I've got a 1999 E-150. Majority of the van is in great shape for the age. One super bad problem area is the rear of the cab, right at the swing door latch.
the cross member that's rear-most on the cab, just in front of the bumper, is almost completely rotted.
I'm having a hard time finding a local bodyshop/mechanic willing to take the project on, and it seems more and more likely this is going to be a first time DIY.
Lots of opportunities to learn, i suppose.
never welded before, no shop available, alls i have is a dirt driveway, some plastic ramps, a few jackets stands and a Badlands off road jack.

Is this a project I should really even try?
I can't even find the part number for the sheet metal I'm referencing.

 

I do not believe this is an impossible project, but it will certainly bring a whole new meaning to the word "Rebuild".

 

Where are you located?
That's a serious job, and the bigger problem is whats left to weld to!!. No one wants the potential for a return repair, or the liability of.
Done a ton of rust and section repairs myself,, but my concern is whats left of the rest of the van...

 

Hey, I'm located just atound Goldsboro, NC. Been looking locally if there are any body shops or custom shops that could handle it, but none have really replied.
I did find the replacement parts, though, but I don't have knowledge of pinch welding or how to separate welded panels and all that. I get drilling the spot welds, and then using an air chisel to break the seam, but that seems like something that can go wrong very badly where the rustout is.

 

The rest of the chassis/frame is perfectly OK. It seems like the area pictured is the worst, and really only, rust.
Van was used for AC repair, and from what I gathered from the previous owner (city owned/school district), some highly corrosive items were left in the back and seeped into the body mount cross member through some holes drilled in the floor to mount some shelving. Everything else on the van is basically crispy new. Except for where the local meth heads cut the catalytic converters out, of course. (I think it was an inside job from yard mechanics, the cuts were too nice and nothing else was damaged. Even left me O2 sensor harnesses where they disconnected instead of ripping them out.)

 

it's daunting, for sure. Ive never welded or cut anything body related before.
worst part is my "shop" is a fee jack stands, couple Jack's, and some cardboard to lay on.

 

What if you found a van with a decent body , but wiped out drive train?

Wonder if it could offer 2 alternatives, switch bodies or switch drive trains?

No welding required, just plain work and lots of it.
Either way , unfortunately , you are not equipped with the facilities to do either.
Maybe some shop would have no problem handling what you might decide, what do you think ?

 

Unfortunately getting a donor for the body is a little out of budget this year. Maybe next, i suppose. I am not really looking to get it 100% restored, the van is getting turned into a light duty camper for weekend trips to the beach/mountains.
been thinking about just cutting some square tube drilled to take the body mount bolt through and just rust convert everything visible.
probably fiberglass the interior section, and grind off the super bad rust underneath, then just coating that whole area with rust converter/undercoating. Doesn't need to be pretty, just functional and not a structural concern.

Will update when I figure it out.