Don’t look!

Hidden nasties

Yep, you guessed it, more areas found that will need attention… well I will only be getting the job done once, so I might as well make sure it’s done right! Bit of a monster post as the guys at Southern Kombi Parts have been really busy on the van and making excellent progress – no complaints from me!

What is beyond repair gets cut out ready for replacement metal
What is beyond repair gets cut out ready for replacement metal

Lots of rust to cut out before replacement metal can be welded back in place.

Rot cut out, area cleaned up ready for the next stage
Rot cut out, area cleaned up ready for the next stage

Clean and protect

Once the rust areas have been cut out and the areas cleaned up, time to protect them with primer.

All cleaned up and given a coat of primer ready for the next stage
All cleaned up and given a coat of primer ready for the next stage

Gutter/window perforations can let the water in and it ends up rusting from the inside out without you being aware of it.

Small areas of damage are isolated and cut back to allow new metal to be put back in place
Small areas of damage are isolated and cut back to allow the new metal to be put back in place

Rust on the inside

With water ingress getting inside the structural sections, some areas can rust from the inside out with you being aware of it happening. These areas need to be treated with cavity wax for future protection.

External perforated metal removed to reveal extent of work required
External perforated metal removed to reveal the extent of work required

Once you start cutting back the affected area, the true extent of the work gets revealed!

Rusted window frame has caused rot at the bottom inner/outer sill area
The rusted window frame has caused rot at the bottom inner/outer sill area

Inner and outer rust

The front cab steps needed work on both the inner and outer sides

Cab steps need work on both the outer and inner sides
Cab steps need work on both the outer and inner sides

Looks like there will be a lot of work to sort all this out!

Poor quality inner cab step ‘repair’ simply plated over rusted metal – it’s got to go!
Poor quality inner cab step ‘repair’ simply plated over rusted metal – it’s got to go!

Bad repair

Another quick bodge type repair was unearthed! Another one that will need removing to be done again properly!

Replacement metal in place and given a coat of primer
Replacement metal in place and given a coat of primer

New metal going back in place ready to be primed for protection

Outer repair beginning to take shape
Outer repair beginning to take shape
Inner repair can now take place
The inner repair can now take place

Both sides at once

Keeping as much original metal as possible, the inner and outer rusted areas are removed and replaced with new metal as things start to get back to shape again.

Inner repair begins to to get welded in place and take shape
Inner repair begins to get welded in place and take shape

That’s looking a bit better now!

Replacement metal in place and taking shape
Replacement metal in place and taking shape

Inner and outer sections rebuilt

One section of metal repair work begins to come together nicely
One section of metal repair work begins to come together nicely

Strong passion

During the stripping out of the van, we found some inspirational words to keep us motivated as the work progressed…

A hidden sign of encouragement revealed :-)
A hidden sign of encouragement revealed 🙂

‘I need stronger Passions to create’ – wise words indeed!

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