Volkswagen T4 Van Rust Guide - Where do they rust?!

Prior to chopping the roof out of my Volvo V70 Estate, Lee from Dubshop Automotive walked me round a very rusty Volkswagen T4 van to chat about where they rust, how they rust and how you go about the repairs! This seemed to me to be an exceptionally rusty example, but apparently it's about the norm! What do you think?
You can watch us build the Volvo V70 California here:
• Volvo V70 T5 Convertib...
#Volkswagen #VolkswagenT4 #VanLife #VWRestoration #VolkswagenRestoration #VWT4Rust #GeoffBuysCars #BuyingCars #SellingCars #CarReview

[@nevillebloodybartos]

I need this exact welding done on my 2002 T4…. Should be getting it done this year… I’ve owned it 7 years, it’s done 260,000 and it’s insanely reliable …. It’s a running joke that it will do anything and go anywhere… I love it

[@fattyshtc]

I've just brought one and it's about 20% of that rust a bit on the drivers outer side but I've not started unpicking it yet so here goes. I've done a lot fabrication work and seems a lot of repair panels available too. Looking forward to the summer shows...

[@GeoffBuysCars]

glad yours isn't as bad as this one!

[@rayokas69]

It looks like a 2.5 TDi 75 kW machine. Well worth of saving. My 2001 van looked almost as bad as this one, when got it really cheaply 4 years ago. But with a MIG welder and ca 2 months was able to sort it out quite OK. Now I have a really cool T4 ACV surf bus and as a bonus I learned to hobby-weld sheet metal. If DIY metal work then T4 is not an expensive project. A lot is possible just to fabricate from a plain sheet.

[@MidnightXAlchemy]

What gauge metal did you use?

[@rayokas69]

@@MidnightXAlchemy I had different pieces of 0,8 mm and 0,9 mm thickness sheet metal. Both worked OK with 0,8 mm MIG wire.

[@menditman2004]

Watching this makes me feel a little better, I’ve just found more rot on mine than I anticipated but it’s no way bear as bad as this one. Even though I’m attached to mine had mine been like this I would have got rid, imo just to much work. Good video 🙂👍

[@ron2256]

I’ve got a 1999 model ex AA van that I’ve had for 9 years and is on about 210,000 miles.. it’s been good. I’ve had a bit of rust and paint done but it’s not bad at all. It’s just passed the MOT with two advisories, one for the hazard switch which as far as I can see works ok and one that the mid section of the exhaust is leaking, nothing about rust or anything.. I have a theory that Volkswagens built before 2001 were better than ones from 2002 onwards when it seems that the accountants took over from the engineers.. I love my T4 2.5TDI ACV SWB Kombi ex AA van.. what is going to kill them off, eventually, is CAZ and ULEZ, luckily, I don’t go into those areas.. Being ex AA it’s the heaviest 1200 van with the best engine and gearbox, built for motorway and towing work. My tow bar looks a bit rusty, I don’t know if I would trust it to tow now but everything else, it’s a brilliant van.. cheers Ron

[@jamesward5721]

All that rust ye pointed out is one thing - but it isn't the doosie-rust. The doosie rust is where the rear shocks mount to the chassis, deep in the rear arch area - it's greatly hidden by plastic panels & the floor. Issue is that the chassis rails themselves will be toast or close to toast & they are a sod to replace as access is rubbish plus you start struggling to find somewhere the rust "stops" in order to start working back from. Plus that rust is structural as opposed to cosmetic like most of that ^^ rust in the video. So check the chassis first, because it's the important bit. I know as I repair these. :-)

[@LordFlashheart1]

JB Weld for the Win lol

[@pollyperkins6931]

Hi. Do you have a picture of the finish product?

[@tailswales]

Where is this garage based?

[@cas7699]

HI Everyone, can someone give me an idea on how much time and a rough cost on cutting out and replcaing right hand side ( sliding door step ) mine is in the same condition ?

[@poberauer]

How does the floor look above the rear springs?

[@GeoffBuysCars]

We didn’t look actuallly

[@handsfree1000]

I’ve just sold my 2008 vivaro van and it was completely rust free. There’s no need for manufactures to be selling rust prone vehicles

[@P8FPV]

Literally doing most this work now 🙃

[@Lot76CARS]

That must be on the verge of uneconomic to repair, but I guess the customer is attached to it so man maths kicked in!

[@GeoffBuysCars]

Totally, it looked to me like a real scrapper but to be fair, I like the stance and wheels...!

[@stereofidelic67]

How does this compare to the T5?

[@chopperhehehe]

4000 for welding plus paint or 4000 in total looking forward to seeing it done well worth the work 👍👍👍😜🏴󠁧󠁢󠁳󠁣󠁴󠁿🦄🦕😁✌️🤞

[@GeoffBuysCars]

I think it was 4K total. Which seems reasonable to me.

[@chopperhehehe]

@@GeoffBuysCars its cheap I wouldn't do it for that lol 👍👍👍😜🏴󠁧󠁢󠁳󠁣󠁴󠁿🦄🦕😁✌️🤞 Ps just done my own van so know what goes into it and mine wasn't as bad as that one lol Still if done right get another 20 years atleast my van is a 91 plate and this is its first bit of attention its needed

[@normanpouch]

Where is this guy please.

[@stephenyoung1506]

That looks very crusty What happened to the 3d thing walk around did I blink 😳 and miss it lol

[@GeoffBuysCars]

3d thing...?

[@stephenyoung1506]

@@GeoffBuysCars cat c 400 car you have done walk around now lol

[@stephenyoung1506]

@@GeoffBuysCars instead of bump starting you tried wee hammer tap on starter lol

[@garybyng8020]

Where DON'T they rust? 🥲

[@channelejg5862]

It always amazes me why people bother repairing these old rot boxes, they are awful things to drive too!

[@danielpatrulei1973]

i taught my transit its bad. but this glorified rusty skip on wells its just the same but 10 times more expensive