Vanning.com logo
Boxdin
Site Navigation


Advertisements
Recent Posts
Good day
by lukester - March 28th 2024 12:26 pm
Crazy mods
by MufflerMan Mike - March 28th 2024 9:38 am
Lew Greger
by MufflerMan Mike - March 27th 2024 5:15 pm
1987 G20 Gypsy
by SDMickey - March 25th 2024 9:39 pm
Featured Links


Previous Thread
Next Thread
Print Thread
Rate Thread
Page 1 of 3 1 2 3
Drip Rail/A-Pillar/Front Wheel Arch Rust Repair - Best Strategy
#748458 May 16th 2019 3:38 pm
Joined: Feb 2016
Posts: 1,266
Likes: 43
old hand
OP Offline
old hand
Joined: Feb 2016
Posts: 1,266
Likes: 43
Hi All,

I have a 79 B200 that in general is in good condition. It was a california van but has pretty bad drip rails and some other sections of rot rust. Unfortunately there are a number of sections in the rails where the rails themselves are flaky and have spread to below the rail and above on the roof. There is even a section on the front wheel arch on the drivers side that is rotted through where the water from the drip rail came down. The A pillar seams are also bad. The low end of the van is totally fine as it never saw snow or salted roads but when the rail sealer cracked as it always did, water was able to collect and destroyed the rails.

Whats the best way to repair this? My thought is to cut donor sections of vans that have solid rails and cut them maybe 2-3 inches below the rail and up on to the roof maybe 2-3" above the rail? I know there are lots of layers to the side/rail/roof assembly and welding that all back together may be difficult and just wondering what the best approach to rust repair in this manner would be.

Any help from anyone with experience on this would be much appreciated. Thank you for looking. A few example photos below.

[Linked Image]
[Linked Image]


1987 B250 - Painkiller
Re: Drip Rail/A-Pillar/Front Wheel Arch Rust Repair - Best Strategy
Death or victory #748459 May 16th 2019 3:40 pm
Joined: Feb 2016
Posts: 1,266
Likes: 43
old hand
OP Offline
old hand
Joined: Feb 2016
Posts: 1,266
Likes: 43
I happen to live in a very rainy state and would love to eliminate any further expansion of rust on this van. I plan to fill in the side windows so body work will be a big project but willing to take it on, if it seems like its salvageable.


1987 B250 - Painkiller
Re: Drip Rail/A-Pillar/Front Wheel Arch Rust Repair - Best Strategy
Death or victory #748466 May 16th 2019 4:17 pm
Joined: Apr 2019
Posts: 96
Likes: 1
D
journeyman
Offline
journeyman
D
Joined: Apr 2019
Posts: 96
Likes: 1
Those drip rails are such a pain in the ass. I tried POR 15 on mine since they weren't rotted through but just get destroyed from always holding water inside of them. Anything that isn't rotted through I try some rust converter and then I like to coat stuff with cavity wax to prevent rust from coming back. I did the same with the windshield frame too. The front fender looks like it won't be too bad, not as much work as the roof at least. Depending on how big the rust holes in the drip rail are I would maybe consider hitting them with a needle scaler, spraying with rust converter and then filling them in with either weld or fiberglass. If the holes are too big for that then transplanting sections from another van would be the way to go. I've done a lot of rust repairs which have held up over a couple years but it seems like a constant battle to stop things like the drip rails, pillars and rear valence from rusting.

A good way to prevent it however, is to drive the van everyday:) If its always on the road water won't pool up in the drip rails haha.

Re: Drip Rail/A-Pillar/Front Wheel Arch Rust Repair - Best Strategy
Death or victory #748473 May 16th 2019 5:11 pm
Joined: Feb 2016
Posts: 1,266
Likes: 43
old hand
OP Offline
old hand
Joined: Feb 2016
Posts: 1,266
Likes: 43
I'll have to take some better pics of the conditions up close on the roof. One section has a few holes (above the front side barn door) then are some sections like along the back corner where the drip rails are eaten all the way through and rusting below the rail line. The metal is getting kinda fragile in certain spots.


I'd like to drive it every day, but even if I did that when its raining, its parked at my work for 8-10 hours while Im in the office. Also its a gas hog. So its tarped while its not being used at home at the moment to keep it from getting worse.


1987 B250 - Painkiller
Re: Drip Rail/A-Pillar/Front Wheel Arch Rust Repair - Best Strategy
Death or victory #748587 May 19th 2019 1:02 pm
Joined: Feb 2016
Posts: 1,266
Likes: 43
old hand
OP Offline
old hand
Joined: Feb 2016
Posts: 1,266
Likes: 43
Alright, here’s some better shots of the rust.

Drivers side rear van corner
[Linked Image]

Passenger side rear van corner
[Linked Image]

Same passenger spot, above the drip rail
[Linked Image]

Passenger side above the side window below the rail seam
[Linked Image]

Same spot above the rail
[Linked Image]

Worst spot is above the barn doors.
[Linked Image]


I know for sure all the rust would need to be removed before fixing any metal but based on these condition and the fact It’s not on a flat panel, but all creased, folded and welded areas, I feel like it’s a real challenge. I could see fiberglass working in some areas, or maybe welding, but I don’t really know.


1987 B250 - Painkiller
Re: Drip Rail/A-Pillar/Front Wheel Arch Rust Repair - Best Strategy
Death or victory #748588 May 19th 2019 1:35 pm
Joined: Aug 2001
Posts: 12,107
Likes: 37
Maniac
Offline
Maniac
Joined: Aug 2001
Posts: 12,107
Likes: 37
That is a comlex joint on the Dodge van body. There are 3-4 different body panels that are pinched together and welded at that seam. You need to do lots on investigating to make sure you have found all the rust and the repair will neutrallize and eliminate all the rust damage.

Start by grinding back to back metal, then remove any interior and inspect for rust inside and out. Start cutting the metal away and keep looking for rust inside the van. You might find far more than you anticipate.

The repair will likely involve fining a rust free van to get sections of the drip rail out of.


Windows- they're what make a van worth owning!
Re: Drip Rail/A-Pillar/Front Wheel Arch Rust Repair - Best Strategy
Death or victory #748589 May 19th 2019 2:20 pm
Joined: Feb 2016
Posts: 1,266
Likes: 43
old hand
OP Offline
old hand
Joined: Feb 2016
Posts: 1,266
Likes: 43
Thanks Reed. I’m definitely worried about finding more than I anticipate. I know it will be a pretty big undertaking if I start it.

It’s difficult finding a rust free van in these parts since it’s so wet. But thankfully I think all of the rails are the same on 71+ up vans so I hope that maybe finding a newer panel van can get me some good quality metal.

I’m going to patch the windows as well whenever I decide to do body work, I already found a clean panel for one side so It will be a slow accumulation of metal I think. My goal is to take the summer when it’s dry and get to as many vans as I can and use whatever I can.


1987 B250 - Painkiller
Re: Drip Rail/A-Pillar/Front Wheel Arch Rust Repair - Best Strategy
Death or victory #748595 May 19th 2019 4:06 pm
Joined: Aug 2001
Posts: 12,107
Likes: 37
Maniac
Offline
Maniac
Joined: Aug 2001
Posts: 12,107
Likes: 37
Yes. The roof is the same from 71-03.

Good luck!

WRCsixeight has a thread on the board about his repair of the roof rail above his windshield. He is a fiberglass guru and used resin and fiberglass to repair his van.

Last edited by Reed; May 19th 2019 4:06 pm.

Windows- they're what make a van worth owning!
Re: Drip Rail/A-Pillar/Front Wheel Arch Rust Repair - Best Strategy
Death or victory #748596 May 19th 2019 6:19 pm
Joined: Apr 2016
Posts: 132
D
member
Offline
member
D
Joined: Apr 2016
Posts: 132
I am about 4 hours south of you. I use to pick up junk older cars and cut up the panels to sell on the internet. I was a pretty good business for a while until scrap prices went up and everyone got rid of their junkers behind their houses. Anyway the point is I would tell some of the people to just use thier rusty van/truck/car as a parts vehicle and let me find them a good shell for the same price. No one would listen! So I would get the same shell and cut it up and send them their parts. Like clockwork about 5 years later they would call asking if I can get them a clean shell this time. There are a LOT better vans to put your time and money into. Even if you have to spend two days driving to LA with a trailer, instead of grinding rust.
Here is one in your town that looks promising.
https://www.facebook.com/marketplace/item/1055267308005973/

Here is one in Washington a few miles east, for cheap. It is in WA, so it may have more rust than the pictures show.
https://www.facebook.com/marketplace/item/896823160666282/

Re: Drip Rail/A-Pillar/Front Wheel Arch Rust Repair - Best Strategy
Death or victory #748605 May 19th 2019 10:47 pm
Joined: Feb 2016
Posts: 1,266
Likes: 43
old hand
OP Offline
old hand
Joined: Feb 2016
Posts: 1,266
Likes: 43
Dang that 78 brown one is really cool. Sucks because I have a good amount of time and money into my current van. I love the 71-78 body style much more than the 79+ but I’ve had it two years already and most of it is in good shape. But I also know that it would cost a lot of $$$ to get it where I want it. Mines an auto with a 360 and is a great running van so it’s got a lot going for it. I have been considering if another van is worth starting over with.


1987 B250 - Painkiller
Re: Drip Rail/A-Pillar/Front Wheel Arch Rust Repair - Best Strategy
Death or victory #748635 May 20th 2019 12:30 pm
Joined: Apr 2016
Posts: 132
D
member
Offline
member
D
Joined: Apr 2016
Posts: 132
Originally Posted by Deathorvictory
I have been considering if another van is worth starting over with.


If the brown one has no rust, its definitely worth it. Go take a peek. By the time you chop off the roof, fill in the windows and deal with the rust starting in the lower bits, you will have so much money in that van you can never get it out. The bad part is in 5 years or less there will be bubble popping through somewhere else. You just have to look around, other people have done what you are thinking about and regretted it. The recent post of the nice green 4x4 van was similar, he fixed it all and painted it, only to have to buy a rust free van from the southwest to replace it all when the rust came back. If you like the 71-78 better start looking for a rust free one and hold out until you do. Your good running power train can be swapped over along with the wheels and visor. There was a shorty mid 70s that was pretty good on craigslist in Eugene for 600. It never sold, the guy got his ad deleted when they started charging last month. I have no Idea how to contact him. He did have it on ebay a few months earlier for a ridiculous price. I looked and its gone from eBays completed listings too.

Re: Drip Rail/A-Pillar/Front Wheel Arch Rust Repair - Best Strategy
Death or victory #748636 May 20th 2019 1:11 pm
Joined: Feb 2016
Posts: 1,266
Likes: 43
old hand
OP Offline
old hand
Joined: Feb 2016
Posts: 1,266
Likes: 43
I don't have facebook so I generally miss everything on marketplace and I certainly cant contact anyone through it which is a bummer. I can pull that up online but I cant contact them. I've looked on offerup and CL to see if its posted there but I dont see it so I'm kinda SOL and will have to keep looking.


1987 B250 - Painkiller
Re: Drip Rail/A-Pillar/Front Wheel Arch Rust Repair - Best Strategy
Death or victory #748646 May 20th 2019 3:26 pm
Joined: Apr 2010
Posts: 2,847
Likes: 42
W
veteran
Offline
veteran
W
Joined: Apr 2010
Posts: 2,847
Likes: 42
If one goes ahead with the improper way to do it ( fiberglass), One shoulld use epoxy resin instead of (fiberglass) resin, which is polyester resin. Epoxy bond strength is quite superior, and epoxy is also more flexible, meaning it can expand and contract with the steel much better than polyester resin.

Epoxy is more expensive, must me mixed in a precise ratio by volume or weight, and then mixed thoroughly within the mixing cup. POlyester resin is much more forgiving with regards to the amount of catalyst and its mixing, and cost.

Use Ospho, available at ace hardware, for treating rust, steel and questionable paint. The rust will turn black, the steel will turn grey, the paint will lift where there is rust below it. The blackened rust can be removed fairly easily revealing brown rust or grey steel below. One can go a bit crazy in basically dissolving all rust with multiple applications and scraping tools, instead of just converting it, but one can get to clean bare pitted steel, if they desire and can reach it all.

Protect from moisture overnight when the Ospho is doing its thing.

A hair drier can speed the conversion process.

Getting maximum possible adhesion of epoxy saturated fiberglass is achieved by 'mechanical tooth' on a grease free surface, which the Ospho should have taken care of( the grease free part). I use rotary carbide bits on teh dremel or cut off wheels to make the steel super rough with sharp valleys and mountain tops for maximum possible adhesion.

Honestly doing it as best as one can with fiberglass is likely a lot more work than if one can cut out and weld in donor parts. I do not have the latter ability, but I am good with fiberglass and have all the materials on hand. My war with rust will ultimately be lost, I just want to slow it as much as possible.

Much of my roof gutters over barn doors side and back, is rebuilt with aluminum C channel, and epoxy and fiberglass.

Its no show van but the gutters are functional and sealed, mostly. The area around the top of my windshield was really bad and I have used a considerable thickness of fiberglas to not only rebuild the skin but to also lend some strength to the fiberglass conversion van roof. The original covnerters used drywall screws and the leading edge of the roof these screws basically did not penetrate steel, so they did nothing other than gouge paint and prep it for rusting and securing the roof here properly became a mission.I did not adhere the roof to the fiberglass covered steel below th econversion van roof and the caulk will still split with body flex. I need to rewax what remains of my roof gutters often and try to prk downhill if it is not going to be driven much to keep moisture from pullding in the gutters.

Re: Drip Rail/A-Pillar/Front Wheel Arch Rust Repair - Best Strategy
Death or victory #748647 May 20th 2019 3:28 pm
Joined: Apr 2016
Posts: 132
D
member
Offline
member
D
Joined: Apr 2016
Posts: 132
Originally Posted by Deathorvictory
I don't have facebook so I generally miss everything on marketplace and I certainly cant contact anyone through it which is a bummer. I can pull that up online but I cant contact them. I've looked on offerup and CL to see if its posted there but I dont see it so I'm kinda SOL and will have to keep looking.



Its not like facebook costs anything to join. You have internet, so your good to go if you want to find a solid van.

Last edited by Don_F; May 20th 2019 3:28 pm.
Re: Drip Rail/A-Pillar/Front Wheel Arch Rust Repair - Best Strategy
Don_F #748650 May 20th 2019 4:28 pm
Joined: Feb 2016
Posts: 1,266
Likes: 43
old hand
OP Offline
old hand
Joined: Feb 2016
Posts: 1,266
Likes: 43
Yeah, screw facebook. I haven't had it for over 5 years. Not intending to go back now.

Last edited by Deathorvictory; May 20th 2019 4:30 pm.

1987 B250 - Painkiller
Re: Drip Rail/A-Pillar/Front Wheel Arch Rust Repair - Best Strategy
Death or victory #748653 May 20th 2019 6:47 pm
Joined: Apr 2019
Posts: 96
Likes: 1
D
journeyman
Offline
journeyman
D
Joined: Apr 2019
Posts: 96
Likes: 1
I'd still say go with a needle scaler, blast thru all the cancer so it doesn't spread and then spray rust converter on whats left behind. Fill the holes and enjoy the van. It would look half decent and last a while too if you do a good job. The van looks nice from those shots so I'd give it a shot fixing it.

Re: Drip Rail/A-Pillar/Front Wheel Arch Rust Repair - Best Strategy
Death or victory #748705 May 21st 2019 4:48 pm
Joined: Feb 2016
Posts: 1,266
Likes: 43
old hand
OP Offline
old hand
Joined: Feb 2016
Posts: 1,266
Likes: 43
I found this old thread which is super helpful to
Visualize what’s happening in the roof of my van. I’m pretty sure if I can wrangle the right help and am patient, I can get her fixed up. Going to stick to my plan of cutting pieces from donor vans that I can find and get a solid plan together for the late summer. Best part about summer here is that it stays dry and warm. I may be able to get this done a time my own house if I can borrow a few tools.

https://www.vanning.com/threads/ubbthreads.php/topics/419699/3.html


Last edited by Deathorvictory; May 21st 2019 7:14 pm. Reason: Typo

1987 B250 - Painkiller
Re: Drip Rail/A-Pillar/Front Wheel Arch Rust Repair - Best Strategy
Death or victory #748712 May 21st 2019 7:37 pm
Joined: Apr 2019
Posts: 96
Likes: 1
D
journeyman
Offline
journeyman
D
Joined: Apr 2019
Posts: 96
Likes: 1
Holy crap, that looks real nasty on the other thread. If that van can be saved so can yours. Glad to hear you going for it though, your ride is too cool to give up on and in pretty decent shape from the pictures of it.

Re: Drip Rail/A-Pillar/Front Wheel Arch Rust Repair - Best Strategy
Death or victory #748714 May 21st 2019 8:54 pm
Joined: Feb 2016
Posts: 1,266
Likes: 43
old hand
OP Offline
old hand
Joined: Feb 2016
Posts: 1,266
Likes: 43
Thanks, I just need to see it through. I’ve got lots of plans for this van and like all things, anything I take on will need something which requires time and money so I’m just gonna keep on truckin with this van. I’m sure mine is gonna be pretty rough in areas but nothing some power tools can’t coerce into submission.


1987 B250 - Painkiller
Page 1 of 3 1 2 3

Moderated by  Astro, nautic1, Ram4ever 

Link Copied to Clipboard
Donate


Upcoming Events
discovery
Who's Online Now
0 members (), 17 guests, and 6 robots.
Key: Admin, Global Mod, Mod
Newest Members
TheDrunkenGunsmith, Jac, LOVclassics, ZenMuffin, Milkman530
12724 Registered Users
Top Posters (30 Days)
SDMickey 129
CatFish 25
frscke1 25
Wedgy 21
Forum Statistics
Forums68
Topics35,746
Posts537,916
Members12,725
Most Online177
May 8th, 2013

Powered by UBB.threads™ PHP Forum Software 7.7.4