[markomate2017]

Hi
I've been working on this van over the Winter.
Its a solid van but the radiator core support has corroded, they all do this!
It means the front drops by over 50mm, the front fenders bend and hit the doors and the cooling fan hits the fan cowling.
Here is the van before I started work.

This is how much the front has dropped

It can only be repaired by removing the front core support and repairing or replacing.
Stripdown started

You have to drill out the spot welds to remove the panel
Panel removed
 
This what it's supposed to look like!

I tried a lot of places but I could not find a new or new/old panel, so I had to repair the old one.

[markomate2017]

Rebuilding the old panel.
I have never welded car before so this will be good practice before I do the welding on my MGB!
I'm using an old Murex (British) MIG welder, 0.8mm wire and Ferroline gas mix.
Watched lots of YouTube videos!
First thing was to find some reference dimensions!
I made a template by measuring the chassis mounting points, then made a simple fixture.
Before then I made some new parts from 2mm steel.
Some before and after pics below.
 
 

[isandpauk]

It would be nice to know what is the exact model&year as there still might be spares for it.
As an example, I got few front cowling panels for my VW Taro-s (Toyota hilux (89-97)) with quite ridiculous price few monts ago.
Sample pic:
https://shop.klokkerholm.com/xProductCat...roup=78522
I know that I cant improve my sheet-metal welding/repairing skills so much by installing entire new panels but I need to save time and money.

[markomate2017]

Adding metal
I'm doing the right side first, it has a little bit more metal left to use as a reference!
I built the panel up using small repair patches with large butt plates behind, the used plug welds to join.
The other side will be neater!





I've just got a TIG welder so Ill be trying that out this weekend.
Using MIG is fine, just got to be careful, use high amps, but only 1 second weld time or it burns through!
The metal is 0.75 to 1mm thick

[markomate2017]

Im using a low cost CAD package (Card Aided Design!)

[markomate2017]

It would be nice to know what is the exact model&year as there still might be spares for it.
As an example, I got few front cowling panels for my VW Taro-s (Toyota hilux (89-97)) with quite ridiculous price few monts ago.
Sample pic:
https://shop.klokkerholm.com/xProductCat...roup=78522
I know that I cant improve my sheet-metal welding/repairing skills so much by installing entire new panels but I need to save time and money.

Hi Its a 1995 GMC Safari/Chevy Astro Van

[highway2hell]

If you need any used parts for your car, the best van scrapyard is in Riisipere. My friend is stripping chevy van and astro buses there. His number is 51907721. Also speaks english!

[markomate2017]

If you need any used parts for your car, the best van scrapyard is in Riisipere. My friend is stripping chevy van and astro buses there. His number is 51907721. Also speaks english!

That's great info thanks
I did try quite a lot of people but probably not him!

[markomate2017]

Started to add some new metal!

[markomate2017]

More metal added. The right side is now finished!

[markomate2017]

Finished welding the core support

[oliveer]

Noice welding job!
What are called those pin points what holding two panels together?

[90Deville]

They are called Cleco’s

[markomate2017]

Nice welding job!
What are called those pin points what holding two panels together?

Thanks! 
It's practice for when I weld my MGB!
Yes they are called Cleco pins or fasteners.
You can buy them on Amazon UK or DE or Ebay Uk or DE
I use them to create a reference hole when fitting panels together, you can overlap the panels, get the right location, then drill for the Cleco,s, then take the panels apart and cut them to size without losing the location.

[markomate2017]

Bodywork is complete!
To refit the core support I had to stretch the body back to shape!
I fitted lifting bars to each side then used an engine crane to pull the front end back up.
I gently used a rubber mallet to ease the panels back to shape.







Some before and after pics!






It's not a full restoration.
The van was going to be scrapped if the body wasn't repairable.
More mechanical work needed, but its now solid.