Mel and I decided to remove the old fuel filler bump on the inside of the van. This not only cleans up the interior but will make interior panel fab easier.
http://images46.fotki.com/v372/photo...MVC015F-vi.jpg
Didn't make sense to leave it as the fuel fill will be in the back now.
http://images108.fotki.com/v191/phot...MVC014F-vi.jpg
We used an air chisel to get the old seam sealer out. Couldn't get it all so using the plasma cutter was just making a mess of it. We ended up cutting it out with a cut-off wheel on a die grinder.
http://images57.fotki.com/v1354/phot...MVC017F-vi.jpg
This left the flange spot welded to the body so we used a spot weld cutter and the air chisel to get that off.
http://images50.fotki.com/v1572/phot...MVC019F-vi.jpg
http://images43.fotki.com/v398/photo...MVC020F-vi.jpg
Bump is all gone...
http://images59.fotki.com/v112/photo...MVC002F-vi.jpg
Made a pattern and cut the patch panel out of some 22 gauge.
http://images20.fotki.com/v422/photo...MVC006F-vi.jpg
http://images12.fotki.com/v155/photo...MVC008F-vi.jpg
Used the rotary shear to trim off what we didn't need.
http://images12.fotki.com/v254/photo...MVC017F-vi.jpg
http://images51.fotki.com/v278/photo...MVC015F-vi.jpg
Mel laid out a pattern for spot welding and punched the holes with the "bench" punch...
http://images55.fotki.com/v608/photo...MVC002F-vi.jpg
http://images61.fotki.com/v53/photos...MVC003F-vi.jpg
Put on a 90 deg bend in the 3 in 1 and set it place.
http://images54.fotki.com/v627/photo...MVC005F-vi.jpg
After a few welds and a touch with the flap wheel it's ready for seam sealer.
http://images52.fotki.com/v729/photo...MVC007F-vi.jpg
Laid in some sealer and it's ready for primer when this is cured.
http://images15.fotki.com/v587/photo...MVC011F-vi.jpg
With that done I shot a few coats of the satin black on the middle floor section. This is ready to go in now.
http://images14.fotki.com/v218/photo...MVC012F-vi.jpg
Mel and I were talking about how hard it would be to work on the back of the van with this piece installed. It's MUCH easier to work standing up then trying to do all of this on your knees...
http://images14.fotki.com/v219/photo...MVC013F-vi.jpg
That's it for van work. Thanks for watching...
Mark