At Mazda Bongo Auto Centre LTD, we believe every Bongo deserves a second chance. This recent project involved a vehicle that came in tired, worn, and rust-riddled—destined for scrap in the wrong hands. But thanks to our expert team, it’s now been completely transformed into a stunning, structurally sound, and adventure-ready campervan.
Let’s walk you through this full Mazda Bongo restoration—from MOT-saving welding and structural repairs to a complete body respray, engine servicing, off-grid electrical upgrades, and all the finishing touches that make it shine.
Free Pre-MOT Inspection – Discovering the Hidden Damage
Like all great restorations, it started with a free structural and MOT inspection. While the van appeared in usable condition at first glance, our deep-dive revealed some alarming issues:
- Major corrosion on the chassis and suspension mounts
- Poorly done previous repairs covered with filler
- Cracks in chassis legs, especially near load-bearing spring mounts
- Perished outer sills and wheel arches
- Leaking transmission oil cooler pipes and damaged coolant plumbing
- Brake discs well below safety limits
It became clear that this van would fail MOT without immediate action—and worse, it posed a real safety risk on the road.
Welding & Chassis Fabrication – Strength Where It Matters Most
Once we agreed a plan with the customer, we set to work rebuilding the van’s structural integrity from the ground up. Our specialist fabricators carried out precise cutting and welding using high-grade steel and factory-level finishes:
- Replacement of full inner and outer sills (both sides)
- Fabrication of new rear chassis legs and tubs
- Repair of front and rear suspension mounts
- Removal and rework of poorly welded cross members and outriggers
- Chassis leg crack reinforced and restructured
- Replacement of rotten quarter panel
We also uncovered bodged body filler repairs, particularly around the O/S quarter panel. We removed it entirely and fabricated a solid metal replacement for long-term reliability.
Exterior Full Respray in Original Colours– A Mazda Bongo That Shines Again
Once the structural work was complete, we turned our attention to the exterior. The customer chose a classic Silent Silver colour scheme, and we went the extra mile to deliver a premium, factory-grade finish:
- Genuine Mazda rear wheel arches installed
- Full prep and primer work for all panels
- Lower half resprayed in Silent Silver, matching roof with matching bumpers, wing mirrors, spoiler, and trim
- Top half in original highlight silver
- Roof and tailgate refinished in matching tones
- Windscreen removed and resealed following rust treatment behind the glass
- New Mazda decals, custom number plates, and complimentary branded mats added to finish the look
⚙️ Engine, Cooling & Gearbox Service – The Heartbeat Restored
With the bodywork sorted, our technicians got to work ensuring the van’s mechanicals were up to the task. A complete service was carried out, including:
- Engine oil, air filter, fuel filter and all top-ups
- Coolant system flushed, fitted with new thermostat, twin sensors, and fresh anti-freeze
- Coolant Auto-Bleed Kit and Ultrasound Alarm installed to prevent overheating
- Transmission cooler pipes replaced due to heavy corrosion
- New rocker cover gasket and coolant T-piece
- Gearbox flushed, with fresh filter and sump clean
This service ensures long-term reliability, reduces the risk of breakdown, and protects the engine from overheating—something we see far too often in neglected Bongos.
Brake System & Suspension – Restoring Safety & Control
No restoration is complete without safety systems in perfect condition. The braking system was rebuilt with:
- New front brake discs and pads
- Anti-roll bar D-bushes and drop links replaced
- New steering components and alignment check
- Suspension components rubbed down and painted matte black for durability and visual appeal
- Comprehensive underseal and chassis protection applied across the underside for years of rust-free adventures
Off-Grid Electrical Upgrades – Ready for Adventure
We’re big believers in real-world use. This Bongo was fitted with a full off-grid power system:
- 160W Slimline Solar Panel with MPPT smart controller
- 240V Inverter neatly installed under-seat
- All wiring and 240V sockets tucked away and moved under the rear bumper for a tidy finish
Perfect for powering fridges, lighting, phones, and laptops while camping, this system gives the owner freedom to roam.
✨ Final Touches – Where Details Matter
A great camper conversion is all about the finishing touches, and this van is no exception:
- Alloy wheels refurbished in Silent Silver to match the body
- New electric window motor on passenger side
- New windscreen professionally fitted
- Polished headlights, painted step trims, and a complete valet
Need a Mazda Bongo Transformation of Your Own?
Whether you’ve got corrosion issues, cosmetic wear, or mechanical concerns, we can help bring your Bongo back to life. We’re proud to offer honest advice, expert workmanship, and results that speak for themselves.
Saltney, Chester CH4
Call us on 01244 907 079
Email: info@mazdabongoautocentre.co.uk
