Rust Removal, Plenum repairs on Panel Van #4 PLUS announcement of what's coming to Astill Design

Howard and Darren have been working on the Panel Van, removing rust using Rust Solutions Rust Remover Gel, repairing the Plenum and checking out any damage to the underside.
Howard also makes an announcement for the new series, Muscle Car Respray along with PPG and Mirka - Introduction episode will be 20th July.
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[@Techbitznpcs]

the attention to detail and checking over the body measurements are all at a high standard as always. Darren's focus on the task at hand when ever he is doing something always shows on his face, a master craftsmans with metal work.

[@AstillDesign]

Yeah your right on there.

[@tinnedanger]

For seams after welding and burning off the coating. I always thin down Tectyl ( that brown waxy stuff ) with acrylic thinners until its really runny. Spray that inside the seam until it wicks out to the outside of the seam. Then go with a thicker mix to ensure a total air / water tight seal. It works.

[@AstillDesign]

Thanks for the info!

[@Hereforfun441]

I wish I had the coin and contacts to keep my car amazing. Great work.

[@AstillDesign]

Cheers mate, it’s certainly a balancing act

[@peteredmonds9378]

Cheers Howard. Really appreciate the knowledge and techniques you’ve been sharing with us bush mechanics. Looking forward to the new project, and the XC van.

[@AstillDesign]

Thanks Peter

[@dtengineering1]

That was a really practical episode Howard. Thanks for all the detail.

[@AstillDesign]

Glad you liked it!

[@Me-dt3ul]

Congratulations on the new series

[@AstillDesign]

Thanks mate

[@schrammrobert699]

This is my favourite series so far Howard! I'm doing an XB (GS) van and I'm at the same stage as this. So I get to follow along at home. I've learnt so much from your videos and appreciate the effort you take to helping guys like me learn how to do it right. Things like how you explained like not getting it blasted and doing it as we would at home or how you pause so we can see the steps. That's so great for me :) I learn from seeing and watching. So to have such a visual reference as your videos is amazing for me (and others I'm sure) and it gives me confidence as I progress. This is like an auto course but not as boring and with great cars for examples! Nice to see you doing a vehicle that is yours though, I think I can tell a difference when it's your own. Less pressure and more passion maybe :) Keep up the good work and thanks so much Howard!

[@AstillDesign]

Our pleasure, this build is getting a lot of interest

[@jamessimpson3162]

@@AstillDesign Not to speak for the poster above, but i think everyone wants to see Howard Astill building his car, his way, with no customer constraints.

[@jamessimpson3162]

Great episode guys. I'm at the exact same spot with mine as you are with this van. It's really cool to work along in real time. Over the years, my process has developed to do it exactly as you are, and mostly the same products (about to try the rust gel). It's the most cost effective and efficient way of achieving top class results at home. Only difference is i prefer the red nylon wire wheels. When you get them "worn-in", it's a nice lasting abrasive that cleans up the tricky spots in no time. And no wire in your socks and face which is a bonus. I do need a spot hole one now i've watched this.

[@AstillDesign]

Good to hear from you and get some feed back

[@Ticonderous1]

I am a die hard Chevy guy .. But damn I love the work you do Howard ... Been a fan since I first saw your Blue Rock 3 Falcon ..Love your channel man ..

[@AstillDesign]

you will be happy that I'm painting a camaro in the new series

[@Ticonderous1]

@@AstillDesign WOW .. can't wait to see them videos ...🤘

[@kjb1336]

Bloody Awesome Video/s Mate 👍 Thank you Howard and Family for all your efforts ❤🤘🔥

[@AstillDesign]

Our pleasure

[@crgclarke45]

Great to watch a Ford XC panel van being restored. I had one (with a 4.9) from new in 1978.

[@AstillDesign]

Me too, they were good times

[@Me-dt3ul]

Thanks for sharing you knowledge mate appreciate you sharing.

[@AstillDesign]

No problem 👍

[@matthewlindsay4701]

I’m glad I’m not the only one with Ozito tools!

[@AstillDesign]

Good enough for some jobs

[@onedayiwillmakesomecontent]

A mate of mine is in the boilermaking/welding game. He repeatedly goes on about how they use sikaflex to "stick trains together, it's that ****ing strong!" The upper loco bit, not the rolling stock. If they use bolts or rivets, the vibration shakes it to pieces!

[@AstillDesign]

Yeah you want make sure you don’t need to remove it. This is a sealant rather than an adhesive

[@robhughes1776]

This new project sounds wicked,can’t wait to watch the process Howard👍

[@AstillDesign]

Cheers Rob

[@danamg9328]

Really enjoying this build, looking forward to the next episode.

[@AstillDesign]

Cheers

[@blairread4414]

I still can't get over, How good that Van is .at this stage...mmm

[@AstillDesign]

Yeah I know!!

[@olebrookswado7565]

Really enjoyed watching the process Howard. Thanks for grinding out another series straight after XBoss.

[@AstillDesign]

No problem, we will bring it out as it happens

[@darrentaylor321]

Thanks Howard love the detail’s looking forward to seeing more

[@AstillDesign]

More to come!

[@leonardgilbreath9004]

I've got to take apart my cowl on my torino and do the same thing looking forward to seeing you're next video on this thumbs up 👍👍

[@AstillDesign]

Thanks 👍

[@stevefinch8519]

Great build coming along and also a really cool vehicle .

[@AstillDesign]

Glad you like it, it will be cool when done

[@joefichera2185]

Looking forward to more episoded, keep up the good work Howard.

[@AstillDesign]

Thanks, will do!

[@graemeburr6463]

Greetings from across the ditch. I've used POR15 on my 48 V8 Coupe its great stuff and further to your tip about keeping the tin lip clean, I put a piece of soft plastic bag between it as well and the lid comes off real easy again and the paint keeps. I have a small tin that is years old and opened it recently for another job and it just as good as before. Wish I still had my base model XA Falcon 500 with 302C V8 ( Aus assembled) I sold back in the late 80's.

[@AstillDesign]

Thanks for sharing, we all have cars we wish we never sold

[@jraposo911]

Looking forward to the PPG paint job series 😊JR 🇨🇦

[@AstillDesign]

Will be good

[@chrisoo8998]

Another top video howard 👌. Please never stop building cars top quality content 👌 looking forward to the muscle car respray I'm sure we will learn alot

[@AstillDesign]

Thanks Chris, will be a educational style series

[@MrButtonpresser]

Love your work.

[@AstillDesign]

Thanks, appreciate your support

[@oldrlh]

Great show, looking forward to the muscle car build up.

[@AstillDesign]

You and me both!

[@mike-rp9cc]

loving this van project but looking forward to the muscle car project, cheers Howard

[@AstillDesign]

Thank Mike

[@SuperBossman9]

I just realised who I was watching when 31:36 31:36 31:36 I noticed the name on your shirt. I remember being amazed and inspired by your cars in Street Machine back when I was a teenager. I’m amused by the diagram in the factory manual, it looks like they just copied the one from the Mustang factory manual! Thanks for taking the time to show in detail what you do.

[@AstillDesign]

Hi, thanks for following, so much of the falcon looks like the USA cars

[@RachelEvans680]

I have been using the Rusted Solutions rust remover gel for the last 5 years on my restoration projects .. it's a really good product.

[@AstillDesign]

It sure is

[@simonstone3336]

Great work mate 👍

[@AstillDesign]

Thank you

[@panelvanman7671]

about to do the plenum on one of my XE vans , not looking forward to it though , im going to enjoy these video's , cheers

[@AstillDesign]

Great to hear!

[@The9meister]

Hi,I put glad wrap between the lid and can of por 15, to be able to reopen it.

[@AstillDesign]

Good idea

[@adriandeluchin5982]

way to go, another top vid @ the van, sure bets watching TV , 13 episodes of prep to pant this will be kool

[@AstillDesign]

There will be 13 episodes of the Camaro Paint job, the van will be on going

[@georgebeare8883]

Note that POR do recommend 2 coats. The second when the first has become tacky.

[@AstillDesign]

Thanks George, it goes on so easy

[@davefiess6698]

Awesome Howard thanks for the detail mate. I’m looking forward to the muscle car episodes as I have an early Pontiac Trans am very similar to the Camaro that I’ll be working on during this time👍👍

[@AstillDesign]

Will be good to have you along for the ride

[@craigjones6887]

great videos Howard very informative for my project as i have an xy going out for blasting on monday.

[@AstillDesign]

Fantastic!

[@craighighmore4302]

Great video Howard. She is in pretty good nick I must say. Keep it up!

[@AstillDesign]

Thanks, will do!

[@darrenfrauenfelder6609]

Nice job again, Sikaflex, sticks like poo to a blanket, if you get it on your skin the only stuff that will get it off is "aeroguard" insect repellent. It works guys

[@AstillDesign]

Thats an interesting tip

[@cqwt6103]

Thanks.

[@AstillDesign]

You're welcome

[@pangaute]

Good stuff, fwiw I make up my own metal treatment by buying 100% phosphoric acid and mixing it 3:1 (3 parts water, 1 part acid) with distilled water, alot more cost effective. Looking forward to the paint series 👍

[@AstillDesign]

Cheers, thanks for sharing

[@andrewlawrance3751]

Another great episode HOWARD. I’m not keen on the old green paint colour to be honest the ford lightening strike would bring it into modern times. Can’t wait for the next episode.

[@AstillDesign]

Not looking for it to be Modern, Plus I like Green

[@glandanit]

Love the bare metal prep on your cars. Could you give some tips how how to prevent burn through the epoxy while sanding in areas that are difficult, such as door jams, and get a show worthy straightess.

[@AstillDesign]

We will cover that in the new series. Muscle Car respray

[@BEAST-ur1wn]

Pretty clean body for it’s age. And they say ford rust seems to me they’re all the same I’m building an 64 EH and don’t know where to start from.

[@AstillDesign]

Depends on we’re they are from, this one’s from western NSW

[@RodChown-th2vc]

Sealing the Plenum is a great idea. When I had my ZC, I always wondered where the water went when I washed it. What driveline combo will you install to yours?

[@AstillDesign]

Cheers mate, 351 single rail 4 speed, BW disc brake rear

[@andrewhughes1949]

Another great video and great attention to detail. The POR 15 and sika doesn’t affect the welding process ?

[@AstillDesign]

As I said in the video, the POR melts a bit but drys out, the sika we keep back a bit from the welds and air cool to keep the heat down.

[@razzledazzler64]

Nice

[@AstillDesign]

Thanks

[@tempest3028]

Looks like you got solvent pop from the application of that por15. I had the same whe applied with a brush and it put me off using it for fear of product failure.

[@AstillDesign]

Just a bit of dust, never had a problem with this product over dioxidine

[@30psi.4g63]

love the content. have you used other products besides the rusted solutions converter? I cant find a supplier here in NZ.

[@AstillDesign]

There are many, cleaning vinegar, citric acid, molasses. do a google search for rust removal products.

[@Gokizzmass]

Since every spraypainter i contact is either only doing smash or is booked out for 2 years, i might have to bite the bullet & do mine myself.. Hence i'll be watching this with great interest to see whether i could actually do it in my shed. 😏

[@AstillDesign]

Sounds like an idea. Best advise I have is lots of photos, bag and tag everything.

[@Gokizzmass]

@@AstillDesign Mine is already stripped & sitting ready in primer, just wasn't game to paint it.

[@chrisbenn8691]

I am doing some patch panel repairs on my VW Beetles, and as I am working away i am asking myself "is this how Darren and Howard would do it?" I've taught myself over the years. Dried Newcastle sand is easier on the panels with a good blasting gun. It siphons much easier than garnet so less problems with heating and warping. Good for the small spots. I haven't tried gel yet, because noone i know sells it! Where to get it?

[@AstillDesign]

The sand sounds good, The gel I buy online and it gets delivered. Rusted solutions. Its a bit expensive but nice and clean.

[@JD-ct9rw]

Just a quick question. Why did you choose to build a dam and use the gell rust remover, instead of using a small sand blaster?

[@AstillDesign]

Easy, I don’t own a small sandblaster plus there very messy. DUST

[@petergill8819]

Yes, you are dead right about that por15 about the lead I did that exact thing and I could not get that lid off. I lost $100 worth It is the best thing since sliced bread though I’m going to do the exact thing to my xa

[@AstillDesign]

Cheers mate, did you see the comments about using glad wrap before putting the lid on.

[@jasonparnis2369]

Hi howard, ive got a massive bonnet that has little pits here and there, its impossible to get it all completely off... Im woreied of making dents... Would the deoxidine treat the pitted area for epoxy ?

[@AstillDesign]

Use rusted solutions gel. rustedsolutions.com.au/products/rust-remover-gel

[@brettgeisler3065]

Hi Howard, do people use Por 15 in the engine bay to save overspray and masking? Thanks mate

[@AstillDesign]

Hi, I don’t believe that would be an option. We use it where it is out of sight and to seal up potential rust areas

[@chrisobrien9334]

Hey mate. Will you put some epoxy on the Van while it’s sitting dormant for a while or just leave it in it’s current state??

[@AstillDesign]

Just leave it until I get it all stripped

[@MicahBell_1860]

I'll go rhythm

[@john2ndname]

what the best air temp to apply the por15 for doing large areas?..i live in QLD and as you know its high humitity.

[@AstillDesign]

I dont have specification on it, but I like to paint around 22 deg as a general rule

[@john2ndname]

@@AstillDesign great thanks

[@beyondcitylimits]

Sorry if I've missed it, I saw BossXC was at a car show without your involvement, so does that mean it's been handed over or will it come back at all?

[@AstillDesign]

Yes it was taken home after Motorex,

[@beyondcitylimits]

@@AstillDesign Thanks Howard!

[@shoominati23]

AS my mate says about rust - If it's BLACK, It's coming BACK

[@AstillDesign]

thats a good saying

[@mkp1625]

What's the car that's coming ?????

[@AstillDesign]

There is a picture at the end of the video

[@mkp1625]

@@AstillDesign i was writing this message lol

[@philyoulten8354]

Darren is a gun

[@AstillDesign]

Sure is, get lots done when he is in

[@philyoulten8354]

@@AstillDesign love your shows howard great stuff

[@rhettcorbett3346]

Ya still filling in windows on side ?

[@AstillDesign]

yes mate

[@timwhalan6417]

🍺👍🏻👏

[@AstillDesign]

Hi Tim

[@shanskinownow1610]

Q

[@AstillDesign]

Cheers

[@rodparnell1953]

Thanks Howard. About to start an LX torana with original paint which has broken down, with surface rust breaking through on the roof, boot and upper surfaces. This information is invaluable. Not a fan of blasting these big panels.

[@AstillDesign]

Good luck! with the project

[@phill2009c6]

You going to fit a LS, all looking good, you going to chop the fire will and smoth it. You going to get rid of the door handles, are you going to fit a pop up sun roof, you going to tub it. Also suicide doors would be good hey

[@petergiannaros9037]

The fire will and smoth it?Interesting concept .

[@AstillDesign]

Lots of questions! you will have to follow to find out.