Heavy metal my new Deli.

[dennis_lambert]

I recently Imported my second Family Delica a Beautiful L300 with only 60K on it.After what seemed like a Forever it arrived.Mardy was extremly helpful and picked it up for me at the docks.He phoned me and said nice Van my freind but your not going to like the roof..
I was hopefull in that he was over reacting.Mardy completed the Complience work (Excellent job)and phoned me to come pick it up.Once I arrived in Van He picked me up at the airport and helped me arrange insurance (Talk about excellent customer service)Unfortunatly he was not over reacting about the corrosion on the roof.After bringing it home to K town I proceeded to remove the headliner and shade mechinisms exposing the sub frame and roof skin.The corrosion appears to have started between subframe rubber isolators and roof skins and ate it way from the inside out.Then the work began.I then Drilled off the spot welds on the structural cross member fully exposing the roof skins.It was really bad...Mardy was right.I have now cut out the corroded skins and preped for new sheetmetal.A work in progress I thought I would share.I highly recomend others to pop off the head liner and check this area (Hopefully you find nothing) and then spray with rust inhibitor.I am going to check my wifes Delica as soon as I am finished this repair.
More to follow..

[mararmeisto]

This issue has been identified time and time again, predominantly in the Crystal Lite roofed models. The speculation is that the 'thick' roof liner (roof liner with blind mechanisms) is trapping greater amounts of moisture and humidity, allowing for roof rot. Not always, but sometimes.

It's good that you've taken the time to remedy the situation, and it looks like you've the means to do it yourself (most are not so handy nor fortunate). Thanks for posting pictures - they'll be of great assistance to others who are looking to fix their own Delica's cancer.

[Luna-Sea]

Looks like your kicking the rust monkey
right in its unwelcome corroding balls!
Good van otherwise I Hope!

Right On!
(when that problem is licked!)

[jessef]

I saw your rig when Mardy picked it up.

It's a shame you weren't able to catch it in Japan.

Good job on tackling it. Rust is a tough one to conquer on metal.

[jwfchase]

Keep us posted on this one... this is what I'm facing too, I'll be doing this exact fix soon. BTW, did you have to remove any of the windowshade mechanism?

[dennis_lambert]

Keep us posted on this one... this is what I'm facing too, I'll be doing this exact fix soon. BTW, did you have to remove any of the windowshade mechanism?

I am hoping to assemble the first stage of repairs this week and will definetly post more Info and Pics.
I had to remove so far the rear shade Mechinisms,Air distribution ducts and wire harness.
More to come..
Cheers.

[jwfchase]

How's the Delica cancer treatment going?

[dennis_lambert]

Hi there, sorry for the Delay.I have done a little.Hopefully I willl finish up this weekend.
The Corrosion has all been removed and the New roof skin inner doubler has been cut and primed.
I then coated the entire patch with PRC an Epoxy based two part super sealant.(I have lots of this if any one else want to do a similar repair, for Delica.ca members the price is only shipping).Its slightly expired Aerospace fuel tank sealent, great stuff just dont get any on your seats etc.
The patch was then put into place and fastened with temporary fasteners while I prepped the rest of the holes (Countersinking)
Then I installed a double row of Cherry Max 5/32 blind rivets with a pneumatic puller.
Next I have to install the filler patch to fill the gap.
I will post more soon.
Sincerely,
Dennis.

[jwfchase]

'Oly schmokes--

This is looking way out of my league!