Repairing rusted Bongo - worth it or not?

[NathW]

Hi all, I hope you can help with a bit of advice.

Recently I inherited a Mazda Bongo, 1997, petrol* 2.5L engine, 150,000 miles. It’s been sat unused for 2-3 years and after taking it for an MOT the mechanic has found a bunch of issues with it. Some damp has also got into it and some of the interior got a bit mouldy, though I have cleaned most of this up.
Realistically I don’t have the skills/time/inclination to do the repair work, so I’m trying to decide if it is worth paying garage price. The stickiest point is the welding; apparently the sills, wheel arches and an area near the towbar are rotten (I've attached some photos of this). It’ll cost about £2700-£3300 to get it roadworthy again (not just welding cost, see breakdown below), is this worth doing or should I really scrap the van? The interior is fairly decent (fridge, gas cooker, bed, wooden fittings, extending roof) and there is some sentimental value, as it was my Dad’s.
Secondly, if I do go ahead with this, the garage said I might have to source the sills and/or wheel arches myself. Are these readily available online?
Any advice would be appreciated.

*Engine also has LPG, but this is not currently working – mechanic suggested it would be worth getting a specialist to fix though.

[NathW]

Adding a few more pics...

[Bob]

It’s sadly not possible to say if the cost is worth it to you.

What I would do is caution you against supplying your own parts for a garage to fit. You can see the problem if the parts aren’t exactly right or there’s a warranty issue down the line.

Fitter says the parts were faulty, parts supplier says they were fitted incorrectly.

If you decide to get the work done I would suggest a garage that cab do the whole job, but bear in mind you probably can’t get a final quote until some panels are removed, which if you don’t go ahead it’s Bongo Heaven for your motor.

Hope that helps a little.

[g8dhe]

Many of the parts you mention are available as new take a look at Bongo Spares for new wheel arches etc. Also a list of many suppliers around the country below. If your looking to use it yourself then its possible you will find repairing it is viable however any resell price is going to be affected by the history of course.

These companies do a range of spares, not all will have everything so try them all;
For smaller parts its probably best to ring companies as not all the smaller parts make it on to the web sites!
SPARES:
Bongo Land www.bongoland.co.uk/shop/ 0114-2550836
Mazda Bongo www.mazdabongo.com/ 01234-480808
Bongo Spares www.bongospares.co.uk/ 01422-823249
Vosper Parts parts.vospers.com/ 01752-636494
Auto Jap Spares www.autojapspares.com/ 02476-474848
AutoLinkUK www.autolinkmx5.com/ 01556-509088
SALES & SPARES;
Ian Taylor UK (Stoke on Trent) www.japcarimport.co.uk/ 01782-594125
Southern Bongos (Southampton) www.southernbongos.co.uk 02380-733995
Stephen McWhirter Services (Cumbria) www.stephenmcwhirter.co.uk/ 07585-304362
Dore Service Station (Sheffield) doreservicestation.co.uk/ 0114-236-4691
Discount Trucks (Newbury) www.disctrucks.f9.co.uk/ 01635-254185
Derwenthaugh Motors (Newcastle) www.derwenthaughmotors.co.uk/ 07596-862711
Bongomaster (Leicester) www.thebongomaster.co.uk/ 07873-314519
Doctor Bongo (Plymouth) www.doctor-bongo.com/ 01752-224651
BREAKERS:
Milton Gough's Shaw Lane Carlton, Barnsley, United Kingdom. 01226 725356 www.facebook.com/Miltongoughs
Bongo Parts www.bongo-parts.co.uk/ 01403-741913

[NathW]

Thanks Bob and g8dhe for the advice. I'll take a look at those websites, they look very handy.

Just to clarify, when you say a full quote isn't possible until some panels are removed - is this because the panels might be hiding rust? And if so, which panels do you mean?

[Bob]

Yes, rust may well be hidden, and sadly structural.

Cills, wings…

[BongoBongo123]

Looking at this face value, I would be worried. You will have to really know what you are dealing with as the costs can mount, you will be looking at £500.00 of tyres for a start on top of that. (They have shot up in price the last years I noticed)

Check crossmember in the front that hold the air conditionining condenser/radiator for rust look under sills and put 2 latex gloves on and feel all the way along for bad rust or holes. Look under any battery trays under bonnet. Put a high pwoer LED headtorch on and look closely/feel along. Check behind and mud flats or plastic wheel linings and behind the rear arches, basically everywhere ! And don;t be afraid to know the truth, bublled rust can basically be a hole held together with bubbled rust !

You have to fine tooth comb this and you need to be getting some serious use out of it to be worthwhile.

If it is an ATP top (roof tent - auto free top) that is good, a tin top, standard metal roof, they are less valuable generally and that might factor in.

I'll try and check back on this thread as and when you post. Maybe put a few under sill photos, under bonnet photos.

2700/ 3300 and then you need the engine sorting on top ? And the tyres at the very least (they are finished looking at them). + ideally coolant, oil change, oil filter, air filter, spark plugs, a windscreen may be due, is it blurry / scratched or chipped and marked to look out of ? Add £350.00

Are all the electrics working ? Windows, lights, aircon, wiper motors, internal fans, side door motor, the auto gearbox, power steering, brake pads/disc, they will all need the fluids checked/topped up changed as well really. Look at the exhaust for rust as well.

Can you get a LPG person to asssess the engine to work out a cost for that before you go further. Might be worth the cost for their opinion/quote ?

There is much to know about and it will factor in as to whether you bother I think.

Good luck working it out though.

[Bob]

Very good post, this will be useful for others, too.

[mickc]

My Bongo had new inner and outer sills and rear arches 18 months ago.

I now find via my friendly MOT man that there is some serious iron worm in the chassis especially at the rear, at the young age of 76 I thought I would scrap it. After I sobered up I decided that I will buy a cheap MIG welderand some 0.9mm steel sheet and repair what ever needs repairing even if it takes me 6 months'
The point I'm trying to make is that almost anything can be repaired if the will is there, even on a rotbox Bongo. Mechanical parts wearing out are no problem youget that on any vehicle.

DO NOT SURRENDER TO THE LAWS OF PHYSICS WHERE Fe turns into Fe2O3......

Buy a cheapo MIG set and FIX IT.

IT IS YOUR DUTY.