Category Archives: VW T4 Project – from bumpy to beauty

VW T4 Project – Interior construction – Removal of all Seats and carpets

I currently do not know anything about the status of my VW T4 interior. Is there rust? Do I need to fix anything before starting to convert the interior to fit the local camper regulations?

Only one way to find out, therefore I started by removing the seats:

So far, so good, but the real trouble might be under the carpet:

in conclusion, this needs to be handled before it means any further trouble.

VW T4 Project – War against Rust – Battle V – Sill Part One

There was a small little hole in the sill on the front left side, but after inspecting it a little further the small little hole reveals as a dirt and rust filled water holding mess. I drilled a hole below the sill for the water to drain off, an sawed the hole into an rectangular shape:

I’ll need to learn welding of some sorts to fix that hole in the future. I am currently not owing a welding helmet, I would like to get an automatically darkening one, but these are usually above 100€ a piece. Hopefully I’ll find a cheaper solution to that.

VW T4 Project – War against Rust – Battle I – temporary lost

I am a bit behind my reporting schedule, but several things have happened the past days. I’ll post them in chronological order.  First of all the rust on the fuel tank cap is back. I really should have used zinc and a bit more sanding on it:

I am going to use a different rust converter on it, it might help when it arrives: It is called owatrol rust converter.

VW T4 Project – War against Rust – Battle IV: Roof

Still not easy finding before pictures, but examining the archives, i found this litte landscape of rust:


Maybe not looking that bad, but still, this is the number one location for rust on T4s – causing water flooding everywhere it can cause damage inside … Therefore it totally earned my attention in the war of rust battle IV 🙂

Clearly, this is not a professional paint job. Also it seems the white of the roof of the VW T4 is slightly brighter by age or by default, but still – it prevents one of the most vulnerable spots of rust and invading rain water.  Sadly on some spots I’ve painted the rubber seal white, which left me no choice but to paint the whole seal a bit more white than I’d have retrospectively. Anyways, the VW T4 looks a lot more worthy than before and hopefully will not develop rust issues on the handled spots soon..

VW T4 Project – War against Rust – Battle IV: Roof - total final result

VW T4 Project – War against Rust – Battle IV: Roof – total final result

There are two more areas to treat soon which I have been avoiding due to the required experience: sill and back right wheel case hole. I am really looking forward to solve this 🙂

VW T4 Project – War against Rust – Battle III: left front area

Unfortunately I forgot to take real before pictures… but still the war against rust is still something really exhausting. The more I circle around the car, the more I find spots that are worth being treated against rust and future conservation. Still collecting experience my quality of removal improves every time, currently I am using a automated wire brush for most rust removal. After that I apply rust removal followed by zinc spray and undercoat before I apply several layers of color matching paint.

Still that progress leaves some transition between old and new paint, but I’ll hopefully improve that soon by gaining experience. Until then, I’ll try some polishing and maybe freestyle paint grading 🙂