RUSTY THE CAMPER GOES FOR RESTO

[camperman3617865]

While surfin the net I came across this thread

http://forum.earlybay.com/viewtopic.php?f=4&t=33777" onclick="window.open(this.href);return false;

To cut a long story short and having a haggle about prices.... its now in our workshop having the parts done to the chassis and loads of other work on the rest of it, including a full respray.

Unfortunately when we started to take it apart ... we found that water has entered between the inner and outer panels in some areas making all the rockwall and insulation very wet, and rust is a major issue.
But the amount of expanding foam I have so far found that has been used on this van, is in my mind ...criminal

Here are a few pics so far

Front panel is a bit rusty and due to be changed back to original low indicator

 

[camperman3617865]

There wasn't much holding the front screen in

But then again it seems that the headlights were only held in with 1 screw each and a load of silicone

 

[gninnam]

So sad the way some of these vans or treated by the PO's :evil:

 

[camperman3617865]

After removing the seats and trim underneath I found a small hole and a lot of corrosion in the n/s tub, which was why the underfelt was wet

Parts like these that were not removed the last time it was sprayed will all have to be cleaned before refit

 

[camperman3617865]

After removing the dash top I found what I can only describe as criminal amounts of expandable foam

 

[camperman3617865]

So I decided to make a few investigations in the rest of the van

When removing the side panel behind the sliding door, I found another panel holding in more wet rockwall.... and would you believe it...under the rockwall was more expandable foam , and on both sides of the van

Strangely enough , if you look at the last picture , you can see weld marks clearly showing where a replacement panel has been welded on the outside of the van ...over the top of the original panel,

Why don't people just do the job properly :roll: :roll:

 

[Nick-Rackham]

Nice one, I'm liking the double skin wheel arches :lol:

 

[camperman3617865]

Nice one, I'm liking the double skin wheel arches :lol:

I think that it may be more than double skinned :lol: :lol:

 

[camperman3617865]

When taking out the interior cupboards ... I found this in the gas locker fixed in with 3 self tap screws

But I am sure its supposed to be riveted on here, well it will be

 

[camperman3617865]

Here we go again, I have found even more insulation , rockwall and even some household roof insulation behind the side panels

And the dreaded expandable foam :roll: :roll:

 

[camperman3617865]

Under the back seat and between the two rear inner wheel arches I found this boxed in area 2" deep

Lo and behold... it contains more rockwall

It didn't need to be there so I took it out

 

[Doris]

UN FLIPPIN BELIEVABLE!!!! you'd think even the cheapest of spray on wash paint jobs would include taking the door catches off !!! That rock wool & expandable foam has just helped to trap moisture.looking forward to seeing the progress. If its anything like Andy's 'old POE' it'll be a beltin transformation :mrgreen:

 

[camperman3617865]

Now, here is a part of the van that has had the floor raised just to put in another 2" of rockwall... I am so glad I have got gloves on, or I would be scratching all night after removing all this


note how well it has all been siliconed in

now removed

 

[camperman3617865]

I am sure you don't need any damp rock wall in between the panels on a camper, let alone this much :roll: :roll:

 

[justcruzin]

Wow. Never heard of using spray foam. :roll:

Good luck with your project!

 

[andewilson]

wow :shock:

i cant believe it moved with all that crap hidden underneath all that mdf.

 

[camperman3617865]

We have found a bit of corrosion under the front bumper when we finally managed to get it off, it had the mounting bolts where they should have been but the brackets were also welded to the inner front panel and chassis :shock:

 

[gninnam]

Some serious work required so far :evil:

Good luck and enjoy

 

[camperman3617865]

Considering how rusty this van is, its no surprise that it has taken a long time to try and get it apart... every nut, bolt or screw has been an absolute pig to undo.
But we are finally getting there with the strip down...just a few pipes and fitting to go now before we start cutting

Here are some pics of how far we have got since i last posted

Sorry about the spots on some of the pictures but the flash picks up the dust in the air

 

[camperman3617865]

Having sourced some more parts we are ready to start cutting the front section open

After removing the upper section of the front panel more foam and corrosion was found

and a huge wasp

The "DAY TRIPPER" sign on the front was also held on with foam and silicone sealant