Cutting It Out

So far, the two essential tools for getting rid of the rust seem to be an angle grinder with a paint stripper wheel and a cutting wheel. If you can’t grind it out, cut it out.

The roof rack was a surprisingly bad area. Since we had stuff and/or a tarp up there for 4 years, it seemed to be a spot where moisture could accumulate and linger. And, all the stuff bouncing around and scratching up the paint probably didn’t help. A perfectly-sized roof box would be the way to go next time, so I’ll be searching for something. If anyone knows of an existing product, please let us know.

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Complicating matters is the rain. I can spend hours grinding out the stuff, then it’s back the next day after wet night. Incredible. But, on the whole, things are moving forward. It’s just frustrating. And, I just keep finding more to do.

I think my biggest issues have been corrosion from the inside out. The entire floor area only had surface rust from the underside. The interior was the big mess.

I think every time we piled into the bus during a rain or spilled water on the floor when filling our sink (every time, basically), a little bit more went under the flooring and just sat there rusting away. It was still wet when I pulled the floors out and the wood was rotten. The best prevention is keeping the bus dry on the inside, I suppose. We’ll be going with linoleum flooring this time around to try to keep the water out.

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The infamous windshield spots were bad enough to let water inside and rust out the  edges of the dashboard! Cut and weld. I’m getting better with practice…

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And, unless someone objects, this will be the last post featuring photos of rusty metal. I hope.

10 thoughts on “Cutting It Out

  • October 7, 2013 at 10:56 PM

    When restoring my 70 Westy, my body shop guy took the rust on my floor out and then came up with the perfect way to keep the rust from coming back. Truck bedliner tinted the same color as the bus !!! This is perfect, mosture from inside the bus can’t get to the metal. Even if you have linoleum it can get under the floor from the edges, and trust me it will, but the bedliner will keep it from the metal and it’s tough stuff. Doen’t cost that much either. Before you put the floor back in, have it sprayed on.

  • October 8, 2013 at 12:24 AM

    Gary – I’m considering some sort of rubberized coating. But, I’ve also been warned against it – two sides to every story!

  • October 8, 2013 at 2:23 PM

    This gives me an idea to build an insert into the original luggage rack that keeps things from scraping the roof. Still, I’d like a lockable waterproof rooftop cargo box. Similar to the popular Yakima or Thule systems, but perfectly sized for the Westy cargo area. Not too much to ask, right?

  • October 8, 2013 at 10:33 PM

    I have a spare fiberglass top, two section, non-westy- sundial USA made. You can have it if you can ship I

    t. Rusty

  • October 9, 2013 at 4:36 AM

    A locking Thule, Yakima box for the Westy rack would be pretty cool ! But either way , something that helps to protect the roof is the main thing. Also too , i don’t know if your looking to paint the westy top itself, but i ended up using yacht paint and a year later still nice and white , no chips

  • October 9, 2013 at 7:22 AM

    Jason: The USMC undercoat/rustproof all their vehicles with Tectyl 2423, give me an address & I will send you a gallon, flat black in color & roll it on with a paint roller. USMC vehicles, some of them “swim ashore” in salt water so they have severe corrosion potential. Inner panel on your Bus use the LPS-3 & lots of it. Bruce

  • October 9, 2013 at 8:22 AM

    Bruce – Awesome! We’ll be happy to try it out!

  • October 9, 2013 at 1:07 PM

    Jason best stuff I have found to stop rust is rust bullet

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