Where do i start with my van cab repairs?

[Peter McNaught]

I am about to start the epic job of repairing my van, starting with the cab floors, lower rear panel, sills and B post bottoms. I keep going and looking but can not decide whether i need to remove the van body from the back. I keep seeing pictures of repaired van cabs without the backs on, but surely you need the van back in place to align the lower cab back panel? I guess there are plenty of van owners out there that have been in the same situation. Any advice would be greatly welcomed.

[les]

I can assure you that the back needs to come off if you want to make anything like a decent job. Once it's out of the way you have full access to the B posts, and will be able to weld the bottoms without burning through the rubber gasket, you also have full access rather than having to clamber through the back doors every 5 minutes! Chances are you will want to remove the cab from the chassis as well, to get to the underside for welding and sealing. Any chassis repairs are easier then.
Regarding keeping things lined up, you will need to take photos and every measurement you can think of, the rear panel should be marked at the point it is welded to the B posts, that way you can fit the new panel at the same height, and so on and so on!
Good luck-----I'm never going there again!

[Peter McNaught]

Thank you for the advice Les, the thought of seeing the chassis in full, minus the cab and back is quite a scary one. I did ponder the new chassis route but have decided to keep the original after much poking and scraping of old underseal, it is not that bad, a few patches which can be repaired.

I shall have to take the bold step of removing the back, i shall post pictures once i get started.

[JPX877J]

However when you refit the back, be prepared to jiggle things!

Also ours is having the B post replaced so needs the back on to square before it is replaced.