fit... so I may need to look again at that in the future. Other than that i'm fairy happy with it.

I've been looking at last years MOT... the advisory list was a bit long...

Advisory notice item(s)
Nearside Front wheel bearing has slight play (2.5.A.3c) now fixed - just required nipping up
Nearside Outer Rear Suspension component mounting prescribed area is corroded but not considered excessive (2.4.A.3)
Not sure which bit this is... possibly chassis above the bump stop? Will fix as part of this welding campaign
Offside Outer Rear Suspension component mounting prescribed area is corroded but not considered excessive (2.4.A.3)
As above
Offside Front Suspension component mounting prescribed area is corroded but not considered excessive (2.4.A.3)
This was the holes in the front crossmember - welded last night
Nearside Inner Front Seat belt anchorage prescribed area is corroded but not considered excessive (5.2.6)
The whole area as been welded within an inch of its life
Parking brake lever has little reserve travel (3.1.6b)
Was as described but working well - but 10 milea from home it became "squishy" so needs investigation before MOT
Play in prop-shaft centre bearing
Done within a few days of previous MOT
Play in steering rack inner joint(s)
This has been an advisory since 2012... new track rods and track rod ends fitted at the weekend

As you may guess - I am trying to get an MOT with no advisories this year... we shall see if it happens!

[RustWidow]

Well, you're going the right way for that ain't you? Good luck for a "clean" MOT

[CHR15E]

Just read the whole thread, that's some effort.

[MinorMatt]

Its all pretty standard stuff... but I did cheat and pay dieselhead to do the work at the back.

Its starting to get to the point where its starting to become properly solid again!

[CHR15E]

I dare say but to want to save it is impressive.

My dad had a similar van a good 10 years back, he got fed up of the welding that needed. Though to be fair he only ever did enough for the MOT each year.

I guess the key is to go to town on it and get it right from the off?

[MinorMatt]

I could have patched it up and got a quick test... but yes do the job properly and do it once.

After this test I am hoping for no more MOT welding for a few years, just a bit of bodywork tidying

[MinorMatt]

I got back from my job (proper work) in Kent last night having been away since friday afternoon. The van is now out of MOT

I couldn't really be bothered to do much tonight so I have just fitted my aftermarket battery tray and put my sod off big leisure batt on the (now solid) passenger side inner wing with plenty of waxoyl underneath!

[transitabout]

looking good mate

[MinorMatt]

I'm going to make a start on the front spring hanger this afternoon - I might make a "how too" post.

Hopefully all the MOT welding will be done this weekend too, then its just fixing the handbrake (and fitting the quaife diff)

[MinorMatt]

Arrgh its raining! I have started removing the old spring hanger but haven't got far because its bucketing down

[derv23]

Gives you time for the 'how to ' compilation

Been miserable up my way (inverness-shire) past couple days

[MinorMatt]

More time spent on the van. I will not be doing a how too as I didn't do it in a conventional way.



The repair panel is totally the wrong shape for a mk5... so it was picked apart (24 spot welds one side, 23 the other)



You can see quite clearly that the inner part steps up - whereas the mk5 chassis is straight... so a new center was made out of 75x75x3mm box section



The chassis area cut out (most of it was ok, but some was rusty and some was damaged during removal, so easier to cut it all out



Replacement chassis let in (again made from the 3mm thick box section) and the inner section welded in place



Then putting the (now cosmetic) bits on...





So all welded up, nice and solid and almost certainly stronger than the factory arrangement. Just seam sealed and chassis black applied after the pics

Next job... brakes and diff

[BROWNYS V6]

that looks like it turned into a b*stard job, how many spot welds
nice job

[MinorMatt]

A bit more tonight after work

Drivers side front step outrigger... DONE!

Front end is now finished apart from putting some bits of trim back!

Fibreglass off



This is the underside



Rusty stuff removed



And new metal in



Seam sealed and painted



I also attacked the step inside





Looks better in blue



If its dry tomorrow the back end is going to get some attention