In short
Rust removal is not just cosmetic—it affects stiffness, leaks, and project lifespan. In Sant Julià de Ramis we inspect sills, floors, and pillars before closing the interior.
Before you start
- Check sills, load floor, and panel joints.
- Photograph suspicious areas with paint bubbles or brown staining.
- Do not cover active rust with foam or panels.
- Ask whether sheet sections should be replaced on your van.
Where rust appears in vans
Work vans often rust under the load floor, in corner seams, and beneath factory sealant. Coastal Girona humidity speeds it up. Alexis lifts temporary floors and checks bulkhead anchor points. A weak spot here can break furniture fixings later. We do not insulate until steel is sound or repaired—trapping moisture inside is worse than leaving it visible a few more days.
Workshop methods
We combine sanding, rust converter, epoxy primer, and spot welding by severity. We do not sell miracle sprays: treatment is part of body prep. Heavily perforated sections are replaced with gauged sheet and anti-corrosion coating. We protect zones that will get cable or water runs so coatings are not damaged. The goal is a stable base for the rest of the build, not a show car.
Link to insulation and floor
The camper floor sits on dry, level structure. Rust under crossmembers makes the new floor creak and wick moisture. That is why this guide comes before insulation and floor guides. When someone buys a cheap used van, the real budget often includes this phase. Better to find out in Girona at the start than in the first Pyrenees rain.
Future prevention
Ventilation, drains, and proper hole sealing reduce recurrence. During assembly we use grommets and sleeves where cable passes through steel. We review hatches and windows on the same line—leaks and rust travel together. We hand over with critical zones documented for yearly checks. Simple maintenance outlasts any pretty finish.
Common mistakes
- Panelling over active rust hoping it will not return.
- Ignoring the load floor because furniture hides it.
- Using home products without primer compatible with later paint.
When to bring it to the workshop
Van coming from hard commercial use? Bring it in—we check rust before converting.
FAQ
Must the original floor always come out?
Not always, but it must be inspected. Sometimes local treatment is enough; sometimes sections are replaced.
Does this affect total budget?
Yes, and it is better upfront. A sound base avoids mid-build stops.
Sources & references
- Industrial paint manual — ferrous surface treatment
- Manual de Reformas de Vehículos (MITMA)