My Van Conversion

How I Treated And Repaired Rusty (Interior)

By on 23rd June 2016

When looking into buying a van you have to be prepare to find rust somewhere on that type of vehicle, this can be due to its age or the ways it been treated in the past. Dont be discouraged on purchasing a van by this as most of the time it can be treated and repaired. (Unless it’s that corroded it’s not worth the time and money).

 

Inside my van I found surface rust on the floor and holes in the wheel arches. I had no idea the rust was there untill after I (Stripped the van and cleaned inside.) <<—— Click to see posts on these.

 

Items/tools used

 

Wheel Arch Rust Hole Fix

 

IMG_1902

 

Step 1: Removing the rust

  1. I needed to see how bad the rust was. A good way to do this is by poke a screwdriver around the rust to see if more rust will flake away. I did not have to do this aggressively, just tap the surrounding area to see if there was more corroded.
  2. I used a wire brush (drill attachment) around the holes until I could see nice clean metal.

    Wire brush surrounded area

  3. Got my angle grinder and cut round the edges. This then left me with clean metal and no rust.
    Treating rust (wheel arch)

    Grinded around edges

  4. To be sure i have eliminated all the rust from the hole, I brushed Hammerite rust killer all over it.
  5. Wait for Hammerite to dry.

 

Step 2: Cover the hole with fiberglass

  1. Purchased a fibreglass kit.
    Fibreglass kit

    Fibreglass kit

  2. Cut the fibreglass sheet to size (1 or 2 inches bigger than hole) x 2.
  3. Pored resin in to plastic cup (enough for one coat), then added some hardener and mixed together.
  4. On the underside of the wheel arch I brushed the mixed resin around the hole.
  5. Placed the cut piece of fibreglass sheet on the hole and coated with resin using my brush.
    Wheel arch with fiberglass on

    Wheel arch with fiberglass on

    Fibrglass covering holes

    fiberglass covering holes

  6. Once dry, i repeated those steps so I had two layers of fiberglass for extra protection and a peace of mind that no water would come through.

 

Stage 3: Put on Underbody seal

  1. When the fibreglass is completely dry i then coated my whole wheel arch with Underbody seal to protect the wheel arch from future damage such as water, stones and salt prolonging. This will extend the life on my van.
    Underseal wheel arch

    Underseal wheel arch

Underseal wheel arch

Underseal wheel arch

 

Stage 4: Filling the hole and spay paint

This stage was not necessary but i needed to get practice with body filler for the future when I fix the exterior body work, so I thought ide have a go.

 

Body filler covering hole after fibreglass work.

Body filler covering hole after fibreglass work.

 

Sprayed wheel arch

Sprayed wheel arch after sanding

 

Surface rust treating

There was surface rust all over the floor and round the edges of wheel arches. This had been cause by all the damp dirt under the flooring. luckily it was just surface rust and none of the flooring had corroded.

Stage 1: Remove the rust

  1. Surface rust is easy to fix as nothing has corroded. I went round with my wire brush (drill attachment) and any surface rust I found I brushed down to clean metal.
    Brushing surface rust

    Brushing surface rust

  2. Coated all the areas I brushed with hammerite rust killer.
  3. Sprayed the floor with red hammerite paint.

 

This was how I treated and repaired rust inside my van. This may or may not have been the correct way of doing this but it was my way. I’ve never had to treat rust. I am new to this and im learning as I go.

 

Any advice for treating rust in the future would be much appreciated. Please leave your tips below in the comments.

 

Next post: Laying the floor and insulation

 

 

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Karl Norton

I have converted a standard Ford Transit van into a campervan to travel and explore the world wherever my heart desires.

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