Body Repair Advice

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Jun 8, 2021
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Van Conversion
Hi Everyone!

I'm a new member and it's my first post on the forum, and I'd be really interested in anyone's thoughts on a predicament that I have!!

(I'm a computer engineer by trade, but unfortunately my mechanical skills aren't up to the same level - so please go easy on me! :-)).

Long story short. About 9 years ago my wife and I bought a used 2003 Fiat Ducato based panel van conversion. We've had lots of good times touring around in her over the years - however it hasn't been the most trouble free experience by any means(I'm sure most owners of ageing motorhomes would echo this). Generally, though, she has been amazing and I don't resent any time or money spent on her so far. Her interior is lovely, everything works and actually she isn't too shabby from the outside.

And then the rust came.

A few years ago, we started to notice rust around the sills which then very quickly deteriorated on both sides. We had some new sills welded on at the time and the underbody was undersealed to help slow the rust. Not a cheap repair at the time, but again I don't resent parting with the money! She's since made it through two MOT's without issue.

I've since located some further corrosion on the front underside and suspect I'm going to need a bit more welding/filling done, and also the paintwork is starting to show it's age in several areas around the van.

My wife and I have been 'umming and ahhing' about whether we should part ways and buy new, but something just doesn't seem right at the moment. I know there's reasonable work that will need doing on our current motorhome, and I absolutely know that bodywork repairs are time consuming and can be expensive - but my gut feeling is that I should at least try and do something about our current van.

And this is where my problems have begun, and where I'd really appreciate anyone's advice or suggestions.

It always, always amazes me how quick a large number of members of the automotive repair industry are either a) Too quick to suggest writing off your current vehicle and/or b) Can't be bothered to quote or do the work.

Let me first say, to avoid argument, that this isn't directed at the entire industry. I realise that there are goodun's and baddun's in EVERY industry! Mostly good, you would hope.

So - In my mind, the way you approach repairs on a motorhome differs vastly from repairs on a car. We all know how motorhomes retain their value whereas the vast majority of cars don't. Yet some bodyshops, chain or independent, big or small(or at least the one's I've dealt with so far!) appear to treat a motorhome in exactly the same way. e.g "It's going to cost you £XXX to have the repairs done, personally i'd get rid of it". This approach is all good and well, but we are talking about a vehicle that is going to cost a LOT of money to replace, unlike a car. I cannot seem to get this point across.

In my industry, it's a bit like saying "Your broadband router's failed. It's £100 to replace but sorry - we need to replace your entire network!!".

I am desperately trying to throw money at people at the moment to get the ball rolling. Yes - I realise that it will potentially be expensive. Yes - I realise that rust can't be beaten. Yes - I realise I might have to spend more on it next year, the year after, and the year after that. Yes - I realise that I may be throwing money away, and am completely aware of it. Yes - I may be a fool. It's only a chunk of metal after all, as some say. BUT - if I was buying new(for the vehicle I'm looking at), we are looking at £47k which equates to £4700 per year as a 10 year investment(As I'm sure readers would agree, for new this is pretty much the minimum for a new vehicle at the moment). That is a lot of money for something which, in my case, will sometimes only get used 6 or 7 times a year. It may cost me a bit of money to repair my current motorhome, but it will be a damned sight less than buying new at the moment and at the end of the day it would only do a few thousand a year.

Ahem - rant over! :-). Thanks for your patience if you've made it this far!! :-).

So the point is - I just need someone trustworthy, honest and reliable to do the body repairs on my lovely van! If anyone on these forums is able to advise me on this and knows any good companies in the North West/North Wales area, I would love to do business!
 
Yep,spend the money.

Sorry don’t know your area for recommended tradesman
 
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Wow that’s a long way of asking for a recommendation for a bodyshop that’s prepared to tackle rust issues.
Your problem I guess is like me, many just don’t want to get involved with corrosion. This is because the rust is always worse that at first it appears, it’s also very messy work and any repairs may deteriorate in a period that’s unacceptable to a customer.
Our company like others simply avoid anything to with corrosion as there is far easier work that you can offer a warranty on with confidence.
 
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Your 47k over 10 years example does not really stack up as your basing that on the assumption that the van would have no value at 10 years old when in fact it is more than likely to have a value of probably 30k or there about.
 
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In my view you need to find a specialist welder. Either on an industrial estate or mobile. I found a mobile welder licensed to work on aircraft, his work was absolutely a work of art. Someone who does it every day will happily tackle it. Check out those who specialise in mot failures or advertise as welders.

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Corrosion on FRONT UNDERSIDE.
Do you mean the front chassis crossmember below the radiator?

If so it bolts on and requires no welding.
The crossmember is readily available for, I believe, around £70.
Even for a blind man it's an hours work.
 
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In your situation I would probably be looking for a classic car specialist or someone similar. As you say, a standard car garage either doesn't know how to do it (as most people will do as they suggest and write it off) or can't be bothered (as they can make more from easier work). A classic car specialist is likely (though not 100%) to be a much better welder and also more likely to understand your point of view in regards to wanting to save the vehicle you have rather than simply chopping it in for a new one.
 
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Thankyou everyone for your points and suggestions!!! This forum is awesome. And yes - crazylegs you are absolutely right - retrospectively my description of the situation was far too long and could have been summed up in far fewer sentences!!! ::bigsmile:

It's a really frustrating thing and perhaps a bit naïve of me to think that I might have been able to easily get it all sorted. I certainly get the viewpoint that there's probably easier ways for bodyshops to make money without potential comeback.

Back to the drawing board!
 
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Your 47k over 10 years example does not really stack up as your basing that on the assumption that the van would have no value at 10 years old when in fact it is more than likely to have a value of probably 30k or there about.
No you are absolutely right. I guess it's me trying to justify the *initial* outlay for a vehicle that's going to spend far more time laid up than on the road.
 
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I agree with RubyOptics in that if you have serious rust corrosion problems and you do decide to go forward and get your van repaired, then a classic car restorer may well be your best option due to the type of jobs they are prepared to take on and their hourly rate may be more competitive.

My business before I retired was classic car restoration and historic race car race prep, and this the worst car for rust that we took on. :Eeek:
It was one of only two made so warranted saving even in as bad a state as it was when it came to us.

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The larger hole in the floor is where a tree was growing though it and the tree had to be cut down to remove the car.

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Finished and back racing again.

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I agree with RubyOptics in that if you have serious rust corrosion problems and you do decide to go forward and get your van repaired, then a classic car restorer may well be your best option due to the type of jobs they are prepared to take on and their hourly rate may be more competitive.

My business before I retired was classic car restoration and historic race car race prep, and this the worst car for rust that we took on. :Eeek:
It was one of only two made so warranted saving even in as bad a state as it was when it came to us.

View attachment 513119

View attachment 513120


The larger hole in the floor is where a tree was growing though it and the tree had to be cut down to remove the car.

View attachment 513122

View attachment 513123

View attachment 513124

View attachment 513125

View attachment 513126



Finished and back racing again.

View attachment 513127
Wow!!!! What an absolutely phenomenal job you did on that one!! Beautiful.

Thankfully our poor van isn't in that bad a state(far, far, far from it actually!), but it certainly makes me feel way more optimistic that something can be done in the right hands!
 
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