A Complete Revival from Chassis to Roof, Built to Last, Built to Drive
This Mazda Bongo came to us all the way from West Sussex, delivered by recovery straight to our workshop. The customer knew it needed serious attention to pass its MOT, and they wanted to make sure it was done right, from the structural repairs to the final finishing touches.
What followed was one of our most comprehensive projects to date, with extensive welding, a full mechanical service, a gearbox overhaul, full chassis underseal, a brand-new respray, and even an upgraded pop top roof and solar system.
Extensive MOT Welding Across All Key Areas
The inspection revealed major corrosion across multiple structural points, all of which would have caused an MOT failure. We tackled every section in detail, from the offside front chassis corner and suspension mount, to the lamp panel, crossmembers, and both inner and outer sills.
We replaced sections of the rear wheel arches, reconstructed the offside chassis, and repaired the nearside rear arch, the steering rack gator, and the front crossmember. This wasn’t a quick patch-up, this was a full structural rebuild with safety and longevity in mind.
Brake Lines, Bushes, Drop Links and Steering — Sorted
While the welding was underway, we also addressed various mechanical issues. We replaced corroded metal brake lines, fitted new anti-roll bar bushes, and installed four new anti-roll bar drop links to eliminate excessive play. We freed off a sticking offside front brake calliper, installed new discs and pads, and ensured the entire braking system was balanced and responsive.
To top it off, we replaced the steering rack gator, ensuring everything up front was compliant, safe, and road-ready.
Full Mechanical Service and Gearbox Overhaul
With the structure sorted, we moved on to mechanicals. We carried out a comprehensive full service including engine oil, fuel filters, brake checks, fluid top-ups, and coolant inspection. The automatic gearbox was removed, cleaned internally, refitted with a new gasket, and refilled with premium ATF oil. We even replaced a missing alternator tensioner, which would have otherwise caused problems down the line.
We also supplied and fitted a new starter battery, free of charge replaced both front tyres, and re-wired the rear electrics with a brand new split charge system and wiring kit, all at no additional cost to the customer.
Fresh Pop Top and Slimline Solar Power for this Mazda Bongo
To add off-grid functionality and space, we sourced and fitted a used pop top roof tent in excellent condition. This opened up the van for camping versatility and added significant value. To support long trips and power reliability, we also fitted a slimline solar panel with a charge controller, ensuring the leisure battery stays topped up wherever the road leads.
A Showroom-Worthy Finish with Full Respray and Detail
Once the structural and mechanical work was complete, the van moved into our paint and detail bay. It received a full exterior respray, including the roof, wing mirrors, bumpers, and roof spoiler, bringing the entire van up to a consistent, polished standard.
We didn’t stop there. The full chassis was rubbed down and undersealed, all suspension components were repainted in matte black, and we applied new Mazda decals, fresh Auto Free Top logos, and even added complimentary branded floor mats to complete the transformation.
Standing by the Work, No Corners Cut
While this was one of the biggest restorations we’ve completed this year, it also reflects what we do best, tackling big jobs with integrity, detail, and full transparency. We even covered additional electrical labour at no extra cost and absorbed the cost of tyres, floor mats, and a battery to ensure this Bongo left better than expected.
From rust repair to respray, from suspension to solar, this Bongo is now safe, stylish, and stronger than it’s ever been.
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
Visit: www.mazdabongoautocentre.co.uk