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Re: 1989 E150 conversion camper build
bubbafat #739476 August 17th 2018 2:28 pm
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It has been a while since I had a van with a slider dor, but I do believe both the front and rear latches are supposed to positively catch and hold. What happens when you rotate the door handle up towards the front of the van? It is supposed to retract the latches and pull the door in tight. If it doesn't do that then you have some internal door linkage issues.I would focus on getting both the front and rear catches working properly before worrying about the stop for the extended arm. This is when you really need a factory service manual.


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Re: 1989 E150 conversion camper build
Reed #739478 August 17th 2018 2:33 pm
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Originally Posted by Reed
This is when you really need a factory service manual.


That's what I'm working from - it's decent in terms of descriptions but does assume you know quite a bit about how things are supposed to work.

I have made an appointment to have a body shop diagnose the issue on Tuesday - I need to get back to the build and let someone smarter figure that out.

Re: 1989 E150 conversion camper build
bubbafat #739484 August 17th 2018 7:19 pm
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Setting aside the door, after work I got about 3 hours before the rain cut the night short. In that time my daughter and I took down the rest of the walls, window and door trim, removed all the insulation, got the rest of the carpet up, removed the furring strips on the floor (leaving the wall strips until we decide on the wall build) and took the louvers off the rear windows. After a vacuum, the decision on the floor was made.

Weekend plan:

- take the ceiling down
- remove the subfloor
- clean the subfloor
- cut and lay 1/2" subfloor
- cut and lay laminate flooring

Once the floor is down I think my wife will calm down a bit about whether or not I've lost my mind.

I mean, she'll still be right.

She'll just be less vocal about it.


Re: 1989 E150 conversion camper build
bubbafat #739545 August 19th 2018 5:37 pm
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Pulled up the rest of the floor and found this:

[Linked Image]

So here's my thought: clean it up and cut back the rust, apply a rust abating primer, then one of the following:

- pull the bolt, weld in new sheet metal, reinstall the bolt.

- take two pieces of sheet metal and notch out a half Moon on each side to wrap the bolt. Weld in place and weld to the bolt.

- weld it over the bolt. The frame is never coming off.

Removing the bolt makes me a little nervous in the event it breaks off. Second option is what I'm leaning to.

But I don't know how to weld. So a buddy came over and gave me the 10-minute intro to mig welding and left me his spare mig equipment.

[Linked Image]

My first four, really bad, welds covering some unused bolt holes from a seat I removed.

Also finished with the rest of the floors and checked the other bolts and I'm ok on the rest. No rust forward of the rear wheel well.


Re: 1989 E150 conversion camper build
bubbafat #739552 August 19th 2018 10:04 pm
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Nice work! You are doing fine. Mill Supply has a lot of patch panels you might need: http://www.rustrepair.com/PANELS/75-FORD-ECONOLINE-VAN-CARGO-PANELS-BODY.HTM


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Re: 1989 E150 conversion camper build
Reed #739553 August 19th 2018 10:21 pm
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Originally Posted by Reed
Nice work! You are doing fine. Mill Supply has a lot of patch panels you might need: http://www.rustrepair.com/PANELS/75-FORD-ECONOLINE-VAN-CARGO-PANELS-BODY.HTM


Appreciate that - thanks. It was a lot more fun than I anticipated.

Definitely bookmarking that site.

Re: 1989 E150 conversion camper build
bubbafat #739586 August 20th 2018 3:54 pm
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Sorry about the rust. But congrats on learning to MIG. It will continue to get better with practice. Nothing liek doing things yourself if you can.

Re: 1989 E150 conversion camper build
bubbafat #740011 September 02nd 2018 2:39 pm
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Floor repairs are finally done!

[Linked Image]

Don't zoom in. My welds are terrible.

Meant to be here last week but last weekend turned into dealing with my daily driver - ended up trading it in. It can be someone else's problem.

Next step is a good scrubbing and then adopting a bed liner before putting down a 5/8 subfloor.

Re: 1989 E150 conversion camper build
bubbafat #740045 September 03rd 2018 6:41 pm
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Bed liner down. Also did several fiberglass repairs on the high-top.

[Linked Image]

I have two leaks I'm chasing. One is coming in at the top of one of the side windows (in the back, not driver area). The other seems to be leaking down the sliding door hinge channel and dripping out where the channel for the siding mechanism meets the pillar.

Any ideas on debugging those?

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