Step one. Bought the van.
Hello Everybody, First post. I camp a lot in tents but after spending three days straight in a tent in the rain at Dolly Sods I swore I'd make a change. Here it is. Bought it Wednesday. Dro...
Forum Discussion
Rust never sleeps
One of those jobs I've been putting off. Previously patched these parts of the van but at the time the best I could do was use Bondo, fiberglass patches and pop rivets.
I'd obviously left this go far too long but could never seem to find the time. It didn't help that the weather around these parts was near daily rain through the whole Spring and most of the Summer. When the first week without rain finally arrived I took some time off work and started in on this project. As is usual, didn't know what I was getting into.
My tools were a hammer, screwdriver and angle grinder with a wire wheel.
The more I dug the worse it got. When I stopped there wasn't much left between the "C" pillar and the wheel well.
I didn't proceed farther up the rocker panel to see how much more needed replaced since I was already feeling a bit overwhelmed by what was in already front of me. Or more to the point, no longer in front of me.
Never previously having done any real sheet metal work before I wasn't sure what thickness to use. I'd ordered a four pack of 3'x3' sheets of metal from Onlinemetals in thickness's from 18 to 24 gauge. Figured I use whatever felt the right thickness.
I took measurements from the opposite side of the van to see where the lower edge of the wheel well should be used that to created a posterboard template.
Since this was a mostly straight piece I used the 18 gauge sheet for this part since it was the stiffest.
Locate where the bottom edge of the sheet should be.
Locate and drill holes to use two bolts already in place on the backside of the rocker panel.
Use a hammer to bend the sheet so it forms against the backside.
On the front side of the rocker panel I cut off what was rusted and using the other side of the van as a guide made another template. Since this piece will have a curve I'm using the 20 gauge sheet since it should be easier to shape.
Here's where it gets interesting. I have no experience with shaping sheet metal for body panels. The only trick I know is what I used when bending the the shield for the extra gas tank. Guess I try it here.
But first, say hello to my new tool. I finally bought a metal brake. Use the brake to create a bend for the edge that runs along the bottom of the rocker panel.
Then back to my old friends, a piece of angle iron and a ball peen hammer.
continued
One of those jobs I've been putting off. Previously patched these parts of the van but at the time the best I could do was use Bondo, fiberglass patches and pop rivets.
I'd obviously left this go far too long but could never seem to find the time. It didn't help that the weather around these parts was near daily rain through the whole Spring and most of the Summer. When the first week without rain finally arrived I took some time off work and started in on this project. As is usual, didn't know what I was getting into.
My tools were a hammer, screwdriver and angle grinder with a wire wheel.
The more I dug the worse it got. When I stopped there wasn't much left between the "C" pillar and the wheel well.
I didn't proceed farther up the rocker panel to see how much more needed replaced since I was already feeling a bit overwhelmed by what was in already front of me. Or more to the point, no longer in front of me.
Never previously having done any real sheet metal work before I wasn't sure what thickness to use. I'd ordered a four pack of 3'x3' sheets of metal from Onlinemetals in thickness's from 18 to 24 gauge. Figured I use whatever felt the right thickness.
I took measurements from the opposite side of the van to see where the lower edge of the wheel well should be used that to created a posterboard template.
Since this was a mostly straight piece I used the 18 gauge sheet for this part since it was the stiffest.
Locate where the bottom edge of the sheet should be.
Locate and drill holes to use two bolts already in place on the backside of the rocker panel.
Use a hammer to bend the sheet so it forms against the backside.
On the front side of the rocker panel I cut off what was rusted and using the other side of the van as a guide made another template. Since this piece will have a curve I'm using the 20 gauge sheet since it should be easier to shape.
Here's where it gets interesting. I have no experience with shaping sheet metal for body panels. The only trick I know is what I used when bending the the shield for the extra gas tank. Guess I try it here.
But first, say hello to my new tool. I finally bought a metal brake. Use the brake to create a bend for the edge that runs along the bottom of the rocker panel.
Then back to my old friends, a piece of angle iron and a ball peen hammer.
continued
