You don't really have a lot of choice but to start by stripping the paint and tape back to see what it's like underneath. In all probability it will have crept back quite a long way under the paint - even with galvanising it does seem to spread slowly over time, and you could end up with an area that's quite big. If you don't care too much about appearance then wire brush the rust down to good metal, red oxide or similar primer and spray yourself with rattle cans. If you do care, probably best to leave it to a body shop.
There's a hint of a notch below, so I would check carefully underneath to make sure someone hasn't jacked at the middle of the sill - that has the potential to do a lot of hidden damage - but it's probably just an optical illusion.
Put the van on its roof after cutting out and gave the inside a coat of zinga Trial fit at midnight! Off out in a minute to weld it up then paint stone chip and pump full of waxoyl (y) Thats the rest of the weekend sorted
That is a useful thread, thank you! As you seem to have pulled it apart, I have a couple of questions if you don't mind?
First, what is the deal with where the roller goes? Is it just paint or something else?
also, what is the bobbly paint along the edges? I have this all along mine and I thought it was (the horror ) rust bubbling under the paint. Is it some kind of protective paint?
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