The CF Bedford Rebuild Begins

Part 3: The rust repairs begin

Because the rust had been sand blasted it was easy to find and remove all of it. Well it's never easy to remove it, as it's always in horrible places, in this case several layers.
The original CF Bedford wheel tubs were removed, as they would be replaced with lower wheel tubs as the originals were way to big and the bigger wheels would never fit in them anyway.
The area in front and rear of the floor had to be extended to except the smaller wheel tubs. Although the wheel arch repair are pretty good (but I have to say that) they don't need to be as I will be making steel flares at a later date.
I have also removed the battery box and replaced the hole with some floor ribs so as it looks original. The battery will go in the modified front foot wells.
The reddy/brown paint stuff is PA10, an etch/rust preventer. The grey is Zinc.

I started on the rear side door pillar first as that corner was only held on by a sliver of metal, the rest had rusted away.
Next was the left rear panel, bottom section. As that was also only hanging on by a thread.
Note the bracing to hold the panels in place, this was removed once the patches were finished.
You can also see in the third picture the bottom of the rear panel (under the tail light), this too had rust so the whole back corners were replaced.

The first photo in this set is still of the left rear panel, the lower rear panel removed and the rust removed and plated.
The second photo is of the left side door pillar, this too was rusted through as they often are from the door hinge. The outer skin is yet to be put on.
The third photo is from the back showing the rust from under the hinges removed, rear panel (inner and outer removed) because of rust.
Sometimes it's easier to remake the panel than to make many repairs on it.

The fuel filler hole was removed as the gas tank is being repositioned due to the midmounted motor.
The pillar below this was rebuilt, inside and out as well as the lower section of the forward panel removed due to rust.
The sill in this case was very easy to remove as the top was not welded on, don't think it was a production fault; rather someone's bad handling or repairs.
I have kept this patch panel off so I can spot weld the new sill on once inner sills have been sand blasted.
I've also removed the roof skin (not pictured), as I want to get the inners sand blasted but am removing the gutters anyway.
The windscreen frame (top) is rotten so is the drivers door pillar, both guards (fenders) have been removed to make the rust repairs easier.
I've had to make a new front pillar, well rebuild 90% of it.
The picture doesn't show too much but you will notice inspection holes around the area, it is rusted top to bottom.

I've tried to cut away as much as I can without loosing any strength, both rear lower quater panels have been removed, the rear lower panel (inner and outer), both sills, both front guards (fenders), front panel, windscreen inner panel as well as a few other bits. I have kept these panels off to be sand blasted, to make sure no rust is left, after sand blasting the panels will be treated with an etch primer, seam sealer and once finished, a good dosing of rust proofing.
Basically the bottom of the main panels had to be replaced all the way around, edges of the roof as well as the inner roof guttering, the front pillars, front inner valance and windscreen hole. As well as the door frames and front skins, front guards, sill. I think I listed them all, sure was a lot of it.