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MOT failure due to body rust
Topic Started: Jul 28 2015, 10:45 AM (1,472 Views)
mfoobar
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Alas, my Iveco Daily self-built camper just failed its MOT due to some bodywork rust. There is a section of box steel just fore of the rear wheels that runs right across the van from one side to the other. On both sides in front of the wheels it has rotten :( The nice lovely understeal hid anything for ages, but it has rotten from the inside out it seems. Due to it being within 30cm of the body mounts it was classed as a MOT failure :(

I took the van to a nearby garage to ask about welding and they said it would be 8 hours welding and that I'd need to 'take the sink out'. On enquiring further they were worried about it catching fire. I pointed out that when they meant the 'sink' they meant the whole kitchen unit... and more importantly if that is what they are worried about, then the whole insulated floor would need to come up. Which sounds a complete pain.

Now, I don't think that where the welding needs to be done would directly cause the insulation to catch fire if they were careful. This garage admitted as much, but said that they had to err on the side of caution, and that an independent welder might see things differently.

Anyone else had to deal with anything like this? The reality is that it is *not* a structural issue at the moment (and the tester did go back and check the regs again and talked it over with a colleague as they were uncertain it would be an issue, but apparently it is). But I guess it will develop to a structural issue if I don't get it sorted.

-Matt
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Spooky_b329
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Could you cut out the rot and bond in a new piece rather than weld? (Sikaflex etc) We know its not an immediate issue as the suspension etc is mounted to the ladder chassis, not the body. Undersealer etc and they wouldn't even know (or are you not allowed to cover the repair before a retest?)
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mfoobar
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Indeed, I know it is not really a structural issue. But it is within 30cm of the body mount. So I guess if the rust spread further it could compromise the mount between the body and the chassis.

I doubt I'd get away with it now, as the tester knows the issue is there (and another tester would see why it failed and inspect closely). The fact is the rust *was* hidden already by underbody seal. That is why i didn't even know it was there. The inspector found it by tapping with a hammer and noticed a section sounding different. So even a fibreglass fix would have been noticed I think.

-Matt
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