The CF Bedford Rebuild Begins

Part 7: The rebuild starts - the rear inner

Starting at the back again, first up I've replaced the lower rear inner panel, the original Bedford one had rusted out in the middle (behind the plate area) as they do and was easier to replace the whole panel, plus removing the old one allowed the sand blaster to get inside and around the other panels.

The rear floor section also had a lot of pitted rust so was easier to also replace. This first picture doesn't really show it but I've welded a bar across the width of the van and replaced the rear floor panel.

In the second picture I've folded up the rear panel and here I'm test fitting the lower back panel for fit, note the exhaust cut outs in the lower panel and number plate recess marked out in the rear panel, also the gussets (original) to keep the rear pillars from twisting, not that I really need it as I'll be adding another set of my own pillars (top section of the door).

The ole CF Bedford is a great van but wasn't rustproofed from factory, companies like the NZ Post Office rust proofed most of their vans and is probably whats around today.
The bottom sections, at the rear and side door are the places that show the rust first but isn't often the main part. The CF is a big van and over time the body moves around and the seams get a bit sloppy. If you ever had a CF you'll know the back doors can come open while driving. The cause is the roof, the seam around the roof allows water in and it settles at the bottom sections, rusting them out. If you want to strengthen up the CF, do the top and the bottom.

On to making the rear door hinges and mounting the door onto the frame before welding anything in.
I wanted a hidden hinge; the old school piano hinge was out of the question as since I had no gutters the rubber must work without obstruction. More on the hinges next.