There were some rust problems that needed to get fixed before I could get the van inspected. I believe the part of the inspection code that deals with rust holes is defined as “Protruding objects. There may be no torn metal, glass or other loose or dislocated parts protruding from the body of the vehicle”
Patch panels are available but expensive. Since this will always be a $500 van I decided to do the cheap and easy fix using old some old steel shelves and pop rivets to make my own panels. The first step was to cut out all the rust. (I could have just slapped the panels over the top of the body but if the van makes it back from New Orleans it should have some life left in it for the next owner)
I made some patterns and took the grinder to some old shelving I had.
Some gentle bending with a piece of PVC pipe and I had some new rocker panels.
I hate rust so I primed and painted everything while it was apart.
And started installing the pieces.
The fiberglass fender flares took care of the wheel well edge. I used some seam sealer between the patch panels to try and keep out the moisture. Did I mention that I hate rust? These patches will be there long after the vehicle is gone from the fool-injected driveway. All it cost me was a box of pop rivets, a tube of seam sealer, some old paint I already had and some shelves that were getting thrown out at work.