If you were to remove the stiffening tubes from e.g. a solid outer chassis rail, then patch weld the inner skin, you could drill out holes in the right place to clear some steel tubing and then weld the tube to both sides of the chassis. Or like the patch piece the tube is welded one side already, probably find the tubes actually poke out the holes in the other side so you can weld round the tube. So repairs involve 2mm sheet pieces and tubing from metal factors rather than expensively made components that you chop up for smaller pieces. Buy complex curved or shaped panels as bay specific parts, make flat pieces. Basically keep as much original metal, especially edges of panels or sills because they are already attached in the right places. If you cut big holes or straight through structural parts there can be a tendency for things to pop out of shape.
Magic! Didn't think about the fact that the tube could stick out the other side which would allow welding Thanks for the tips about choosing what to fabricate myself and what to buy prefab. All super helpful.
Haven't posted an update in a wee while because I've been busy with work and also working on the van! Got pre-occupied with moving most of the van stuff out of the garage into my attic so I've got some more working space... the units from the van have become additional furniture in my already cramped bedroom aha! Also built myself a welding cart to move the welder around the space! So on deeper inspection the chassis turned out to be worse than hoped with rotten hangar tubes, fully disentegrated and corroded bumper hangar points and deep surface corrosion on quite a few points. After assessing the damages, I'd have to patch about 80% of it, so I decided to cut the rear portions fully out, along with the inner and outer valance and D pillar bottoms as they were both shot too unfortunately. Lots of measurements taken first to ensure it all goes back together again right! In hindsight, it might have been easier to replace the chassis sections first before removing the valances/D pillar bottoms, but lesson learnt! Chassis sections primed with electrox and a coat of rustoleum before being welded together. Used etchweld primer in sandwiched bits and any areas that would get cooked by the welder. Decided to install the gearbox and crankcase with hangar bar so I could get the positioning spot on for the rear chassis sections. Definitely helped despite being a bit of a faff. Chassis sections tacked and valances test fitted before welding. All's lining up with measurements nicely. Chassis sections welded in and tested fit again, all's where it should be so far...! Fairly pleased with my welds too considering they were in some tricky positions! Doing this so far has really helped me realise a few bits about how much attention to detail is needed, best approaches for cutting stuff out, how to use the paint properly and how many hours this kind of project will take. So satisfying welding the new bits in tho.
Ahh thank you mate! Got many more hours ahead but trying to remember that it should be mostly enjoyable otherwise what's the point. Comments like this deffo help!
Wee little update. Managed to squeeze in a bit of work this weekend patching up the chassis rail tops. Patches cut... Insides painted... Welded in. Not the neatest seam as I blew through in a couple of spots, but the plug welds were a doddle. Some rust treating with my homemade deox c gel made from citric acid, water and wallpaper paste flakes. Works a treat! Unfortunately ran out of time to prep everything properly for primer and paint, so have given it all a quick rattle can to stop any flash rust till I can next get to it. I think with the wonderful power of hindsight I would have tackled this job differently, leaving the original D pillar remains and inner valance in place, cutting out the chassis rails then I have a few more reference points to go off of as It's deffo been a bit of a headache getting it all to line up right. The rails have shifted horizontally slightly out of where I'd like them to be from shrinkage of welding in the top patches. It looks like there's enough give to lever them to where they need to be when I come to fit the D pillar though, so hoping that works. Will keep updated tho! Thought I'd share this reflection for anyone else who tackles this area. Continuing to learn heaps and open to feedback and tips as always incase anyone spots anything that could bite me in the butt further down the road. There's so much to this process and many skills to hone
Has been a while since an update! Been a very hectic few months trying to make some new freelance work more stable, gigging and finding a unit to move the van to as my mum's due to move mid September. It took a good couple of months of searching, looking at a few different places but pleased to say I found a unit nearby to Bristol which was big enough, was okay with me doing noisy grinding and in budget, only hitch was the doorway was about 16cm too low... So in what I have coined 'enJoeneering' fashion, with zero experience I built a body dolly for the van, so I could both lower it enough to get it in the space, as well as be able to move it about into various positions once it's inside. Took me the past few weeks designing it, sourcing the bits of steel I needed for it and building it, but pleased to say it worked a treat. Tested it thoroughly to make sure it would be safe enough to use, as you should do with any of this kinda thing also. My two brothers have been so helpful with the move and my mum's partner's building skills came in handy to make the ramps to get over the threshold of the unit doorway. My mum helped heaps with tasty food and looking after my bro's dog whilst we worked on it. QJB recovery also sorted me with transporting it over, and would deffo reccomend them for anyone based in Bristol/somerset/west Wiltshire area. Good price and super chill (plus they have a cute dog). Here's some pics of the process!
Ah…. It’s when you fit air ride suspension and it’s lowest setting is such that the frame member of the van / car sit on the floor. It’s what the cool kids do. I did just Google “laying frame” and there is another, more riske, explanation to the one above!
Hahaha that's jokes. Didn't know people make them so low that it's literally undrivable. That kinda stuff has always confused me, humans are weird for sure. If I wanted the low ride I think I'd just cut a hole in the cab floor and go Flintstones style on the dollies it's now incredibly easy to parallel park which is a bonus too!
They don't drive them with the chassis scraping the ground, the really low ones have adjustable air suspension and a compressor(s). But the cheapskates do lower them until they have problems. I followed the Splitscreen club once between a campsite and a show. There was a huge holdup when we got to a speed bump that a bunch of them simply could not get past. To make matters worse their tucked in front wheels meant they had to do 10 point turns. Laughable really - but such vehicles IMHO should not be used on public roads at all.
Haha that's quite amusing. I've never got the whole 'lowering so low it looks like a slug' type thing, but I know there are those that love it. Making something barely drivable just for the look of it??
I was reading somewhere (probably Hayburner) , describing somebody trying to drive into Austria in an ultra-lowered prototype bay, and the police stopped them and said basically get out, or we will seize and scrap it with less than 10cm ground clearance as it wont pass a local safety check. In this case with your new storage , it must be a bit soul destroying to have to take the suspension off again when it comes out, or have to move it again before final assembly.
Ahh I see hahaha, that makes a bit more sense (barely tho!) I too wonder if it's just people enjoying the challenge of it. We do all sorts of weird Marmite to amuse ourselves I suppose!
For sure! Definitely an upgrade from my mum's windowless and dusty garage (which was more than a blessing anyway though to be honest!) For sure, that aspect is less ideal but I'm just glad to have found a space relatively close to Bristol that isn't obscenely priced. Rent prices in Bristol are beyond crazy now and finding somewhere was proving really difficult. There's courtyard space out the front so hopefully when I get to that stage of the project I can chat to the farmer (they're super lovely) about finishing it off out there maybe under some sort of cover...
