top job fella. might give my van a bit of welding tlc.
interesting thread as i have a 2000 MK5 Luton with about the same amount of rust :/ As I live in it I would be daft not to repair it
I saw a diagram of the body structure of the latest Transit to come out --- almost all of the cab (everything forward of the 'B' pillar) is either Boron steel or a 'high strength' steel.
The load area floor still seems to be the usual automotive stuff.
I doubt there will be many examples of the latest van being lovingly put back on the road once they start failing MOTs through rust.
Give it twenty years and they'll be full of rivets. The MOT manual will have to change to allow riveting of exotic chassis members and panels.
Incidentally we saw one on the road today. My friend and I both looked at it and said "its starting to look more and more like a classic bedford shape". That was a 63 plate van, that would've passed at a cursory glance (were the paint not so bright)for a van from the original Italian job film.
From what I've read elsewhere most vehicles are scrapped when only 7% of the metal has corroded
Thanks. Be my guest.
Do ford even use token rustproofing ? Anyway , great work well done.
It appears not lol
Knocked up some drop in pins to attach a ratchet strap to form a safety rail for guys handling cylinders on the bed of the truck.
Then welded them on...
More chassis repair sections...
These stiffener sections had to be re made as they were too far gone.
These reinforce the area over the bump stops.
Should've filled the dents but time was getting scarce by this stage and we needed the truck back on the road earning again.
After all that the heater matrix and fan packed up...
Looking good mate, that certainly has been quite a re build, well done indeed.
That's a nice tranny. :-)
Thanks. It's not a job I'm keen to repeat but we've got another two to do. Fortunately it's just the metalwork this time, body prep and painting will be farmed out to a friendly local paint shop.
I'm going to see about investing in a secondhand four post lift before we tackle the next try though as lying on the concrete in the cold and rain isn't my idea of a good time
Nahh that the horrible part Jim and it makes it hard to motivate yourself to get on and do it, I recently bought myself one of those vehicle rollers, but I wouldn't think you could put something as big as a transit on one of them.
Tell me, with the cost of your time, all the consumables and the painting is it really worth doing? Shirley :-) you could by a second hand one for similar cost?
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old smiley face tranny pick up can carry approx 1500kilos
new tranny pick you are down to under a 1000kilos
hence the repairs also newer tranny are unreliable with with pump problems electrics etc
Few reasons really, main one is as said there is no viable alternative to the 3.5 tonne truck for us, the 7.5 tonne route looks attractive, but the added costs of servicing, operators licence, CPC and insurance, plus the cost of ADR trained drivers made it uneconomically viable.
We deliver a fair amount of manifolded banks, basically a pallet with 12 cylinders linked together with an assembly of pipes with an outlet on each side and a big armoured canopy to protect the pipes up top. These can weigh in excess of 1400 kilos and we haven't found anything better than the Mk 5 Transit for carrying them.
Sure, we could use a modern truck, ditch the tail lift and cut down the bed to the bare minimum, but it would be useless for carrying the individual cylinders.
We've put galactic miles on these old trucks and the mechanicals are utterly bombproof, ok the bodywork and chassis are prone to rot but we let them go way too far before tackling them so a lot of that is our own fault. I'm sure there are better examples to start with but our trucks are known quantities, some have had engine swaps, or back axle rebuilds and you could find one with a tidy body but come unstuck with bodged mechanicals so we stick with what we know.
As for time invested, we reckon it cost 6k to rebuild that truck (a lot of mechanical bits were sorted too during the course of the job) and on the face of it that seems like a lot of money to spend on a vehicle of that age, BUT it's out on the road 5 days a week and clocks up 45,000 miles a year and it takes very little in the way of upkeep to make it reliable, no £1,500 electronic injector pump, no dual mass flywheel, hell, if you snap a timing belt it does no damage at all to the engine, buy 8 new pushrods and a timing belt kit and you're back in business in a couple of hours.
They are noisy, and slow, and they have nothing in the way of creature comforts, but for the job of moving heavy loads from place to place economically and dependably they are a tough act to beat.
We are on the lookout for a replacement for the venerable Transit though as we realise we cannot keep them going indefinitely, personally I'd like to import some tidy bodied vehicles from a dry country like Spain or Turkey and go just have mechanicals to sort instead of rot but I expect the import costs and red tape would negate any savings to be had there.
Well it certainly sounds like you gave it a lot of thought before going the repair rout Jim and my compliments on being so thorough. One thing you missed out though, or perhaps you just wouldn't admit it, and that's that once you get going it's just bloody good fun and the achievement at the end when you stand back and look at it all shiny and like new, is a very good feeling
why cant i see the rest of the photos,its telling me to upgrade photobucket,wtf
That's down to me, I haven't figured out how to upload pics from my phone to this site without using photobucket and it looks like I've exceeded my photo limit in the free version, it wants me to upgrade to Photobucket Plus.
just a point
with the back end it would make more sense to remove the back body on the next one give you lots more room also the chassis rots on the top rail as well as the bottom
makes it a lot less bother to weld and clean paint etc too
but that's just my opinion
with body off you could make a spit to turn it up to 90% each way again makes like much easier as you have two more to do
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