Chapter 6 - Holy Moly!

My apologies for the tardiness of my latest exploits I caught a nasty virus from someone at work, and by the time I'd finished my normal "9 to 5", i was taking 2 Anadin extra and crashing out in bed, trying to sweat the foulness out of myself. so I've had a week off the van, and some time to order and shop for some bits and bobs for the van. (more of that later)

My original expectations of the work required to get this van mot'ed seem to be getting longer and longer.

On top of the 4 arches, sill, rear corner valances, and lower front panel lip, i have found that all 4 inner arches require some if not a lot of work before any major panels can be fitted, i'd also discovered the the plate above the rear trailing arm had rotted away, and required replacing, I've also discovered this:

This is a shot of inside the rear wheel arch, showing the rear chassis leg, part of the wiring loom, and where the engine bay bulkhead actually meets the chassis leg (or should that say where it should meet?)

The engine bay bulkhead has a 8 inch long and 1 inch wide slot in it now ( the position inside the engine bay is where the coil bolts to! (you can just see the two screw holes!))

Anyhow, as you can see i've brushed off all the dirt and muck, and poked it all out, all thats left is to move the damper, out of the way, cut the rusty edge out, and fit a plate - I've just knocked up a template or two (8 actually so far!)

For those of you unfamiliar with this process, the way to make your plates in mild steel, is to fabricate the plate, in cardboard, trimming the shape perfectly, and there by making drawing it out on a piece of steel easier, and ensuring that if fits as it should when you get it in place (well that's the idea!)

I also noticed some paint on the floor flaking, and got the grinder out ,

To be fair,the rusty edge was only about 4 inches long and was the beginning of turning nasty, so i cut it back to within a inch of good steel, zinc primer'ed it, & made a plate -  The daylight you can see is because the outer sill, on that side has already been removed! (this is directly above the sill)

This is the 2mm thick steel plate thats about to be welded into that hole

Here's a picture of Lee, welding it - not entirely sure that he's got the wire brush in the right pocket, but that's just reminded me to order a new one for just me, lol

We've welded it in already, but I've not ground it back and cleaned it up or painted it yet

I'm back tomorrow, weather permitting, to carry on with the patching up, so i'll try to get some more pics of it finished.

I've also been preparing areas, while making templates,

Before we can fit the front arches ( and patch up any holes) i need to peel away the remains of the front arch (if you look along the rusty line you can see where we cut the old one off and where the new one will fix to

In this shot you can see where were pealing that old bit of steel away (a small flat chisel, and a bit of patience is required - originals are spot welded to the a-post)

With it peeled off, i'll finish wire brushing & grinding this to prepare it to have the rot at the bottom cut out, and another plate fitted (in the middle, you can see where i have stripped back the sealer, and the steel is still grey!)

Right time for some kip, weather permitting i'll have a load more to report on - night - Pleasant dubs ;)