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Zippypilot

Member

From: Sussex

Registered: 2019-06-25

Posts: 112

Rear end rust! Have a look at my MOT failure today!

Hi all, been a while since I posted.

Today is one eye opener of an MOT!

The issues are....

Offside Rear Vehicle structure excessively corroded within 30cm of towbar mounting (6.1.6 (i) (i))

Nearside Rear Vehicle structure excessively corroded within 30cm of towbar mounting (6.1.6 (i) (i))

Now, this year I removed the tow bar frame and the electrics, to refurbish them, and inspected the areas above (obviously with the spare wheel  removed) as we now have a trailer tent. Spare wheel removed, all looked ok. I refitted the refurbished frame etc and all looked good. Ok on the nearside it was rusty around a box section but nothing too excessive (after all it had passed 4 previous MOT's with the same and the off side was pretty much great looking.)

I took the trailer tent out a couple of months ago, not issues at all and that's that.

Ok, the MOT today has revealed one hell of a cover up, was going to say 'bodge' but a bodge is a temporary repair not this!

Both sides have blown for a better word, there is so much rust and little metal left, all covered in filler and paint! Please see the pictures.

To say I am really not happy is an understatement, I mean, I missed this for 4 years of ownership and so did all the MOT places!

Please check out the pictures and maybe have a look at your van and yes it is a known problem but really, covering in filler is so dangerous!

I will be stripping the rear end, bumper, liners, tow bar etc to see how far this rust has gone, if it stops at a reasonable structure, I will be fabricating a full repair (if so I will try and document what I do) nothing is irreparable but geez glad the MOT was today and not next spring after taking the trailer tent out for another run!

Hope this is useful

Last edited by Zippypilot (2023-10-16 22:42:32)

Zippypilot

Member

From: Sussex

Registered: 2019-06-25

Posts: 112

Re: Rear end rust! Have a look at my MOT failure today!

AlvyLad

Member

Registered: 2021-06-11

Posts: 266

Re: Rear end rust! Have a look at my MOT failure today!

wowza... that's a days work for a welder (these parts of the woods £300-£400), and got to be sure appropriate steel is used (I think it's 2.5mm) and afterwards rust proofing etc

I had some, but got minor welding sorted- got MOT, but clearly last one, as for the next one, it'll be near like yours

Zippypilot

Member

From: Sussex

Registered: 2019-06-25

Posts: 112

Re: Rear end rust! Have a look at my MOT failure today!

Hi, yep a real shock, thanks for your reply.

I think it's going to be a lot more than a days work for a welder but yes, £300 to £ 400 is about right. The extent of the cover up rust is way beyond this box sections and into the rear structural valance etc

I will be doing most of the work myself, the cutting out and going back to good metal, the fabrication of new box sections and brackets etc. I can weld ok for these things but welding them to the structure is a bit beyond my skills.

I think you maybe right with the structure being 2.5 mil, some of the panels around these places are 1.2 mil so guessing will need a good welder to do the attachment work.

I am going to my mechanic friend Thursday for the appraisal, if he says write off, well I will just have a good go myself, nothing ventured etc

If it is a write off, I will try and take as many pics as I can to post for details of this for others to see if this affects their vans too.

Last edited by Zippypilot (2023-10-17 23:17:38)

JohnDragonMan

Member

From: Derby, East Midlands, UK

Registered: 2020-06-02

Posts: 387

Website

Re: Rear end rust! Have a look at my MOT failure today!

i was quite lucky with my van, on mine the rust was not so bad in this location on both sides. i still thought it was a pretty bad place as the rear wheels fling all the much up into there.
i cleaned it all up, painted it with a paint with built in rust converter and plated over it.

heres a before and after:

---

- JohnDragonMan
Notice: I have the tendency to void warranties, blow fuses, cause fires, and other fun stuff.
Words of wisdom: Internally rust proof the sills and subframe! both skins!!. There's always user serviceable parts inside. "Oh that shouldn't have happened".
My Crazy Mk2 2005 Dispatch Camper Project

Zippypilot

Member

From: Sussex

Registered: 2019-06-25

Posts: 112

Re: Rear end rust! Have a look at my MOT failure today!

Hi John

I have been watching your YouTube vids on this! What a great job you did. Love to know the paint you used.

To be honest, I am very unsure how far this rot monster has gone until I start stripping it all back, yours does look very similar to mine, mine is covered in filler (presumably by some shyster to get through an MOT years ago, it's now showing it's true self!. I know many will just scrap the thing but that's not my thing. I can fabricate and sort of weld (I can make all the parts need) and do all the cutting out etc, just welding back these to the structure needs a good welder me thinks lol.

Your vids on your repairs to your van has given me confidence that I can actually get this thing fixed and better than manufacture with the addition of extra gusset plates from the rear beam to the sub frame. And yep, the mud and crap flys in from the wheels so will be making a close off 'skirt' around the rear of the rear wheel arches.

Thanks for your inspirational vids

Last edited by Zippypilot (2023-10-17 23:31:11)