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Anon
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Front Wing Corrosion at top corner

I've got some corrosion in the top corner of the front wing that's been there for a while, and when I tried to plate it over, water continued to seep out and corrosion always comes back through. I've pulled the metal away and found a sort of fibrous substance underneath that can best be described as being like some sort of tough fibre board. It looks original and appears to have some sort of structure around the outside edge of the wing. Any idea what it's for, and as it keeps absorbing water and causing the rust, can I rip it out and weld back over to sort it out once and for all? I'll publish some pics on my blog tonight to make it clearer.
Cheers,
Dave
Wed 30 Apr 2014 @ 15:42 Edit this messageQuote this messagePMQuote this message
Anon
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Have just added some pictures to the blog to explain the problem:

http://trevorthevan.blogspot.co.uk/2014/05/rusted-front-wing-repairs.html

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Mon 05 May 2014 @ 22:06 Edit this messageQuote this messagePMQuote this message
Anon
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You need to cut all of the "infected" metal away until you get to good clean and solid steel, and then repair by welding in replacement metal. I always treat the surrounding area with Kurust or something of the like too for good measure. The reason the corrosion keeps coming back is because not all of it has been cut out. Corrosion is like a cancer, if you dont get rid of all of it, it will just spread.

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Wed 07 May 2014 @ 09:54 Edit this messageQuote this messagePMQuote this message
Anon
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Thanks for the info, but it's not 'how to weld' info that I want - i've already welded up vast areas of the van originally as it was a wreck. The problem here is the water retaining resin behind the metal which will rot the metal back through quickly again. I really want to know what it is and what it's for. I'm tending towards taking the whole wing off now and as resin replacements are only £70, I might well go down that route. Anyone got any experience good or bad of them?

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Wed 07 May 2014 @ 19:55 Edit this messageQuote this messagePMQuote this message
Anon
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Front Wing

I am about to repaint the cab etc, on my cf facelift. it also has the same badly rusted areas on the wings, whilst removing loose rust a rubber pad appeared.I don't have a welding kit anymore, so iv'e 'treated' the rust and filled with re enforced cataloy.

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Wed 07 May 2014 @ 21:41 Edit this messageQuote this messagePMQuote this message
Anon
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If there is wadding behind the panel that is retaining water then pull it out. I would imagine it's there for sound insulation (can'tsee any other reason for it) but a rust free van has got to be better than a noisy one.....

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Wed 07 May 2014 @ 22:37 Edit this messageQuote this messagePMQuote this message
Anon
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I delved further today and got to the bottom of it - it's a bead of sealer keeping the top corner of the wing in position and spacing it to the metal work underneath (the structural metal of the Dash). Updated photos on the blog. I guess the top flange of the wing is effectively floating - there's no way it could have been spot welded to the A pillar, so this would have controlled it's position along that floating top edge.

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Thu 08 May 2014 @ 09:29 Edit this messageQuote this messagePMQuote this message
Anon
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To close out this topic, I've blogged about the problem I found and how I fixed it. See attached if interested.
Finding the problem:
http://trevorthevan.blogspot.fr/2014/05/rusted-front-wing-repairs.html
Solving it:
http://trevorthevan.blogspot.fr/2014/06/front-wing-repairs.html

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Thu 26 Jun 2014 @ 11:21 Edit this messageQuote this messagePMQuote this message
bluebedouin
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"....I can't get the bolts out of the doors..."

"...I always keep two grinders on the go - one with a normal grinding disc and one with a diamond cutting disc for making up the patches and cutting back the old metal...."

There you are then,problem solved.

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Thu 26 Jun 2014 @ 12:04 View bluebedouin   Email bluebedouin   Edit this messageQuote this messagePMQuote this message
Anon
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ha, good plan. I've ordered some new impact driver bits to try and get the screws freed up.... if that doesn't work, yep.

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Fri 27 Jun 2014 @ 11:30 Edit this messageQuote this messagePMQuote this message
Gethin
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try using a Mini Gas Torch to heat the bolts up if they are extremely tight.
Fri 27 Jun 2014 @ 19:00 View Gethin   Email Gethin   Edit this messageQuote this messagePMQuote this message
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