cladding removal, rust mitigation, cladding remount

cladding removal, rust mitigation, cladding remount

Postby foxfire [OP] » November 4th 2020, 8:25pm

Trying to take care of some rust before it gets bad, and add some 'flair' (pun intended). Gotta start with a question, though...

...this aint factory, right?

20201104_131015.jpg


Drivers side door cladding. Thwre was two fat strips of double sided foam stacked on top of another holding (barely) at the bottom...same with the piece just behind the door.

I bought a couple rolls of 1/4" 3M VHB mounting tape. I see where it goes on top, but how do I adhere the bottom?
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Re: cladding removal, rust mitigation, cladding remount

Postby foxfire [OP] » November 4th 2020, 8:27pm

Correction...

The pic ois of the behind the door piece. But the door cladding was in a similar fashion.
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Re: cladding removal, rust mitigation, cladding remount

Postby foxfire [OP] » November 4th 2020, 8:35pm

20201104_132354.jpg


While im asking questions...whats with the upside down pics on this site? Easy fix?
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Re: cladding removal, rust mitigation, cladding remount

Postby AstroWill » November 4th 2020, 9:21pm

foxfire wrote:While im asking questions...whats with the upside down pics on this site? Easy fix?


https://www.astrosafari.com/viewtopic.php?f=5&t=122977

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Re: cladding removal, rust mitigation, cladding remount

Postby foxfire [OP] » November 5th 2020, 1:15am

Oooo, thanks!
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Re: cladding removal, rust mitigation, cladding remount

Postby Rod's Trucks » November 5th 2020, 2:11am

Foxfire,
What you have for attachment looks just like some of what I found on my '98.
I know mine had been through a body shop previously, so mine may not have been original.
Some of my sections had a heavy plastic extrusion that the cladding clipped into at the top edge, and then the tape was at the bottom. The heavy extrusion was also held in place with the industrial double-sided tape.
Using the 3M roller wheel took a lot of the effort out of getting the tape off, but it still took a lot of time and effort.
I think I have some pictures in my gallery.
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Re: cladding removal, rust mitigation, cladding remount

Postby foxfire [OP] » November 5th 2020, 4:09am

This van had an accident reported, and i can see signs of "work" done on the drivers side. My big question is...is the thick foam slab nessicary? Or is there somewhere/somehow else i should secure it? Gonna have the VHB tape on top, and plastic fasteners on the bottom.
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Re: cladding removal, rust mitigation, cladding remount

Postby foxfire [OP] » November 5th 2020, 4:15am

The panel on the door was only held on top with tape (secure), and the foam hunk middle-bottom (not secure). Nothing at all towards the bottom edge. Same with the panel to the rear. Dont seem right.
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Re: cladding removal, rust mitigation, cladding remount

Postby foxfire [OP] » November 5th 2020, 4:37am

Results of day 1:

20201104_112924.jpg

20201104_152408.jpg

20201104_155605.jpg


Couple-few hours of work and a few beers in (moving slow recovering from knee surgery)...so far not too bad under there.
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Re: cladding removal, rust mitigation, cladding remount

Postby foxfire [OP] » November 6th 2020, 3:59am

Day 2...passenger side.

20201105_200102.jpg

Someone jacked in the wrong spot. Driver side too. I used a wood block to hammer the door gap back even and bent the pinch seam straight.

20201105_195945.jpg

This is what i was worried about. Same damage as my last van...gotta be a design flaw. Between the two big spots is packed full of spongy sealant foam. Holds water/salt/crud.

20201105_200310.jpg

Probing for solid metal. You can see the spongy demon foam hanging out the bottom hole.

20201105_201422.jpg

About as good as it gets this round. Still foam in there...would have to cut it open much more to get it out. Thinking once its all prepped/converted/sealed, gonna fill the top hole with screen and bondo. I'll probably leave the bottom hole open to let it breathe (any naysayers, please say your nays). The red mark notes top of the cladding, so it will be hidden.

20201105_201207.jpg

The mess made it around behind the slider too, so i got started cleaning that up.
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Re: cladding removal, rust mitigation, cladding remount

Postby AstroWill » November 6th 2020, 4:09pm

What a mess, glad you are getting it done!

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Re: cladding removal, rust mitigation, cladding remount

Postby foxfire [OP] » November 7th 2020, 2:47pm

A bit more progress yesterday.

20201107_064529.jpg

Got the ol' Frigidaire up in the air at the end of the driveway and popped all the body plugs. Cleaned up both sides of the pinch seam with a wire wheel...wasnt bad. The front side will get some anti-rust paint. The back, undercoat (along with the wheel wells).

I cut a legnth of flexy 1/4" hose and fit it to my compressors blow gun...this let me blast out all the debris from inside the rocker and the other cavities. And there was debris...probably a pound or so of sand and pebbles came flying out of there. Didnt see much for rust flakes coming out, though...so thats a good sign. Once im done with all the paint work, i plan to flood out all these cavities with fluid film.

20201107_064732.jpg

Where i need to patch i bent the edges of the hole in a bit and brushed all the bare metal down with a rust treatment, hitting insides and back sides as much as possible. Another light sand, then I stuffed it with some rolled up nylon window screen. In my head, this is gonna do a couple things...provide backing for the bondo (the fiberglass reinforced stuff for first two coats), and hopefully hold it off the back metal enough to allow drainage...hopefully.

20201107_064842.jpg

A little smoke, a little drink, some Charles Mingus on the hi-fi...and plenty of noxious fumes in the garage. The disposable "cup" i fabbed up for the rust treatment says it all.

Still...managed to keep my head in the game long enough to get two good coats of glass filler, and one nice thin coat of regular bondo.

20201107_064358.jpg

Gah...found this while poking around. Gonna clean it up a bit and give it a coat, but i gotta stay focused on the areas behind the cladding. Been blessed with a stretch of warm dry weather, it wont last long.

Alright...sun's coming up, better get back at it...
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Re: cladding removal, rust mitigation, cladding remount

Postby foxfire [OP] » November 7th 2020, 2:57pm

Quick questions...

First, the lower hole on the fender...leave it open for ventilation or stuff it with bondo?

Second, i cant find replacements the rectangular plastic fasteners that held the bottom edge of the cladding...anyone know where these could be had, or a good alternative? Im thinking maybe some of those plastic xmas tree looking push in plugs, if i can find the right size.

Speaking of those plugs...i hate the idea of running the self tapping screws back in there. Think with a few extra well placed tape strips, i could use the plastic dealys in place of the screws?
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Re: cladding removal, rust mitigation, cladding remount

Postby sfeaver » November 7th 2020, 3:22pm

Those are part number 15690729. A google search shows online dealers selling them. Not sure if aftermarket makes them, but I would think somebody does.
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Re: cladding removal, rust mitigation, cladding remount

Postby foxfire [OP] » November 9th 2020, 4:30am

Lots of progress...pics to come.

Trying to track down the thick foam tape for the door panels. Its 1"×5/8" (actually, strips of 3/8" and 1/4" sandwiched together). These panels have nothing but tape holding them...want some good stuff. Anyone got a line?
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Re: cladding removal, rust mitigation, cladding remount

Postby foxfire [OP] » November 9th 2020, 5:25am

20201108_220245.jpg

Mmm...bondo.

20201108_214014.jpg

After owning a few of these vans, I've noticed where the common rust issues are. One of the spots is the leading edge of the front fenders. Surenuff...paint was flaking off, rusty underneath. Tedious work, but hopefully worth it.

20201108_214204.jpg

Soooo much work getting to this point.

20201108_214230.jpg

At last, color.

20201108_214329.jpg

Next up, tackling this pile...
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Re: cladding removal, rust mitigation, cladding remount

Postby icebrrg3rd » November 9th 2020, 12:54pm

Mine has that same issue of someone jacking the front and bending the pinch weld and pushing the rocker up into the door gap. Think it's probably from a hoist and the mechanic didn't set the blocks to allow clearance for the rockers. I'll have to try your method out, I was going to take it to a frame shop where they have hydraulics to straighten frames, but never go around to it.

Good luck with the rust repair.

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Re: cladding removal, rust mitigation, cladding remount

Postby foxfire [OP] » November 9th 2020, 1:48pm

Looks like im missing a few parts...

astro_cladding (6).jpg


astro_cladding (5).jpg


Stole these images from this site...

Of the hardware shown here, i only had the 2 metal channels for the rockers (rusted away) and the fat foam tape. On my door panels there are tabs mid-height that look like they should snap into something (look at my 2nd post above, pic of door panel). What i dont have are the 4 black plastic looking things lower left of the first pic. In some of the "cladding removal" posts around here, i keep seeing a 3rd (mid-height) tape line for the door panels.

Id like to do this right...what do i need? Cant even find a good parts diagram for the body.
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Re: cladding removal, rust mitigation, cladding remount

Postby foxfire [OP] » November 10th 2020, 4:26am

Still at it...

20201109_211404.jpg


20201109_211449.jpg
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Re: cladding removal, rust mitigation, cladding remount

Postby wentworthassoc » November 10th 2020, 2:14pm

how do i save atopic that i like? Like this one.
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