[chris161190]

More bare metalling, rear panel behind the sliding door, this panel was replaced 15 years ago and although had its fair share of filler like everywhere else is pretty good and flat!
the p36 sanding discs I bought made quick work of stripping this large area!

not quite up to date and I’ve now stripped most of the window aperture too but forgot to take a snap.

the van is currently at my place of work so I can do 30 mins before I start 30 mins after a quick lunch and 30 mins after work which soon gets through the hours!

Chris.

 

[chris161190]

Also been filling my attic with cleaned/ restored parts knowing if it’s up there it’s been cleaned, checked or repaired and ready to go back on.

 

[chris161190]

More stripping over the last few days, slowly getting there taking out layers of old paint from seal channels, nooks and crannies window apertures but starting to look good!

and engine out too! Wanted to give it a good clean and a service whilst the van is gone!

Chris.

 

[chris161190]

Yet more bare metalling and odd jobs of welding.
my welding is shit and I have a friend who is more than good and enjoys doing it with me so any odd holes or bits that needed doing as a result of removing old paint and filler are being done...

Side panel and gutters all stripped, nothing to report here there are a few badly repaired dents in the higher section of the rear corner but I should be able to beat these out without too much drama.

Small patch also needed in tailgate seal channel...

So happy to be going all the way back to metal, there won’t be any bad previous repairs underneath this time around....

Two dents in the rear corner, quite significant but my panel beating skills although basic aren’t too bad so should be able to get the bulk of these out...

Then got the van back inside, cleaned and degreased with alcohol before a couple of light coats of epoxy primer upto where I’ve got....

 

[chris161190]

Shows the dents I need to pull out in the rear corner....
Would have got these out before priming but I needed to get that section primed yesterday so will have to get them out after and reprime that local area

and the small patch in the seal channel

Afterwards I moved onto the offside rear corner which I knew was a little more suspect but didn’t think it was as bad as it was so we’ve chopped out the corner along with the battery tray and lower section of the D post.
Luckily I have a skilled friend will to help!

Out with the crusty!

Chris.

 

[chris161190]

An hour today saw that dent pretty much removed...

The one in the swage line above will be harder on account of access being much poorer but we’ll see how that one goes!

Chris.

 

[chris161190]

Finally finished the stripping today!
so happy to have got all this done, some more welding this evening and we’re getting there! There are a few dents to pull and scabby bits on this side that need sorting but progress non the less!

Last delivery of panels arrived from Alan H Scholfields, their panels fit like Lego!

Chris.

 

[chris161190]

Last part of the van in epoxy primer, they’ll be more to do as the last of the welding is done but now protected again, we’ve been lucky to have such dry warm weather recently which has helped to keep the pressure off a bit...

zinc rich non porous epoxy is now the base below any filler needed for a completely sealed base

Panels back from blasting, the large flats have been left to bare metal by hand to avoid distortion.

And finally today stripped the face of the sliding door and got it in epoxy...

Chris.

 

[chris161190]

lots of progress updates today. Firstly got the new inner rear valance in…

chassis rails prepped

insude of chassis rails slathered in rust remedy and panel offered in…

D post lower sections then going in.

New wheel arch closing panel in and then battery trays…

 

[chris161190]

Rear corners were next on the list, the existing panel was joggled everything plug welded with the join on the exterior to be stitch welded afterwards…

and repeated the other side

Finally the outer rear valance went on…

Panels then stitch welded and ground down,

Everything bare metalled again and epoxy primed.

 

[chris161190]

Lastly was the lower section of the panel opposite the sliding door which had had a whack sometime in the vans early life, this was the most filler I’d found on the van at about 20mm thick!

This will still need some beating and a skin of filler but loads better than it was!

 

[chris161190]

Yesterday morning the van was loaded up and sent for paint!

Chris.

 

[chris161190]

Bits continuing whilst the van is at paint…

Dashboard has been blasted and had a couple of coats of epoxy primer, matching top coat arrived with us today and will be sprayed tomorrow. I’ll try not to spill brake fluid on it this time!

Chris.

 

[chris161190]

Tailgate blasted, repaired and primed, will drop this off with the painters on Saturday morning…

 

[crispies]

Looks like a good solid bus now, what colour scheme you going for...
ours is in progress too at the moment hopefully another couple of weeks and will be in epoxy primer too. Dare I ask rough cost for painting to give me a guide.....

 

[crispies]

Got my big front brakes all on bled and tested!

They revolve around a t4 vented front disc and amorok/ mk7 transit front calipers. It's a Bosch unit used on both vehicles as far as I'm aware.
These calipers have the same bore as stock bay so still use two 41mm pistons so fine for the stock master cylinder but are a sliding caliper so the pistons work together meaning a much larger pad that stock bay window. This means that the pedal should be similar feel to stock but with more braking ability...
Brackets are milled from 1" thick steel so no questions regarding strength there. And boy does it stop now! Also powder coated yellow like the rears. With no chance of the discs warping now during heavy braking with the thicker vented t4 item.

Fills up the wheels well...

Chris

what set up did you use on rears, we used Mk4 golf/sharman combination

 

[chris161190]

Looks like a good solid bus now, what colour scheme you going for...
ours is in progress too at the moment hopefully another couple of weeks and will be in epoxy primer too. Dare I ask rough cost for painting to give me a guide.....

Not sure on final cost, it was one thing first based on a simple resorts but after the amount of metwl work that’s been done, needs something more….
bmw alpine white on top, RAL 9007 to match the wheels below

 

[chris161190]

what set up did you use on rears, we used Mk4 golf/sharman combination

Yes similar, sharan discs and golf mk3 callipers….

 

[chris161190]

Dashboard top coated…. Looks a little grey from reflections in the booth but spot on in the sun

 

[chris161190]

Been to the painters this morning to have a look at progress, a lot of the skimming has been done, and starting to look flat!

Should be primed next week!