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This page last updated on 31 December 2008 Job description:The main area of work to this campervan was the replacement of the nearside rear corner, corrosion to the lower areas and around the gutter was the reason for total replacement. Corrosion to the nearside rear corner and around the windows of this campervan has finally forced the need for major repairs, water seeping in around the windows has corroded the edges and the nearside rear corner/arch/rear panel areas are in need of urgent reconstruction.
After removing the rear panel outer skin the full extent of corrosion became apparent, the loose flaky rust was cleaned away and the rusty metal cut back.
The nearside rear corner and arch was then removed, this revealed the extensive corrosion to the sill area and inner rear arch, the battery tray was removed and new metal was grafted in to the rear upright.
The new rear corner panel was trial fitted, repairs were made the engine bay chassis legs, upright panels and rear panel. Zinc paint was sprayed onto new metal panels before enclosing with the outer skins.
With the structure of the vehicle now strong again our attentions turned to the job the vehicle came in for in the first place, the leaky corroded window frames. First a template was made from cardboard, this was transferred to sheet metal which was then plasma cut out, the corroded metal was removed and the new panel was then spot-welded and glued in place, finally another piece of metal was cut and welded in place where the corroded metal was along the lower edge, welding the window frame in place in this way gives more strength to the frame and more thickness for the window rubber to sit on.
The inside was painted the colour of the van, Neptune Blue L50K.
Spray filler was applied to the areas that had body filler on, this was block sanded smooth and sprayed with high-build primer, which was in turn sanded and the top coat sprayed on.
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