Starting on the rust....

one picture

Well... time for an update! I wanted to have it ready to go away in September but other things came up and when I knew it wouldn't be ready so slowed down a bit... I also wondered if it would ever get back together, wondered dear god what have I done and considered a box of matches and a can of petrol... but I can now see an end in sight. I've been able to spend a bit of time on it over the past couple of weeks and now see an end in sight. Hopefully it won't be too much longer before it's running and I can use it!

All the welding is done which is great and the cab has been painted... ish.

It's not a perfect paint job but it's fine at the moment. The shuts, engine bay etc. are ok. I need to paint the outside of the doors so next year when the weather is better I'll spray the outside again. It's at least watertight so I'm happy! I have made sure it won't rust again! I waxoiled the arches, sills, front panel, engine bay.... I have also coated the arches and front crossmember with underseal on top. It should be protected now! I wonder why I went to so much effort in some parts of the engine bay, now I've sprayed waxoil it looks all mucky now. But no rust!

I decided not to weld the battery tray in place. I trial fitted it and it will bolt in place, I've just painted it and the air filter box etc. Once they dry I can fit them! At least being bolt in I can keep an eye on it and make sure it won't rust under there... though with all the waxoil it's unlikely!

One question, where does the fuel filter fit to? I've been putting little bits and pieces back together today and and struggling to see where. Unless it's to the battery tray?

I've had a bit of a problem this side. I have fitted the fuel pipe but unfortunately the mk2 wings are different with how the fuel filler sits so the pipe must also be different. It's fitted but sticks out so I either need to cut and weld the pipe, or I need to try and find a mk2 pipe - which is the preferred option. To clarify this was a mk1 model but now has the mk2 front, wings and doors.

The doors were a nightmare to fit. The mk2 handles are slightly different to the mk1, it has a shallower dish for the fingers. The latches, handles all look the same but are slightly different. Also in between the hinges there is a gap I need to fill in on the a post. I thought the doors were a straight swap but there are differences that are or will cause lots of work!

Another question, the engine wiring by the arch, should this run in between the inner and outer wing?

While everything was apart I decided to add a bit more soundproofing. I have fitted closed cell foam soundproofing and sprayed a truck bed liner on top. I am also going to fit some bitumen tape on top. Plus the existing liners and carpet will go on top. Hopefully it will make it a bit quieter.

It's difficult to see but whilst I was doing the welding I cut into the footwell arch and have given myself a footrest. My foot was always uncomfortable as the wheel arch would tilt it - now there's lots of room! And still plenty of room for the wheel - phew!

With the truck liner sprayed on...

dsj1979 schrieb: ... The mk2 handles are slightly different to the mk1, ...

Hallo Daniel,
I have a problem to understand: What do you mean with mk1 and mk2? Can it be that you means the Typ of the Ducato: 280 or 290?

But otherwise, you have done a good job. Congratulation!

Thank you! Yes 280 and 290. It's a 280 vehicle with now 290 front panel, wings doors etc.

The subtle differences between 280 and 290 are annoying, things look the same but a tiny difference provides an annoying headache!

Hi Daniel, you ask, One question, where does the fuel filter fit to? I've been putting little bits and pieces back together today and and struggling to see where. Unless it's to the battery tray?

The fuel filter is located at the front part, across the fuel pump. Unfortunately i can't make photo's at this moment because i am painting our camper now.

Hallo Daniel,
sorry, I did not read your question. Here is an picture from the fuel filter .

Ah, excellent thanks. I was putting it all around and couldn't see where it fits. I maybe missing a bracket on the new front panel for it to fit but that is easily sorted.

All the engine wiring is (hopefully) all plugged in now with the exception of the lights and indicators. That'll be done once I make some brackets to mount the headlights. Another one of those 280 going to a 290 problems!

Daniel, there aren't problems, they are challenges. :daumen2:

I've fitted all of the bitumen sound proofing to the cab! That means I can start putting the dash back together!

I've fitted a new windscreen now which has been sealed in with window sealant as well; hopefully if no water gets behind the seal it won't rust again. I have covered the underside of the wiper panel with waxoyl (as with the rest of the cab!) so I'm hoping not to have to work on it ever again!

The wiper system is all fitted and appears to be working, the little bits in the engine bay have been painted and fitted. Battery tray, air filter box, spare wheel bracket etc.

The battery tray has been bolted in so that provides easy maintenance should I need to get behind there in future.

December has been a good month, I've managed to get lots done! There will always be a million jobs to do but I'm hoping it will be roadworthy and able to be useable by the end of January!