When it comes to campervans, rust waits for no one.
At Kinmel Campers in North Wales, we’ve recently taken on a Citroën Relay campervan that’s in desperate need of some TLC — and we’re giving it the full treatment. This blog documents the work-in-progress, showing how we’re tackling five rust-affected panels, performing critical welding work, respraying bodywork, and applying a comprehensive underseal to protect the vehicle’s future on the road.
If you’re thinking of restoring or converting your own van, this behind-the-scenes look at the process will give you a clear idea of what’s involved — and why it’s so important to do things right from the ground up.
It Starts With a Strip Down
The first stage of any restoration is stripping the affected areas down. On this vehicle, that meant removing seals, trim, and components from five separate body panels. This allowed our technicians to identify all hidden rust and prep for welding and repair.
We then masked off the protected areas in preparation for sanding, priming, and panel repair.
Essential Welding to Save the Shell
Welding is often the only real solution for structural rust damage — and this Relay needed multiple welded repairs around the windscreen and panel seams. At Kinmel Campers, we specialise in campervan welding services that restore strength without compromising panel shape or future conversion potential.
Our welding work on this project included:
- Cutting out rotted metal from critical seams
- Fabricating custom patches from automotive-grade steel
- Fully seam-welding repairs, not just spot welds
- Smoothing welds to prepare for paint and sealing
💡 Rust may start small, but left untreated, it spreads fast. Proper welding restores both safety and value.
Panel Prep: Sanding, Priming & Masking
After welding, we moved on to preparing the five affected panels for respray. This included:
- Sanding out surface rust, scratches, and flaking paint
- Treating any bare metal with rust-inhibiting primer
- Masking off surrounding panels to protect during paint
- Checking alignment for seamless respray blending
With the surface prepped, we’re now ready for high-build primer and colour-matched topcoat to return the van to its best appearance — and keep it that way.
Undersealing for Long-Term Rust Protection
Underneath is where a lot of rust begins — especially in the UK. That’s why this Relay is also receiving a full underseal treatment as part of its restoration.
Our undersealing service includes:
- Cleaning and degreasing the entire underside
- Removing any loose or flaking factory coating
- Treating any rusted areas with rust converters
- Applying thick, protective underseal coating by spray
This forms a long-term barrier against water, salt, and road grime — making it ideal for anyone planning off-grid or coastal travel in their camper.
Why Rust Repair Matters in Campervans
Many campervan owners focus on interiors and gear — but your van’s bodywork is what keeps everything safe.
Ignoring small rust patches can lead to:
- MOT failures
- Structural weakness
- Water ingress
- Higher long-term repair costs
That’s why our campervan welding and rust repair services are often the most important phase of any van’s journey to conversion. With this Citroën Relay, we’re ensuring that every inch of steel is protected, sealed, and ready for years of adventures.
More Than Just a Paint Job – It’s Preservation
This isn’t just cosmetic work — it’s preservation. By stripping, welding, treating, sealing, and undersealing this van, we’re extending its lifespan and making it ready for conversion, sale, or years of dependable use.
🚐 Whether it’s your full-time home or weekend warrior, your campervan deserves a solid foundation. At Kinmel Campers, that’s exactly what we deliver.
Want to See More?
This Citroën Relay restoration is still ongoing — and we’ll be sharing more updates as the work progresses, including:
- Full colour respray results
- Underside before & after comparisons
- Interior upgrades (if the customer opts for future conversion)
📸 Follow us on Instagram and check our blog for future stages!
Start Your Own Campervan Restoration
Got a van with rust spots, MOT issues, or old paintwork? Don’t wait for it to get worse. We offer:
✔ Free rust inspections
✔ Honest advice and no-obligation quotes
✔ Full welding and body repairs
✔ Rust-proofing and underseal packages
✔ Mobile or in-workshop service (Rhyl-based)
📞 Contact Kinmel Campers Today
📍 Kinmel Campers, Rhyl, North Wales
📞 Call: 01745 771 231
📧 Email: info@kinmelcampers.co.uk
🌐 Website: https://kinmelcampers.co.uk
