This page last updated on 30 March 2008

Job description:

To strip exterior trim, remove corroded panels, replace as required with new.

Remove the front spare-wheel carrier and return to original specification.

Extensive welding to lower areas of vehicle.

Prepare the bodyshell, fill as required and apply 2K primer.

Paint the elevating roof white and apply clear lacquer over the graffiti artwork.

Lower the suspension.

Service the vehicle.

Shovel Count to date .....16.....

This is the amount of general dirt, filler dust, rust, off-cuts of metal, and anything else that falls off the vehicle.

The bodywork of this late model German Westfalia bay has had some previous work, unfortunately the quality is not as good as it could have been, as usual most of the lower panels are corroded, needing replacement.

The front panel also needed work, the spare wheel box is to be removed, the front bumper extension cut off and the crush panel welded back in place again. The holes in the front panel from the brackets welded up and dents pulled out and filled smooth.

A new front bumper is needed when reverting the front panel back to original, as the old one was cut to slot the spare wheel into it.

Corrosion at the rear was excessive, it had been repaired before but the panel hadn't been replaced, so we cut away the corroded lower corner , cleaned up and recessed the metal and fit a new lower corner. Zinc primer was sprayed onto the jointing faces of the areas to be welded.

Both rear pillars were rotted out at their bases, this is a common area to rust but cannot be seen or repaired without cutting away the lower corners. After welding wax-oyle was injected through a hole in the rear panel, future applications of wax-oyle will have to be injected through the rear bumper mounting bolt hole.

A new battery tray was welded in to the offside prior to a new lower corner panel being welded in place. Finally the new outer rear panel was welded on.

After completing the rear corners our attention was turned to the front arches, sills and rear wheel-arches. The front arches, whilst looking reasonably solid were actually badly corroded on the inside of the cavities. The offside sill was not the original, and had been poorly repaired, both inner and outer, and the sill strengthener was missing completely. These panels were all cut away along with the front out-rigger and jacking point.

The front arches were originally to be patch welded, but after cleaning the areas to be welded it was decided that replacing the panel completely would be the way to go.

The front arches were the last areas to be welded, the vehicle was then sanded down and then body filler applied where needed, sealer was then brushed over the seams and joints. The vehicle was then masked up and primed, the door shuts were also painted in the original colour at the same time.

The outside of the campervan was then sanded down, doors and bolt-on panels re-assembled and windows etc  re-masked and then the graffiti artwork sprayed on, then finally lacquered.

Our attention was then turned to the suspension, lowering front and rear.

Next the underside was under-sealed and wax-oyle sprayed into the cavities and generally everywhere.

After unmasking, the windows were refitted using new genuine seals, new door seals were glued in place next. A new roof canvas was fitted to match the new paintwork. Finally the cab doors were built up and the camper was ready to go for it's MOT test.

After a full service and a final check over and a clean up this one of a kind Westfalia was ready for collection.