CaveVan Forum
VW T4 "Eurovans" => Exterior => Topic started by: robinson1509 on November 30, 2016, 07:41:23 pm
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I took my '99 off the road about a year ago when i got my 2000. The clearcoat started peeling off and rust started showing up in the usual places so I decided I would make it my winter project. I started with the rocker.(http://uploads.tapatalk-cdn.com/20161201/8988271772cb8f7afa69b3649839c569.jpg)(http://uploads.tapatalk-cdn.com/20161201/ce0f7c653675df83c2eddd0190fb68db.jpg)(http://uploads.tapatalk-cdn.com/20161201/8d3ed3d4cf1810d82c9d5e20288d40bd.jpg)(http://uploads.tapatalk-cdn.com/20161201/19eff6e49ef987262e27b6ac22d6fa43.jpg)(http://uploads.tapatalk-cdn.com/20161201/8da0da627379222687a924714b9d2ba0.jpg)(http://uploads.tapatalk-cdn.com/20161201/8b6e30da2f449db6e56d8875889f2d6c.jpg)
Then I stripped the clearcoat on the hood and roof.(http://uploads.tapatalk-cdn.com/20161201/e544c57b1a2dc992cbe65805b35d3fbc.jpg) the chips on the hood had to be feathered out primmed and block sanded.(http://uploads.tapatalk-cdn.com/20161201/5facb22ff5dcb626b8d12724f8042fbc.jpg)
The roof took about 8 hours to strip the clear and sand. The coutours have to be hand sanded.(http://uploads.tapatalk-cdn.com/20161201/98d0bf2bd398355cf565ebdf3c3eb348.jpg)
There was a lot of blister rust on the tailgate.(http://uploads.tapatalk-cdn.com/20161201/7a29353b87e18ccf800b68d83130ecf6.jpg)(http://uploads.tapatalk-cdn.com/20161201/8dc0de30fd98427449bcded7cef267f2.jpg)
And some under the bumper.(http://uploads.tapatalk-cdn.com/20161201/019a79e0c48a82faa86cc7a496cf8e49.jpg)(http://uploads.tapatalk-cdn.com/20161201/3b9a4a8f81509a5f2b6457d86145e7b0.jpg)
There were a few small dents.(http://uploads.tapatalk-cdn.com/20161201/6313b007036219cd97ad23b166b582d6.jpg)
So far I have spent close to 100 hours block sanding.(http://uploads.tapatalk-cdn.com/20161201/7d1f5c3711c89fdf2ca72e49637050e1.jpg)
On spots that have bare metal I primed with a light coat of etching primer, then build up with a few coats of 2k urathane.
The pillar stickers were not too bad but I decided to strip them off.(http://uploads.tapatalk-cdn.com/20161201/9bfeda56f6af012d97f2208a65087e0f.jpg)
I pulled off the front and rear bumper and I decided to replace both bumper reinforcements. I was surprised with the extent of the corrosion because the undercarrage is relatively free of rust.
(http://uploads.tapatalk-cdn.com/20161206/ea42ded099b210d2ba76934ab35d02a9.jpg)(http://uploads.tapatalk-cdn.com/20161212/69e53f00151ccfcf9521858abe7e1e3c.jpg)
Started removing brake and suspension rust.(http://uploads.tapatalk-cdn.com/20161212/df17567d866204ac9404e4dba9cc63b5.jpg)(http://uploads.tapatalk-cdn.com/20161229/4ffd93d2ba8c2232c8636b66d8068242.jpg)
And removing factory chip gaurd under rockers(http://uploads.tapatalk-cdn.com/20161212/3ef4bac2f701695ea3ad839eef12f224.jpg)
The cold weather and impending holiday slowing my progress.
De rusting rear brakes and suspension.(http://uploads.tapatalk-cdn.com/20170107/036909989fdfe4d5426e981fa5b9056c.jpg)(http://uploads.tapatalk-cdn.com/20170107/b71c634d9d27fd897f025885a5ef4938.jpg)
I have spent four days on my back sanding priming and painting the undercarrage. I started in the rear and I have made my way to the frame cross member where the swing arms attach.
I started de rusting the right suspension(https://uploads.tapatalk-cdn.com/20170117/f71abc1856cd424994ecd12e2aefac74.jpg)(https://uploads.tapatalk-cdn.com/20170117/653a507dad76cf9e21cc732ed4226582.jpg)
I found some rust in the wheel well so I went to work patching(https://uploads.tapatalk-cdn.com/20170117/3b71f4ed47c15d402a643a72bc88b35b.jpg)(https://uploads.tapatalk-cdn.com/20170117/126aa030e6526805720253c462e94880.jpg)(https://uploads.tapatalk-cdn.com/20170117/d52938ac37f1b5b7493625eb3e9e7fb8.jpg)(https://uploads.tapatalk-cdn.com/20170117/f0ce05f611ac2f7b28df173e2cb05ef7.jpg)(https://uploads.tapatalk-cdn.com/20170117/de84c5fd364b399a603d9de69de9780f.jpg)
I am old school I prefer to gas weld most of the time, this time I wish I had used the mig. While I was welding I had an unfortunate incident. The seam sealer caught on fire and burned up my cab carpet and passenger door panel.(https://uploads.tapatalk-cdn.com/20170117/78338365678b7679eb652ca48e72562e.jpg)(https://uploads.tapatalk-cdn.com/20170117/29a9a6641f01e8b6432216afac680b0c.jpg).
Soo careless. I found a carpet replacement with lh drive in the uk but it does not have the step up behind the front seats. I think I found a doner with good interior.
Took off the right fender a lot of debris between the fender and inner well.(https://uploads.tapatalk-cdn.com/20170122/92bb6487e6be4c741f905def196e0ae2.jpg)
...And the left.
(https://uploads.tapatalk-cdn.com/20170122/e7434bb7aebef896122bd8fc37c24467.jpg)
I removed the factory chip gaurd/ seam sealer below the slider door and eliminated some hidden rust.(https://uploads.tapatalk-cdn.com/20170122/937c16d3d6b0e2f0dca6b3f72b5ef460.jpg)(https://uploads.tapatalk-cdn.com/20170122/a25792f95a795111ea9eab515ba35a39.jpg)
And repaired small dents on rocker.(https://uploads.tapatalk-cdn.com/20170124/3020796b4f3a41d98e2d184f5d1a9de2.jpg)
Started derusting the last wheel.
(https://uploads.tapatalk-cdn.com/20170130/fe76e5cd32120531b63d2cc2ed43872b.jpg)(https://uploads.tapatalk-cdn.com/20170130/e54409afe42ca6037abf5ed36f98c5b0.jpg)
(https://uploads.tapatalk-cdn.com/20170204/9ec3b0e0744def4dba531fdb983bb80c.jpg)(https://uploads.tapatalk-cdn.com/20170204/d2146fc34de053adaf113e3713d06430.jpg)
Did some priming today.(https://uploads.tapatalk-cdn.com/20170219/7783451c64fcce1e2bebb221e76a9042.jpg)(https://uploads.tapatalk-cdn.com/20170219/9d50010ecace2f3e13cb1cab6a1460df.jpg)(https://uploads.tapatalk-cdn.com/20170219/56dd98cd1139de2dd0f844ac28bf6704.jpg)
(https://uploads.tapatalk-cdn.com/20170221/e6fb52cc774213c177431f7900370d08.jpg)(https://uploads.tapatalk-cdn.com/20170221/e4d8a1d844d9a31425fb0c6b54584722.jpg)
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What are you using for rust removal? Wire wheel? Looks pretty good when you are done!
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I took my '99 off the road about a year ago when i got my 2000. The clearcoat started peeling off and rust started showing up in the usual places so I decided I would make it my winter project. I started with the rocker.(http://uploads.tapatalk-cdn.com/20161201/8988271772cb8f7afa69b3649839c569.jpg)(http://uploads.tapatalk-cdn.com/20161201/ce0f7c653675df83c2eddd0190fb68db.jpg)(http://uploads.tapatalk-cdn.com/20161201/8d3ed3d4cf1810d82c9d5e20288d40bd.jpg)(http://uploads.tapatalk-cdn.com/20161201/19eff6e49ef987262e27b6ac22d6fa43.jpg)(http://uploads.tapatalk-cdn.com/20161201/8da0da627379222687a924714b9d2ba0.jpg)(http://uploads.tapatalk-cdn.com/20161201/8b6e30da2f449db6e56d8875889f2d6c.jpg)
Then I stripped the clearcoat on the hood and roof.(http://uploads.tapatalk-cdn.com/20161201/e544c57b1a2dc992cbe65805b35d3fbc.jpg) the chips on the hood had to be feathered out primmed and block sanded.(http://uploads.tapatalk-cdn.com/20161201/5facb22ff5dcb626b8d12724f8042fbc.jpg)
The roof took about 8 hours to strip the clear and sand. The coutours have to be hand sanded.(http://uploads.tapatalk-cdn.com/20161201/98d0bf2bd398355cf565ebdf3c3eb348.jpg)
There was a lot of blister rust on the tailgate.(http://uploads.tapatalk-cdn.com/20161201/7a29353b87e18ccf800b68d83130ecf6.jpg)(http://uploads.tapatalk-cdn.com/20161201/8dc0de30fd98427449bcded7cef267f2.jpg)
And some under the bumper.(http://uploads.tapatalk-cdn.com/20161201/019a79e0c48a82faa86cc7a496cf8e49.jpg)(http://uploads.tapatalk-cdn.com/20161201/3b9a4a8f81509a5f2b6457d86145e7b0.jpg)
There were a few small dents.(http://uploads.tapatalk-cdn.com/20161201/6313b007036219cd97ad23b166b582d6.jpg)
So far I have spent close to 100 hours block sanding.(http://uploads.tapatalk-cdn.com/20161201/7d1f5c3711c89fdf2ca72e49637050e1.jpg)
On spots that have bare metal I primed with a light coat of etching primer, then build up with a few coats of 2k urathane.
The pillar stickers were not too bad but I decided to strip them off.(http://uploads.tapatalk-cdn.com/20161201/9bfeda56f6af012d97f2208a65087e0f.jpg)
I pulled off the front and rear bumper and I decided to replace both bumper reinforcements. I was surprised with the extent of the corrosion because the undercarrage is relatively free of rust.
(http://uploads.tapatalk-cdn.com/20161206/ea42ded099b210d2ba76934ab35d02a9.jpg)(http://uploads.tapatalk-cdn.com/20161212/69e53f00151ccfcf9521858abe7e1e3c.jpg)
Started removing brake and suspension rust.(http://uploads.tapatalk-cdn.com/20161212/df17567d866204ac9404e4dba9cc63b5.jpg)(http://uploads.tapatalk-cdn.com/20161229/4ffd93d2ba8c2232c8636b66d8068242.jpg)
And removing factory chip gaurd under rockers(http://uploads.tapatalk-cdn.com/20161212/3ef4bac2f701695ea3ad839eef12f224.jpg)
The cold weather and impending holiday slowing my progress.
De rusting rear brakes and suspension.(http://uploads.tapatalk-cdn.com/20170107/036909989fdfe4d5426e981fa5b9056c.jpg)(http://uploads.tapatalk-cdn.com/20170107/b71c634d9d27fd897f025885a5ef4938.jpg)
I have spent four days on my back sanding priming and painting the undercarrage. I started in the rear and I have made my way to the frame cross member where the swing arms attach.
I started de rusting the right suspension(https://uploads.tapatalk-cdn.com/20170117/f71abc1856cd424994ecd12e2aefac74.jpg)(https://uploads.tapatalk-cdn.com/20170117/653a507dad76cf9e21cc732ed4226582.jpg)
I found some rust in the wheel well so I went to work patching(https://uploads.tapatalk-cdn.com/20170117/3b71f4ed47c15d402a643a72bc88b35b.jpg)(https://uploads.tapatalk-cdn.com/20170117/126aa030e6526805720253c462e94880.jpg)(https://uploads.tapatalk-cdn.com/20170117/d52938ac37f1b5b7493625eb3e9e7fb8.jpg)(https://uploads.tapatalk-cdn.com/20170117/f0ce05f611ac2f7b28df173e2cb05ef7.jpg)(https://uploads.tapatalk-cdn.com/20170117/de84c5fd364b399a603d9de69de9780f.jpg)
I am old school I prefer to gas weld most of the time, this time I wish I had used the mig. While I was welding I had an unfortunate incident. The seam sealer caught on fire and burned up my cab carpet and passenger door panel.(https://uploads.tapatalk-cdn.com/20170117/78338365678b7679eb652ca48e72562e.jpg)(https://uploads.tapatalk-cdn.com/20170117/29a9a6641f01e8b6432216afac680b0c.jpg).
Soo careless. I found a carpet replacement with lh drive in the uk but it does not have the step up behind the front seats. I think I found a doner with good interior.
Took off the right fender a lot of debris between the fender and inner well.(https://uploads.tapatalk-cdn.com/20170122/92bb6487e6be4c741f905def196e0ae2.jpg)
...And the left.
(https://uploads.tapatalk-cdn.com/20170122/e7434bb7aebef896122bd8fc37c24467.jpg)
I removed the factory chip gaurd/ seam sealer below the slider door and eliminated some hidden rust.(https://uploads.tapatalk-cdn.com/20170122/937c16d3d6b0e2f0dca6b3f72b5ef460.jpg)(https://uploads.tapatalk-cdn.com/20170122/a25792f95a795111ea9eab515ba35a39.jpg)
And repaired small dents on rocker.(https://uploads.tapatalk-cdn.com/20170124/3020796b4f3a41d98e2d184f5d1a9de2.jpg)
Started derusting the last wheel.
(https://uploads.tapatalk-cdn.com/20170130/fe76e5cd32120531b63d2cc2ed43872b.jpg)(https://uploads.tapatalk-cdn.com/20170130/e54409afe42ca6037abf5ed36f98c5b0.jpg)
(https://uploads.tapatalk-cdn.com/20170204/9ec3b0e0744def4dba531fdb983bb80c.jpg)(https://uploads.tapatalk-cdn.com/20170204/d2146fc34de053adaf113e3713d06430.jpg)
Did some priming today.(https://uploads.tapatalk-cdn.com/20170219/7783451c64fcce1e2bebb221e76a9042.jpg)(https://uploads.tapatalk-cdn.com/20170219/9d50010ecace2f3e13cb1cab6a1460df.jpg)(https://uploads.tapatalk-cdn.com/20170219/56dd98cd1139de2dd0f844ac28bf6704.jpg)
(https://uploads.tapatalk-cdn.com/20170221/e6fb52cc774213c177431f7900370d08.jpg)(https://uploads.tapatalk-cdn.com/20170221/e4d8a1d844d9a31425fb0c6b54584722.jpg) Ready for paint, emerald pearl green paint code 47503
Finally got to paint. All weekend non stop.(https://uploads.tapatalk-cdn.com/20170924/b7b5d7fb360a3e1c41cf3e76cb6a1c13.jpg)(https://uploads.tapatalk-cdn.com/20170924/ab148d1bf2cf4025ad3d9fdc1175cb6d.jpg)(https://uploads.tapatalk-cdn.com/20170924/f072079813fe7232e015aea091a0156d.jpg)(https://uploads.tapatalk-cdn.com/20170924/621e0bee6fc5f048c0fe2e2e09dd8e5f.jpg)(https://uploads.tapatalk-cdn.com/20170924/ca16327ef1724188c3be1a2e0d413831.jpg)(https://uploads.tapatalk-cdn.com/20170924/b7a0ddf33c25a9ae5ad655e68917e74e.jpg)(https://uploads.tapatalk-cdn.com/20170924/f28a92cd76236d3fe1c7eee614410d48.jpg)(https://uploads.tapatalk-cdn.com/20170924/29717e29336dbccfd1e144a4d3cc74c1.jpg)
And after nearly a year it is finally done.
(https://uploads.tapatalk-cdn.com/20171002/dcca6227fff609125728c5fd63fe41eb.jpg)(https://uploads.tapatalk-cdn.com/20171002/6310ad9ed3e8ed3e52072b5f4ac99420.jpg)(https://uploads.tapatalk-cdn.com/20171002/8fd33d3ef86ecf0f77ba35100648a1d0.jpg)
And now I have to decide which one to drive.(https://uploads.tapatalk-cdn.com/20171007/77ea30e5aebaff41d9e655156bba36b4.jpg)
(https://uploads.tapatalk-cdn.com/20171029/6519f4f5ba0ab094331aaeadf8310a16.jpg)
https://youtu.be/0wasLwvePy4
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What are you using for rust removal? Wire wheel? Looks pretty good when you are done!
On the suspension parts I start with a needle scaler then use a knotted wire wheel with a right angle grinder, for tight spots I will hit it with a siphon cup sandblaster, and flat pieces a flap disk.
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Thank you for the reply. I've used everything except a needle scaler. I might have to pick one of those up and give it a try.
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Thank you for the reply. I've used everything except a needle scaler. I might have to pick one of those up and give it a try.
I also use a spray bottle with white vinegar to help break the rust and keep the dust down when I use the wire wheel. Then after the rust is gone I scrub it with a parts brush and lacquer thinner before I paint.
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For small components, I soak them for a couple of days in a plastic tub filled with a few gallons of vinegar then rinse them off with water.
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Thanks guys! Vinegar is something else I haven't used. I'll have to play with both ideas next time I'm dealing with rust.
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Okay, needle scalers range in price drastically. Do you have a recommendation? Thanks.
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Okay, needle scalers range in price drastically. Do you have a recommendation? Thanks.
I think I paid about $40.00 for the needle scaler, I'm not sure how much I paid for the air chisel I have had it for a long time.