you don’t know jack unless you look

Right, with one side of the bulkhead sorted, we need to sort of the rear side/inner arch area next.

Rear of bulkhead/inner arch sorted
Rear of bulkhead/inner arch sorted

OK, so what was going on under the recently painted areas? Good solid repairs? Only one real way to find out…

Inner Sill/Jacking point not looking too clever!
Inner Sill/Jacking point not looking too clever!

Errrrrr, not so good! The Jacking point/inner sill area are not looking too clever, and a quick coat of paint will not make the problems disappear!

So the usual process of cutting back the metal to a good solid area begins, so that replacement metal and a new jacking point can be welded back into place.

Cut out rusted area of inner sill under sliding/cargo door
Cut out rusted area of inner sill under sliding/cargo door

Replacement section gets put back into place…

Repair inner sill area under sliding/cargo door
Repair inner sill area under sliding/cargo door

…before welding in a new replacement jacking point.

Weld in place replacement Jacking point
Weld in place replacement Jacking point

Now back to the inner arch area to replace the other painted over ‘repaired’ area, but this time with good solid metal welded back into place!

Replace previous poor quality repaired area
Replace previous poor quality repaired area

Once the replacement sections are welded into place, the welds are then cleaned up, ground back and the area given a protective coat of Red Oxide primer before seam sealing all the joint edges for added protection.

Give a protective coat of Red Oxide primer and seam seal all joints for added protection
Give a protective coat of Red Oxide primer and seam seal all joints for added protection

Once the final preparation is undertaken, these will all disappear under multiple coats of primer and top coat so it will look like new again, but this time 100% solid!

Now that the days are getting to get a bit longer and the sun is out, I can’t wait to get this classic VW Westafalia Camper back on the road again, it is what it was made for, summer fun!

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