Kevtherevagon

[billybigspud]

Get the vents from this stitched on. You know you want too.

http://www.brick-yard.co.uk/forum/t3-bo ... 71223.html" onclick="window.open(this.href);return false;

[Plasticman]

well thers someone on here looking for a rear 1/4, this has it ,though dont know the state of the lower bit but thats repairable anyhow, thees loads of bits on it if it isnt all hidden under pod
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[billybigspud]

shame I have had mine painted, I would have bought it and had them grafted on. Sad i know!!!!!!

[Plasticman]

Tis not sad at all,
Well, boring sunday so diod an hour or so, the O/S sill area,, this van had some waxoyl equivalent treatment and you can see the result inb the next few picks,
first is the rear end

and this the front

good metal under it so its done its job but unfortunately they only squirted it in about a foot as the centre is dry and this is where the rot was/is

so cut out all the rot which was confined to the lip in the centre

a new bit of 1.4mm steel made and let in

gassed this in and will touch the other side with the grinder, after a coat of seam seal it will be undetectable and as its let in and butt welded as opposed to a patch there should be no further rusting within the overlapped join

so on with welding the sill and side panal bottom in tommorow.
the O/S rear 1/4 that I made, I have tweaked the corner to fit

happy with that bit and now I have SCRAPPED the whole bit, I had measured wrong and the swage ended up about an1/8 low, not a lot but not right so will make another in the morning
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[kevtherev]

I hate that too
I built a panel for a water pump system, the control box was just not sitting quite square, probably a degree out, Only I noticed it but whenever I looked at it ...
It mocked me

I thought it had been waxed, but not inside the cavities

[Plasticman]

Oh its been waxed kev, b ut however they did it they didnt shove a long 360' applicator down the section,
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[nicktennear]

How nervous were you starting this?



This is such a great thread. It's like that show Inside Nature's Giants.

[shepster]

How nervous were you starting this?



This is such a great thread. It's like that show Inside Nature's Giants.

Or excited!

[Plasticman]

Well. you lot are a bit too observant for my liking, your wrong though, it was for the tears.
been away on a little jolly,but back too it.

sorted the sill and side panal, weld thru applied and ready for welding together, the extra length of lip is a piece Ive added to go under the floor(top closure of sill section)

closer up

this is the side panal with a lip spotted to the rear and ready to accept the next bit

this is the top panal now spotted to the sill and floor lip and while it was still warm dose it again with weld thru which permeates right into the seam

this is now held in place while its all aligned

Im happy with the seam and join and the small gap will take a little lead and be right

this is the inside view, the item circled is the rear view of the panal clip holding the skins together, the extra lip I welded to the lower sill is now under the remainder of the floor section so will be an easy weld down


the rear wing is now alligning better so now that its all correct I can weld the sill bit on then the rear wing and that about it for the welding


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[kevtherev]

my favourite pic..


IK Brunel would know this look..
looks strong and permanent Mike, superb.

[Mickyfin]

Top banana as per usual Mike Stella work there mate.

[Plasticman]

Well.finnished most of the side panal,

making sure the angles are right and its straight-ish.lol

doing it this way ensures you have very little grinding off and also very little distortion, also if your not the greatest welder it dont matter as your only plugging at the rear

you can see the area where there is previous damage,usual scrape, the new rear wing in dark is to be seen sandwiched between the centre panal and the C post,

riight I said earlier that I would have to remake the osr 1/4 panal as I made it a touch too tall. NO I didnt, the aftermarket lower repair panal is too tall, rubbish, never seen them this far out, and I know that I was right as I measured the first one off the factory rear 1/4 I have !
More later
this is the start of the new panal, flat sheet and swage added, curve put in and lip area notched

starting to fit it

you can see the 2 lines at the bottom, this is the ammount that the pattern lower panal is to tall by.

gradually fitting a bit nearer

Ive put a tape mark on the wing and marked where the lower panal comes to , its also a p*** poor fit at the rear but I can reshape this

very nearly there

I have made the final fold in the corner and given the panal a curve in the vertical as well as the horizontal and am now 99% happy with it

so this is now ready to weld on fully

as is the rest of the side

my own fault for not paying more attention to the aftermarket stuff, would have saved me a couple of hours .
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[kevtherev]

Mike, do you think it's possible that the repro panel "stamps" or whatever they're called are getting worse, deteriorating..or has it always been this way?

Nice metal work on the lower rear mate, how you get that complicated bend around the corner spot on I'll never know.

....that final shot is a surreal one as I'm so used to seeing a rusty mess.

[Plasticman]

I dont know kev, either the wing is too long below the last swage or the lower panal is too long, maybe a bit of both.but I do know that the lower panals are a little longgggggg. either way its my fault for assuming and not checking, lesson learnt.
I think it depends on the maker of the panals, there are more than one manufacturer, and I dont think the dies shrink or grow but I will pay loads more attention as these are some of the worst I have come across
the final bit of curve round the corner? well you just sort of have an eye for where it should be as you cant measure it, you get at least 2 goes before the metal is too messed up
Im happy when I look at the body now as i dont like to see patches over stuff nor under, I prefer letting metal in, the side panal will get a smear of lead and a wipe with finish filler I think at the end of the day most of the external body will be new/good metal and yes there will be filler but it will be smoothing cosmetic only. when Ive treated the bare metal i will do the seamsealer in one go as the brushes are scrap within the hour..
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[jimpainter]

Excellent work
I have to say though the rear corner I got from schofeilds, albeit a S/A panel so the top half was useless (I didnt need the top half anyway) was an excellent fit. It went straight on with no work at all apart from me cutting it and getting it to fit where i Had removed the old panel. Curves were spot on, as were the swage lines. But that is why the panel was £195

Just goes to show the difference between repro and genuine. Always worth the extra I reckon in the long run as it can reduce the labour costs.