rust is just so yesterday, nu metal rocks!

OK, time for some more updates. Good news is that pretty much all the ‘not so good’ areas have been found now, so the process of cutting out the rusty, damaged or perforated areas is pretty much completed, so now the bus can get new metal or replacement panels welded back in place!

Bare metal all cleaned up…
Bare metal all cleaned up…
…and given a protective coat of primer
…and given a protective coat of primer

I’m trying to keep as much of the OG metal as possible, so where a localised area is rusted through, then it is cut back to solid metal and new metal is welded back in place to create an invisible repair.

Localised pinhole damaged areas cut out to preserve as much OG metal as possible…
Localised pinhole damaged areas cut out to preserve as much OG metal as possible…
…and new metal welded back into place
…and new metal welded back into place
More localised repairs, old rusted metal cut out…
More localised repairs, old rusted metal cut out…
…and new metal welded back into place
…and new metal welded back into place

Unfortunately there were areas that were too far gone and the best route was to use replacement panels, such as the front valence

New inner front valence panels ready to go in
New inner front valence panels ready to go in
New inner front valence welded in place
New inner front valence welded in place
New inner front valence welded in as the lower front gets rebuilt
New inner front valence welded in as the lower front gets rebuilt
The lower front gets rebuilt inside and out, all nice and solid again
The lower front gets rebuilt inside and out, all nice and solid again
Rather than rust and perforated metal, good solid new metal takes its place!
Rather than rust and perforated metal, good solid new metal takes its place!
The repairs are looking good and solid as the strength is returned to the bus
The repairs are looking good and solid as the strength is returned to the bus

So far, so good, things are progressing nicely. It is going to be a really 100% solid bus when the metal work is completed.

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