Had I known before how much this would get out of hand, I probably would've sold the Hiace.
After replacing the ignition coil, plugs, leads, distributor O-Ring, vacuum hoses, clutch hydraulic line, front discs and pads and probably more... it didn't pass inspection because of rusty brake lines and rust holes in the frame rails (
). I was a bit embarrassed about the brake lines, because I checked them and missed a spot beneath some plastic protection.
So I proceeded to replace 60% of brake lines (5 pieces, total ~5 m, replaced with self-bent CuNiFer lines), a few new pieces of 1,5 mm sheet metal in the framerails, all remaining rust-holes on the outside of the body (0,8 mm steel) (except for around front and rear window seams, those are really bad still).
I had three angle grinders in parallel in use to derust the shit out of it, but I had to remove the fuel tank to really get to places.
After doing that, I discovered the fuel lines going through the fuel pump mount would maybe hold up for the next 6-12 months. So I got some more CuNiFer lines in proper diameters. I needed 8 mm, 6,35 mm and 10 mm as sleeve to hard-solder new end pieces onto the last good pieces of steel pipes.
A replacement mount wasn't to be found. It has become a rare car over her.
The upside of the tank, formerly completely hidden, was in bad shape too. Lots of rust. None on the inside though. One thing just kept leading to another...
Soo again, a few hours of grinder action and a total of 1,5 litres of paint for underbelly and tank made me sufficently confident to go for another run at the inspection. At the time, four months overdue..
Returned to the shop - didn't pass because of defective catalytic converter. /&"§%"&!. OEM part: Something like 600€. Ordered the cheapest cat I could find (and a flex piece, while I'm at it...) and welded it in. Of course beforehand I ripped a stud from the header-to-downpipe flange, but luckily was able to weld a nut onto it (stretching halfway into the car from beneath with TIG, so both arms) and get it removed, woohoo. Possibly the most joyous moment for me in the past few years, not kidding (sadly).
So, finally - it passed inspection (in june or july already though). Still the insides of the framerails are rusted as hell, so I won't be able to keep this car forever.
I did some inside-protection with "Owatrol" and "Fluid Film" but will put something even denser in it some time, maybe this Mike Sanders stuff.
It's a semi-win, because it shall live on the street for another two years, but I'm not too optimistic for later-on. I did put in probably 100+ work hours for that though, which is the semi-fail part of it. Oh and it still has its sounds-like-rod-knock-sound at idle. Coolant pipes also look close to death too. I'll stop thinking now, I starting to realize how stupid I am...