Bought back in 2006, my 1973 VW Baywindow camper looked pretty reasonable, and in fact the tax had only just run out a month before, amazing when you see the rot I found when the strip down was started.
On removing the rear bumper, the rear valance showed rot, but behind it what was revealed was…..a totally rotten rear cross member, both rear chassis rails were completely rotten through!
This led to the following being found –
I’m still unearthing little pieces of rot as the process goes on, but the build up so far goes something like this. Both rear chassis rail sections replaced, new rear cross member fitted, rear valance and two new battery trays made and fitted. Various repairs made along the length of both chassis rails and outriggers, complete centre cross member fitted and new outriggers and jacking points welded in. Inner and outer passenger sill, both rear quarter panels, both front cab step areas, complete passenger cab floor replaced.
The drivers side needed a little more so a complete front tub area was welded in, (didn’t take much to cut it out!) On looking at the front panel, it was obvious it needed to go, and is probably the biggest job attempted on the van so far. The lower bumper deformation panel came off quite easy, but the front panel took great effort to be cut off, as all the upper and lower spot welds needed drilling out, then the panel was cut in half up the middle to enable the sides to be peeled away from door jams. Replacing the new panel was also a real chore, best described as – overlap round one door jam edge, clamp to lower deformation panel lip, then use ratchet straps to “pull” the panel round to the other door jam and at the same time ensure the upper edge marries to the window lip. When all this was done it was a simple matter of spot welding top and bottom and folding the door jam edges over.
The story continues with the interior stripped out, both doors replaced with better ones needing only light repairs and the body stripped of up to five coats of paint in places and copious amounts of filler.
Mechanically, so far all the front steering and suspension joints have been replaced, (the front ball joints being a right nightmare to get out), and I’m gradually working my way back from the front of the van…………To Be continued
