Back in March my van failed the MOT on rot as well as some electrical, brake and suspension issues. I couldn't scrap my beloved van, especially when it has only covered 110k miles, I had to make it live again at all costs!
The crossmember had been 'repaired' previously with some fibreglass and for some reason they thought stuffing rags inside would be a good idea!! Needless to say the rot spread from the inside out, showing little signs of the carnage hidden by the bumper plastic.
The rot had spread to the headlamp supports and the chassis outriggers, in classic T4 style. By searching some posts on this forum and much research, I set about rebuilding the front end, seeing what others had done. I thought I'd post the build on here for others to see, as I couldn't find very much info on the subject. I'm not sure if I was navigating the site [old version] properly? The new site is much more user friendly,
A year previous, I had some rust repaired by a garage by means of 'MOT welding' - which I've found to be - enough to get it through till next year! This is the result of 16 Gauge steel plates patching up and a thin layer of underseal to protect it.
The big can of worms was showing its face on the driver side too!
Of course, I should have been aware of this, but I was blinkered to know what goes on beyond the battery or the depths of the engine bay. You tend not to look until it all goes wrong! ?
Cutting off the N/S outrigger reveals the extent of the rot issue.
