Replacing Rusty Bits

  1. Burdekin

    Burdekin Chief Bodger

    Messages:
    4,882
    Location:
    Aberdeen
    Going to be replacing a load of rusty bits starting with the floor and outriggers. Not planning on writing too much but hopefully will get plenty of pics. Getting time at the workshop is the hardest bit but hopefully I get a good run and get stuff done. Pretty much half the floor pan out now and fixed a bit on the inner sill, chassis rail and was just lining up the new outrigger when I had to head home.

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    monky harris and andy_v like this.
  2. Shedendman

    Shedendman Member

    Messages:
    3,925
    east sussex
    Before you close it all up ie get the floor down,coat the inside of the chassis/outriggers etc with some sticky stuff or whatever and plug up all the pre drilled holes
     
  3. Burdekin

    Burdekin Chief Bodger

    Messages:
    4,882
    Location:
    Aberdeen
    Got to be a wee bit carefully though when welding as they're normally flammable. I prefer to leave the drain holes and cover them with grommets.
     
    Mee likes this.
  4. Shedendman

    Shedendman Member

    Messages:
    3,925
    east sussex
    Well laugh at this one,when i did my van took the whole floor up did the repairs then plugged all the holes up with PU then slapped around a load of vaseline, welded a floor back on using 3mm sheet from an old oil tank,no fires,no sparks etc nothing,guess what,no rust either,that was 5 yrs ago;)
     
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  5. Burdekin

    Burdekin Chief Bodger

    Messages:
    4,882
    Location:
    Aberdeen
    Welded in the front outrigger after work. Next got to cut out the rear one and make a new section.

    Not very good pics, I broke both my work lights so only have my old rubbish one at the moment.

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  6. Burdekin

    Burdekin Chief Bodger

    Messages:
    4,882
    Location:
    Aberdeen
    Got a better pic tonight. Didn't have much time but made a start on the rear outrigger.

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  7. mechman Member

    Messages:
    1,762
    Location:
    great britain n.e.lincs
    What type/make of van is it or have I missed it.
     
  8. Burdekin

    Burdekin Chief Bodger

    Messages:
    4,882
    Location:
    Aberdeen
    An old Volvo Amazon.
     
  9. brokenbiker

    brokenbiker Member

    Messages:
    10,437
    Location:
    Llanbobyll, south wales
    my fathers old mate used to use vaseline...he was into modifiying leyland vans, putting v8's in them, turning them into 6 wheelers or pick ups, tow trucks etc...i only knew him for about ayear before he died but he would always coat everything in vaseline after welding it and them plating over the top
     
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  10. Burdekin

    Burdekin Chief Bodger

    Messages:
    4,882
    Location:
    Aberdeen
    Prepping for replacing the rear outrigger, all the bits are made and just a little surface prep and I can weld everything in. Welded in one small repair already. Took me about 8hrs so far to prep everything so a bit slow going. Made a new outrigger with my little Gabro, it couldn't quite bend the small flanges so I had to finish them with a hammer. The outrigger is 2mm thick. Will get it all welded in this week after work is the plan.

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    slim_boy_fat likes this.
  11. Burdekin

    Burdekin Chief Bodger

    Messages:
    4,882
    Location:
    Aberdeen
    Just need to tidy the welds up, weld in a new seat nut/plate and that's the structural repairs done. I ordered a 13mm belt sander last Thursday but it's not turned up which is annoying.

    My wife is on call this weekend so I can have a weekend at the workshop which is great, just need to get a new bottle of gas Saturday morning first.

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  12. Miggy89

    Miggy89 Member

    Messages:
    129
    Location:
    Somerset uk
    looking pretty tidy that tho it is always a pain trying to find time when doing projects
     
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  13. slim_boy_fat

    slim_boy_fat Forum Supporter

    Mine arrived from Amazon today, not had a chance to play yet but looks OK.

    Enjoy the weekend!! :drunk:
     
    Burdekin likes this.
  14. Burdekin

    Burdekin Chief Bodger

    Messages:
    4,882
    Location:
    Aberdeen
    Will get one from B&Q tomorrow if it doesn't turn up today.
     
    Mee likes this.
  15. Coo

    Coo Member

    Messages:
    751
    Fife
    Great work bending 2mm

    Must be really satisfying having new metal in there!
     
    Burdekin likes this.
  16. Burdekin

    Burdekin Chief Bodger

    Messages:
    4,882
    Location:
    Aberdeen
    Thanks. Yeah it's a bit depressing when you find rust but feels good getting it fixed. Bit like going to the dentist, you don't want to go but after you're glad you did.

    Plenty more to do as well. Going to get the old girl rust free. Just found the inner NS wing has been replaced and only tacked in so need to work out if I fit a new one or try and weld in the old one properly which might be more hassle as it's lapped over so cutting it accurately to be butt welded could be difficult.
     
    Mee and SIP-Free like this.
  17. SIP-Free

    SIP-Free Member

    Messages:
    991
    Location:
    Dan Saff!
    Nice work there.
    What (in the pics) are you using to spray the shiny, welded parts?
     
    Burdekin likes this.
  18. Burdekin

    Burdekin Chief Bodger

    Messages:
    4,882
    Location:
    Aberdeen
    It's zinc galvanising spray, I just sprayed it on last night to stop any rust for now.

    At a bit of a quandary if I just give the chassis rails a good clean, 3 coats of gal spray, then Dinitrol 4941 then plug weld the floor in or paint all but the flanges with epoxy mastic. Trouble is the epoxy is more heat sensitive and catches on fire and flakes off. I think I'll start a thread to ask and see what's best.
     
    Mee likes this.
  19. SIP-Free

    SIP-Free Member

    Messages:
    991
    Location:
    Dan Saff!
    I think I'd galv spray inside the enclosed parts (even the weld areas), weld it up, treat the outside to epoxy primer, seal the seams and use your choice of cavity wax.
     
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  20. Burdekin

    Burdekin Chief Bodger

    Messages:
    4,882
    Location:
    Aberdeen
    Finished removing the old floor, welded in the new nut/plate for the seat, dressed some of the welds, fitted up the floor pans (took me longer than I thought), started oxy butt welding on a bit of extra metal to the rear pan as it isn't big enough to plug weld.

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