Ford Transit Van Rust Holes [MOT FAIL!] Welding Repair Guide For UK 2.2 FWD Van | 14
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- เผยแพร่เมื่อ 26 ก.พ. 2023
- Ford Transit Van Rust Holes [MOT FAIL!] Welding Repair Guide For UK 2.2 FWD Van | 14
Here are a couple of the things we used during this work:
Waxoyl underseal: ebay.us/EYxOAm
Welding Wire: ebay.us/ZKT33z
Clarke Weld MIG 150 TE Turbo: ebay.us/jbdfE8 (this is the newer version)
Argon/CO2 Welding Gas & Regulator: ebay.us/7BOngD
Angle Grinder Wire Brushes: ebay.us/sSJjtM
Safety Goggles: ebay.us/2Dvt5C
Every year in the UK vehicles have to go through a government test to ensure that road safety is maintained. It checks things like the steering, suspension, brakes and structural integrity of the vehicle. Also in the UK we put a lot of salt on the roads in the Winter so vehicles do tend to rust a lot. So this year when our Transit went in for its MOT it failed. It being an older vehicle, a teenager now, I expected something to come up. Wear in the steering, suspension faults, brake wear, all of these things were in my mind. I was a little surprised when it failed and listed things implying major problems with structural integrity. At first I thought, “ OH no, the van is dead and on its way to the scrap yard”. But then I realised that I have been under the van and it certainly isn’t falling apart. So I go the MOT inspector to walk me through the areas of concern. It soon became obvious that although the rust holes were quite bad, they certainly weren’t terminal. The transit has two very hefty chassis rails that the suspension is connected to, the rust that was picked up wouldn’t cause a problem with them for some time.
The most important thing was to cut the metal back to where the rust was only on the surface. This meant that most of the holes became a lot bigger when they were cut out. We did put some rust treatment inside the areas where the rust was before welding new plates in, but it will still need some more effort when the weather gets better to ensure that the rust doesn’t become a bigger problem in the future.
Although not overly difficult it did take a couple of days or more overall. We were very lucky that the weather was “reasonable”. We didn’t have anywhere to work inside, so it had to be done on the drive. If it had rained, or snowed, we wouldn’t have been able to do the job until another time. There was a time limit on us, because if a vehicle fails the test you can have the parts it failed on retested within 10 working days for free, otherwise it is a full new test at full price. We wanted to get in within the time period, so there was a bit of a push to get it done.
There was also a bulb out for the test. I am sure it was working the day before when we checked them, we aren’t totally stupid. This was easy to replace. There were also a few advisories, these are things that the inspector notes, but are not bad enough for it to fail the test. A couple of tyres need replacing, we aren’t sure if we are going to change the wheels, so we need to decide on that before we buy tyres. There was also the frequent brake lines covered with grease, comment. I will look at cleaning them and painting them with a rust-inhibiting paint when I give the underside some more attention.
Overall it wasn’t too bad. When I took it for the retest they were very happy with the repairs we had done. I really must give it some attention this Summer, or we will be doing it again with some new holes next year 🙂
For more helpful how-to guides and restoration project logs, visit our blog: www.spannerrash.com/
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Had transit vans all my life. Always the same. Still love them.
They are great vans, despite the rust issues!
Transit vans are like the Firth of Forth rail bridge….you’ll never stop welding them🥴🥴
Eventually it'll all be new. Ha. Keeps you busy!
Great video
Thanks for the visit
Great to see that van not going to the scrap yard.
Thanks, still a lot of life in the old girl yet!
I have a 2003 transit van. For the last 10 years I had to weld something for every MOT. I’ve become quite an expert now.😂
Haha! Yeah they are quite a pain for rust. It's a real shame as they're great vans otherwise. At least you got to learn a new skill. 😆
@@SPANNERRASH the engine is faultless but the body not so good. I have just done both sills this year and it was pretty easy.
Same here good van other than that!
I’ve got a 53 plate mk6 going to weld seals up next
@@1961kickboxer when I ordered the sills there was two options. One was around £7 more expensive. When I went to collect them they was out of stock of one of the more expensive one’s. I took one of the lower cost one’s for the drivers side. However it took more work to get it to fit then the more expensive one I had got for the other side. If you do end up cutting out the old sills consider getting the better ones if that still is an opinion for the parts now.
nice job
Thanks, just the rest of the underside to underseal now.
Might be buying an old ford nugget soon, nice to get some insight into rustmageddon.
Haha! Have a good look underneath, sadly they are notorious for rusting. Shame as they're great vans overall.
Those jack stands 😮
Not living quite as dangerously as you think. Some blocks of wood, and the jack under tension, before venturing under. But yes, must get some better ones.
From Australia , It's hard to believe that people who live in a country with permanent wet weather do not make moves to rustproof their vehicles as much as possible, surely the car industry could have a whole industry coating the underside and every nook and cranny with a rust preventor .
What, and ruin a whole industry of aftermarket rust proofing snake oil, and welding equipment. Plus the fact that the built in obsolescence of the modern electrics can't be relied on to kill vehicles off and needs a back up plan. :)
@@SPANNERRASH You are not wrong my friend .
Same old Transit rust problems , I’ve had a fair few myself , I carn’t understand why Ford don’t use galvanised chassis and body panels to stop this , the Vauxhall vivaro / Renault traffic / Nissan primastar all use galvanised steel chassis and body and don’t suffer this problem , I have a 16 year old vivaro with no rust on the chassis or body...!
Come on Ford get with the programme.... it’s probably down to them not wanting the vans to last too long so they can sell more... 👍
@@yensabi Yeah its a real shame as they are excellent vans other than that really. Interesting you say the other marques are galvanised, I didn't know about that. I wonder if Ford have changed their ways on more recent models.
Back in the 1970s dealers would ask if you want zebart to rust treat and underseal your new car a firm in Oxford I had escort Mexico done there.
Glad that you got the pass but I think that you may have to look at the sills before next year.
The rust has taken more of a hold than I realised. I intend to give it a good seeing to this year, but I intended to do it last year and didn't. However it does seem to have become a priority. The weather has become a lot more damp now, so it will have to wait. I just hope I don't forget or get too distracted before getting to it :)
Wire brush and lanoguard the entire underside- will hold it back for a good while 👍
I keep hearing good things about Lanoguard, I suspect I will try it soon.
The only issue I have with the video was those Coca Cola axle stands, they maybe rated for 2 tons but I certainly wouldn’t trust them with the weight of a Transit on them, my son had a pair the exact same ones he put them under a VW Golf one day on a concrete driveway just like yours and one of them keeled over, he was very lucky not to have been under it at the time.
The whole van is less than 2 tons, but I know what you mean. That is why we put an additional Jenga set of blocks under and never went under if it didn't have the jack under a bit of tension as well.
Hi there. Just watching your video. The holes in the inner sill were not in a prescribed area. They were more than 30 cm from the seat belt anchorage points so should NOT have failed the mot. Should have just been advisories. Time to change mot stations. Hope your van got on ok this year.
Thanks for that. I do try to find sensible MOT stations, but to be fair the inner sills did need attention.
Hello, nice job !!love it
i ve just got a transit mk7 and i have rust just below the renforcment bar next to the door, do you know why there is rust here how can i stop the water who come here like thos it s not happen again ?
Moisture seems to get into all of the box sections so trying to completely seal them all doesn't seem possible. Ford couldn't manage it :) I try to spray rust preventative wax into every hole that I can find, on a reasonably regular basis, at least once a year or so. The sooner you start doing that in the life of the vehicle the more successful it will be. That and fixing the places where the rust does get a hold seems to be the only strategy. Good luck.
Welding sheet metal - no fun. Overhead sheet metal, even less fun. Good job!
You couldn't be more right about that James! Not a fun gig at all. Cheers!
Some of those holes not to bad to weld the problem with transits is there are a body type constructed of lots of pieces ie box sections and sill Panels which makes any corrosion within 30cm of a mounting point a failure. The exhaust although looked a bit rough as fine for an MOT they all look like that
Yes, they seem set up to rust. Maybe Lanoguard would slow it down. Exhaust does keep exhausting though, just looks ugly.
disturbing jack work... and you have 2 wheels you took off the car, so easy and handy to act as a safeguard in case the bodgey jackstand and brick/block fail.
Instead of finding somewhere else to put them, I reckon a wise person would put them under the van to avoid organic mincing.
How many people a year die under vehicles from lifting failures?
You are right to keep us vigilant about working under a jacked up vehicle. We used "2 ton" jack stands, backed up with some wooden blocks, and also had the jack against a jacking point when we were under the vehicle. We try to have at least two supports for the corner we are working on, and make every effort not to become complacent. It's a thought about putting the wheels under, but we only had one wheel off at a time, and one would just fit under the van anyway so not really an option.
Great repairs, I have saved a few Transits from the scrap yard in my time . Was that Flux cord wire you using ?
No, I think you can see the big cylinder of Argon/CO2 we use in a couple of the shots.
@@SPANNERRASH any issues with using gas outdoors? I’m trying to teach myself to weld at the moment to do some repairs on my Alfa (this channel has been an amazing help btw!) and, having been led to believe flux core was my only option, I’m struggling on with very little success so far. Wondering if I might actually be able to get away with using gas if the weather is kind…
Cheers @@liamcorrigan3158! To be honest it seemed to work just fine. The bigger issue was getting clean metal to weld my patches to. Of course in high winds your gas would blow away I'm sure, but maybe you could up the litres per minute to counteract that somewhat.
I've seen people get great results with flux core, but when I was playing around with it I could never get clean results. Although that was a long while back when I knew a lot less about welding. I might try it again one day.
Hope you get the Afla sorted!
The smiley transit was the last transit worth any money...
Everybody loves a Transit! :)
I used to be a Transit fan but no more, 2:2 engine is crap even with full history like mine had.. As for rust take a look at the later ones underneath, saw a 2018 recently and it was shocking. I’ll stick to my 15 year old Vito no rust anywhere , sound engine 50 mpg motorway driving.. can’t wait for the slagging lol…
Haha! No, in all honesty the Transits are bad for rust, its such a shame!
However, I haven't had any issues with the engine. What went wrong with your 2.2?
It started chucking out oil from the top if I remember , was told it’s very common on the 2:2.. only seven years old with ok miles and rusty door steps but I did clean and paint/ waxoyl everywhere then engine went…
How thick was the plate that you welded
Approx 1.2mm. It seems to be one of the most common gauges used for lots of body work.
If ford had galvanized the van this wouldn't be such an issue I saw a 51 reg Renault traffic the other day no rust at all on outer bodywork.
That does make you think. Transits do seem to have more of a problem than others.
Get yourself some decent 5 ton rated stands , those things your using look well dodgy , you only live once make it last... 👍
Yes the do seem a little flimsy! Used an extra support and the jack as well when underneath.
😂 I would of moved the axle stand a few more times just to be sure
Worked out fine in the end.
How many times does it take to position a axle stand??? 😳
Enough so that you are happy with it :)
Why not use lanoguard on your under of your van
Using Lanoguard is one of our future plans. But we are also considering Waxoyl, not sure which way to go.
Loved these vans but come on never again. Dad spends a fortune each year on his keeping it on road please
They can take some care, but everything is doable, and most inexpensive.
Very poorly supported vehicle, I personally would have something more substantial holding it up. You only live once!
I agree, in my defence I didn't just use one thing to support the van at each point. Individually I wouldn't have trusted each support, but with axle stands, a Jenga tower of wooden blocks and the jack on pressure I think it was workable. We really do want some better lifting kit, let's hope we live long enough to get them :)