westy kitchen side panel

[jdreamer]

Just started to sort this on my van - rusty top of sill & side panel etc. Anyone know if you can get a complete lower side panel (the whole middle side panel below the kitchen window, so not including the window frame itself). Heritage appear to sell the complete side panel with window frame etc, but it's VERY expensive. Got a repair panel from Schofields for the sill & 6 inches or so above, but looking at the water/leccy inlets and strengthening bar it's looking like replacement of that whole panel might be easier - as per the example link from the wiki (rustbuster side panel replacement from a dutch site). Looked on vagcat and can't see the panel, as only the whole thing listed (as above including window frame). Any help on where i might find one appreciated. Cheers, j

[poshbuggers]

I have that panel chopped out of a LHD Caravelle Iinside and out) in good condition. Did it for the same reasons but never used it.

If you need the lot it's there to cut and trim to your hearts content.

£100 and its yours.

07798 746534

[Bert2]

I have just completed that repair on my van, The only panel that size (from below window) I could find was a cut out from existing vans, make sure you get a correct side for your van ie from a L/H or R/H drive van I dont think they are the same, that who ever picks the van apart leaves enough of the seam to weld to your van. I was lucky the chap on ebay who provided my panel did a good job and it fitted well good luck, any advice ask away.

[jdreamer]

Ta for the replies guys. Trying to patch up the existing panel - welded in new metal today, not finished but not too bad so far. If it turns out looking cra*p then I may well have to go the route of using a panel from another van. Thanks for the offer poshb, we'll see how it goes and I'll come back to you if I need to follow that up.

Cheers, J

[poshbuggers]

Hope it doesn't come to a full panel. Best of luck.

[waltraud]

U got any pics of this work, i'm interested as have to do the same or similar soon, spots or rust on the outside and seam rash may be ok but i'm guessing that like most things rusty- a little thats visible usually means lots that is not. Cheers, Tim

[jdreamer]

Ok, so an update.....decided to go ahead with replacement of the lower outer sill/side panel, as per the heritage panel. Chopped out the old panel and the rotten floor section behind - glad I got in there as it wasn't pretty. Limited pics, but give u some idea - same as most others posted up here over the years.

1.jpg

2.jpg

3.jpg

More to follow.

[jdreamer]

And a couple more fyi..

4.jpg

Note primer is electrox zinc based (Bilt Hamber) - I like this stuff.

5.jpg

Note new panel joined in the u-shaped pressing (just below joker stripe) and filled - needs sanding etc. but should look ok.

Got to paint the damn thing now...maybe sometime before I get it finished!

Cheers, J

[Damien]

Think i've still got the worst one to do, goes right through to the corrugated floor and most of the ends are missing, you can see the inner sill in one hole and the ground in another 90% of the way across.

[jdreamer]

And whilst I'm here, big thanks to all those chaps who've done similar and posted as such. Makes this stuff sooo much easier when you can see others have done it before ya.

[jdreamer]

Think i've still got the worst one to do, goes right through to the corrugated floor and most of the ends are missing, you can see the inner sill in one hole and the ground in another 90% of the way across.

Ouch. Good luck!

[waltraud]

Great work! Couple of questions re this, any tips for removing westy kitchen unit? Was thinking undo gas joint at floor and take electrical connectors apart in same area, unscrew screws from storage cabinet into fridge side , take out fridge flue vent...try to life and???

Also wondered, where you have made the join in the side panel U section did u use a joggler to step the joint or a but weld?

Many thanks. have you thought about Rustoleum / combi colour with a roller for re-painting?

Cheers, Tim

[jdreamer]

For kitchen removal, I took the whole unit out, so didn't remove fridge first. Once you've undone the few bolts holding it in place (LH side panel and floor if I remember right), you can pull it fwd to get at the fridge flue pipe and leccy connections. Didn't take too long, but needed some persuasion to come out - 27 years of not moving I guess! Then removed unit to LH side with water tank etc. Again, a few bolts here (seat side and wardrobe I think) and the main leccy connections. Time will tell if I can remember how to get it all back together

For the join, I left plenty of the original upper panel in place, below the u-channel, so had an overlap. Seam welded on the outside edge, in the middle of the u-channel. Then some spots/tacks along the inside edge (lower down). The new floor/sill closer panel sits on the little ledge on the inside of the new panel (where the sill line is pressed into the outside face). There was enough to weld to here, but didn't bother with a continuous weld for that as didn't see the need. All seems very rigid now all in place and welded. Also jacked up front & rear on that side after, to test that all was sound - no groans or cracking joints thankfully. Didn't want to put it all back and then have the van snap in half when I tired to take a wheel off

Note some replacement side/sill panels don't have the pressed sill line so no lip to attach floor/sill closer too. As per other threads, some folks have used angle to make a ledge to sit the floor/sill closer on.

Also had to chop out a load of the side panel strengthener bar, so replaced this with large angle - again, once in place seems rigid enough. Although I noticed you can actually still get the strenghener bars from classic VW in Germany.

Hope that helps.

Cheers, J

[jdreamer]

And to answer the paint question....I'm going to spray it (cellulose). I have a compressor and have done a bit of spraying in the past, nothing great but it does the job. Also, I bet you can't get rustoleum in "Escorial Green" and I love the colour too much to change it

[waltraud]

Very helpful. When you say about the join in the chanel did u leave metal in place below the join nd in effect lay the new panel over the old U chanel or am i getting this wrong? cheers, Tim