Any hints and tips on rust would be great.
I purchased my 638 110CDi November last year.
A month later I discovered the black death, and then over Christmas one of my springs snapped for no reason.
Van hasn't moved since as I have decided to overhaul the complete suspension to get it all over and done with in 1 go.
Currently replacing front and rear ARB bushes, drop links, CV boots, track rod ends, wishbone bushes and springs.
I have also started tackling the rust issue. Cleaned off all the loose rust inside the wheel arches (front only so far) and degreased them.
Then I gave them 4 coats of Waxoyl rust proofer (The one designed for high impact areas like wheel arches etc).
The arches have started to bubble and if you put your fingers inside the arch, you will feel there is a perfect little shelf for mud and crap etc to sit and rot through the metal. I jet washed loads of crap out of mine, before giving it a dam good spray (4 coats) of the Waxoyl stuff.
The actual bubbling will be grinded down before being treated, then sprayed with some rust preventing undercoat, before having some fibreglass wheel arch extensions fitted and painted. This will help cover the metal where I have had to grind it back.
The drivers side bumper support bracket crumbled in my hands too !!!
Looking further under and along the van I can see rust all along under the sills. Can't see anything when you look at the van, but only under it. I intend to attack this with a stiff wire brush, treat it with some rust killer and then again, spray the whole lot with Waxoly stuff. The actual chassis only has mild surface rust, but again, I will clean it up and spray it with Waxoyl.
The bottom of the doors are I think, beyond saving. Again, looking at the van the look great, but feel under with your fingers and you can pull flakes off. There is a company on ebay that sell 100% refurbed and rust free ones for £110 (were £80 till a few weeks ago), so I think I will just replace them when needed.
Door sills all have surface rust which i have allready attacked with a wire drill attachment and treated with rust killer. I just need to apply some filler, smooth it down, primer, spray and then fit my new door sill protectors.
Front cross member has been removed from the van as it was literaly falling to pieces, but I managed to pick up a virtualy rust free one from ebay for £5
Will rub it back, spray it with anti chip paint and and squirt Waxoyl into the cavity.
The slight bubbling at the top of the windscreen, the small spots on the corners of both sliding doors and the scratch on the front bumper will be tackled by a proper paint shop.
I will post up some pics as and when I do things. I don't have any proper "before" photos of my wheel arches as my camera was playing up. See below!! No idea what was up with it
I have more pictures of my actual rust but I fear i have already hijacked this thread enough. Sorry.
I came from owning a 10 year old Ford and it was 99% rust free. So much for Merc build quality. Last time I had something with this much rust on it, it wore a Lancia badge
If anyone else can offer rust advice, please do so.