Before starting the actual build, I stripped the van down to its base to understand its real condition. This included removing the side panels, the floor cover and the partition wall.
I also removed a custom sheet metal duct used to guide the warm air from the parking heater. The remaining rivets still need to be drilled out, as they couldn’t be removed easily.
The process itself was mostly straightforward. Removing the door panels was a bit tricky due to the openers and I lost a small omega clip in the process. Taking out the floor required an extra pair of hands.
Only after stripping everything down did the actual condition become visible — especially the amount of rust hidden underneath. Some areas require proper rust treatment.
It also became clear that parts of the initial build were not done properly: Exposed metal surfaces had not been treated against corrosion. This was especially the case around the rivet nuts, which are harder to access and therefore more challenging to handle.
Overall, the van provides a solid base, with only minor areas that need attention.
I also checked the secondary 100Ah AGM battery, which was down to 8.5V, and removed it for further inspection.