Prepping
The worst rust on the van was the area below the front windscreen - all these Sprinter vans seem to have this problem. I ground the rust out down to bare metal and painted it with a rust inhibiting primer. I then fiber glassed the whole area (sorry I forgot to take pics) and then skimmed the whole area with a layer of body filler and then sanded it down. Sounds simple enough, but it took 2 full days. I should have taken more photos!
There were a few dings and scrapes which had to be filled - not too bad though considering it's past life as a delivery van. The front left headlight had had a knock and had to be repaired.
Total time spent on sanding (lots and lots), filling and priming and the final spray was about 6 weeks - most evenings and weekends.
Spraying
Because the van's base colour was already white, I decided to go with an arctic camo (snow camo) theme. I used a technique called "leaf camo spraying" where you simply spray over foliage - there are loads of video tutorials on YouTube. The whole van was sprayed using normal spray cans (rattle cans).
The whole van was then sanded down (again) and sprayed (using a compressor and gun) with 4 coats of clear matt spray. I'm pretty chuffed with the way it came out especially considering I had never sprayed a vehicle before.
Headlight Restoration
The headlight lenses were badly oxidized! I used a technique I found online for restoring headlight lenses. They were sanded down with 1200 grit sand paper and sprayed with a UV resistant clear coat.
Before
After
