Happy New Year Kevin, Good job so far. I myself have done a few big projects just like what you are doing. I once did a 1968 MGB-GT that was in the same condition as your van, it came out great. My brother has a 61 Sunbeam Alpine and I have a TR3 in the barn. I know these projects take a long time to finish and sometimes your biggest enemy can be keeping your motivation up. I have been a welder in a shipyard for many years and I can tell that you know what you are doing and that you are going about this project in the right way. I wish I could help you but I live on the other side of the world. I know it's hard to work when it's freezing cold outside.
If you are this far into the project, try not to cut corners when doing some of these jobs. What I mean is to make sure that you do the job completely. Once you start putting things back together you most likely will not want to take it all apart again. So don't get ahead of yourself. Take your time, and do it right the first time. Don't leave any of that flaky rust on when you make the new piece of metal. If you do it will rust again sooner than you would think. The rusty parts look as how I thought they would. Just cut out the bad parts in pieces and make some new pieces. As you know, it's only metal.
I will follow this very interesting thread for updates. Have fun and don't get discouraged. :B --Safety advise, (1)wear safety glasses or face shields. I have had metal in my eyes about 15 times, it's not fun. (2)wear ear plugs when grinding. If you want to hear your grandkids laugh, then wear ear plugs. (3) wear a dust mask. That sand blast grit can mess up your lungs when you get older, and so can the dust from the grinding wheels. --I'm an old pro, believe me. Have fun. I will write again later.
