In a message dated 10/10/2006 3:47:34 P.M. Eastern Standard Time,
LISTSERV@GERRY.VANAGON.COM writes:

Well  it's time to finally address the rust on the body panel with the
camper  hookups.  Here are some questions I have:

=20

*   Does one have to remove the kitchen/sink cabinets to  apply new
undercoat behind the panel in order to do a proper job?  =20

*        Is it a big deal to remove and  reinstall these cabinets? =20

*        Can a body  shop merely cut out the rusty metal from the outside
and weld a new piece  in its place or does he have to replace the entire
panel?  =20

*        If it's only surface rust, does  sandblasting to bare metal and
painting with POR15 do the job?  The  rust only seems to be on this
panel.

    Gerry, the only way to do a proper job here is to  remove the cabinets.
You'll see why once the cabinets are outta there.  I  just did this on an '87
yesterday.  It took me 4 hours to remove the  cabinets, clean and prep the area
which is now ready for preping for POR-15  application then adding new metal.
 You will need to remove as much of the  rusted metal as possible and leave
only what is solid enough to make a  connection to the new metal.  I will now
POR-15 the entire area inside  including the rocker panel which is now opened
up and accessible.  Then, I  will add new metal from the inside using
countersunk pop rivets on the joint  that shows outside, inside just standard pop
rivets. Any small rust holes  that cannot be covered with the new metal will be
filled with POR-15 and/or  POR-15 Putty and chopped fibreglass matting.  Then the
entire area  will be covered with POR-15 inside and out.  The outside will be
 primed using automotive primer on the surface before the POR-15 is dry to
provide maximum adhesion then Polyester body filler will be used to repair  the
uneven surface area where the two metals are joined with the pop  rivets.
This is the method I have used successfully a number of times  and seems to work
the best.  Welding new metal will require a very high  level of competency on
the part of the welder so as to not warp the entire body  side panel and
thereby creating a very big job of straightening afterwards.

Cheers,

Frank  Condelli
Almonte, Ontario, Canada
'87 Westy, '90 Carat, '87 Wolfsburg  (Forsale) & Lionel Trains
Vanagon/Vanagon Westfalia Service in the Ottawa  Valley
_Frank Condelli  & Associates_ (http://members.aol.com/Fkc43/busindex.html)
_Vanagon Stainless Steel Exhaust  Systems_
(http://members.aol.com/Fkc43/stebro.htm)
_BusFusion_ (http://members.aol.com/BusFusion/bfhome.htm)  a VW Camper
camping event, Almonte, ON, June 07 ~ 10,  2007