Bodywork - Part 5 - Welding

Quick recap.

Cut, grind, template, transfer, trial, prime steps completed. Now final clean and weld in.

Most panels areas required another trial and also to remove, clean the weld areas. Then a few holes or flange edges to ensure a good fit then tacked into place and then final weld.

There are not loads of photos in this section as I spent most of my time under the van welding and grinding to take photos!

 

 

All I can say is that welding upside down under a van with a welding helmet is hard!

But welding i find is strangely addictive!

After all welds are completed and have been ground down... next step finals painting

Stay tuned for Bodywork - Part 6 - Painting 

Battery & Tray restoration

Time for a new Starter Battery as Betty's battery has trouble starting after a long drive and only giving 11.78V at best.

Strange how the battery was struggling when the engine was warm but it is in the direct flow of the cooling air.

So new Battery was purchased and a free morning to fit it.

The old battery was a 48 A/h 220A and appears to be the original Brazilian battery as it was made in Brazil. So could be from 2004!

Upon removal it was clear that the battery tray was in need of some rust removal and restoration. Major water trap and also a weak spot for any bus.

Rust is only surface but needed treatment before replacing the battery.

After some cleaning and wire brushing the worst was removed. 

Surface treated with Hamerite rust removing Gel. Cleaned back again. No More rust! Then primed with the Hamerite Primer.

Resprayed with Hamerite smooth spray. Quite a good match to the VW Candy White. Close enough for inside the engine bay.

New YUASA 50A/h 440A Silver 5000 Battery. Should last a while and not too big for the Alternator to charge.

Starts after 2 Seconds and totally smooth turn over from the starter motor.

Will now be able to connect the Leisure Battery back up and think about replacing the rubbish split charge relay for a smartcom.