Man this is rotten as a pear, we will rebuild

[John A. Ross]

Been desk working today, some more work was done on van at weekend.

The drivers side inner wing structures and chassis all now repaired. Just the upper section at windscreen to do, that will be getting bonded, not welded near the screen.



So thats both sides done and I can assemble the air filters, power steering, plenum, catches and so on.

Starting to look like a van again.




All under constant supervison of course by the local mafia.



And end of sill section made for passenger side, thats now fitted so small lip section for inner arch and the new rear outer arch half can go on and then the wing.




In the mean time I created a new metal bashing tolley and clamps that lets me work on the metal, cut safely and bash bits with one hand, so managed to get the pan folder, shrinker/stretcher, camps and small ise on board.

OK needs to live outside but with a tarp over its all good and I can work standing up as bending over was how I ended up in this mess in first place .

[John A. Ross]

Now passenger side back together inside and out as strut is a pain to get to.

[John A. Ross]

And some plastics repair on th bumper as the retaining bosses melted away when I had to drill out th front bumper bolts.

So make shift mould, re-enforced polyimide hot poured material, two cut 3mm plastic discs, all melted to gether with heat gun

No more fingers were hurt due to the hot plastic.

THIS PROBABLY HAS MORE STRENGTH IN IT NOW THAN NEW !

Chocolate steel and ice cream plastic and every bolt seized, has to be a ford

[John A. Ross]

End result turned out OK, probably more solid attachment that original flimsy 2mm thick plastic.....

[John A. Ross]

And off with the drivers side did not take much as there was no metal, the ford underseal which is more like a 3mm plastic coating was all that was holding it.

[John A. Ross]

And although I had the full step panel I decided as rest was solid just to use a section, then folder up an inner sill



Thats is also after removing the inner/outer wheel tub seams and making some up.







OK, its not an imp but still a big pain in the ass on sills and wheel tubs

[John A. Ross]

And yes the eagle eyed among us will have spotted I no longer have the splint on the hand, it apparantly was doing more harm than good to my wrist so its on its worn now doing light work.

Hand is still swollen like a sponge, so much so its hard to see any first knuckles but hopefully with some actual activity it will reduce.

But feek me it hurts now....

[John A. Ross]

Well door off today and the outer arch and sill cut in, should have seen it from the photo but it measured OK, the step portion and inner sill section I made were 20mm too far up at front measurted perfect, pattern panels, pain in the arse.

So chop front loose and pull down/weld again.

Days work and back to where I was yesterday, but uglier. Not an imp but its bloody feeling like one

Anyway, knees, back, shoulders and hand/wrist killing me now (the list is long)

Another ball ache was the stress fracture and rot behind the lower door hinge I had to fix, only seen it after digging down for the hinge plate which fell inside the door pillar



Fixed that and had to epoxy in the hinge so I could fit door.

End result is a fitting panel and inner lips, not perfect but looking OK.

[John A. Ross]

Inner sill sections finished, outer wheel tub fabricated and set, seam sealed up ready for final outer attachment tomorrow

Another day should have inner wing and outwer wing on as well.

[PMCG]

Have you not considered "accidentaly" setting it on fire?

[John A. Ross]

Me would never even consider such a thing, would not be worth it, better breaking for parts as neww clucthc/flywheel in it.

[John A. Ross]

thats final fixed arch on (wing bolts on) and strut is back on as wheel tub, step and floor all sealed stone chiped and matt blacked.

Just rattle can single stage, outside with a wind but itworks plus the scabs on the B pillar are now gone.

Clear coat now. again rattle can

[John A. Ross]

Well break time from the imp

Thats the vans front end to the back of the cab done (bar the oil leak which looks like the sump is perforated on front edge)

All paint and panels cleaned up, underside all stone chipped up and coated






And finally add the wheels trims, sorted

[John A. Ross]

And then on to the back side, now up in the air

Plenty to do underneath, loads of ford rubbery underseal peeling off and the only thing holding metal together at some places.

Time for a harsh blast treatmnent to clear off all the crap (nice white salt residue under some bits) as any coatings on that is a waste of time.

No such problem at front as I ended up cutting all of it out 2 bad chassis bits though, found out hard way jacking it up, soft as poop

[John A. Ross]

Carnage ensues, feek me I was covered, really ned to get all the slaty cursty crappy underseal stuck shit off.

Had to pull exhaust as well, add it to the list, I will make one for it.



And some bits of chassis section in



Cross brace and thats that side done (other side done already)





And the requireds sweeping up what was the chassis, some sections swollen to about 10mm thick and came away like gravel chunks