Replacing Lower Outer Skin

[si macc]

Hi everyone,

I've got a pretty serious looking bit of bodywork that needs attention on my 88 Westy. I think it was most likely caused by a leaky tap on the sink. The lower outer skin on the kitchen side has got quite rusty and has separated from the upper part of the panel (will put up photos tomorrow), I can now get my little finger between the gap and it's not looking too good. I need to remedy this pretty soon as I don't want it to spread to other bits of the van so I have 2 options:

1. Take it to my garage and get them to do it
2. Buy a MIG welder and spend some time learning how to weld and have a go myself

I wanted to get some advice on what is the best option, I would rather go down route number 2 as it's a good skill to learn and would save my self cash in the long run. I'm hoping it may actually be fun... I've got some questions about the practicalities of welding:

- Is it realistic to think I can get the job done by myself bearing in mind I will have to work on my van on a road (maybe able to use a friends parents drive)
- To replace the panel is it just a case of cutting out the old and then welding the new one in place or is it not that simple? Such as having to fabricate parts to complete the job
- Am I biting of more than I can chew?!

Any help would be greatly appreciate! I am very keen to get stuck in but don't want to trash my van!!

[si macc]

Seen a few people have had similar issues and have been keen to fix themselves. Bought a 'haynes bodywork manual' and it suggested starting off with a clarke 100e mig welder, can anyone tell me if this is? I'm definitely sure I'm going to give this a go but my main concern is the location of the welding....

[dugcati]

have a GOOD look around the forum as many of us, myself included have repaired the very area your thinking of doing. There is a mountain of info,photos, pitfalls and successes documented

If you do decided to do this yourself do 2 things,

- take pictures - lots of them
- understand you will get frustrated and sometimes quite depressed with the speed of progress/lack of and how bad your van looks when it's guts are hanging out! That said when it goes back together and goes right the resultant smugness is more than worth it


Oh... a 100 amp welder is fine for body work, just get a GAS MIG welder as gas-less MIG'ing is not as easy as gas MIG and it will not give you the visual end result and will mean more clean-up afterwards - the biggest rule in any welding is "cleanliness rules", you successfully cant weld cak to cak and you can't weld painted/greasy metal!

[si macc]

Thanks for the reply, wasn't sure what I was searching for in terms of the panel name. Was I correct or is there a better term?

Is it safe to do on the road? More worried about other people than myself as I can't dish out protective google to everyone!

[dugcati]

hmm not sure about working out on the road welding and grinding - local council might get a little upset not to mention sparks etc on passers by and other cars

oohh the panel your talking about is normally called the something along the lines of "centre lower section, behind the fridge"

[Cruz]

Some good info in the WIKI about this somewhere

[si macc]

Thanks everyone for the info.

Not sure what to do... Do you think constructing a gazebo around the van would help, or is that just a huge fire risk?!

[jamesc76]

Welding in the road side is a massive no no, if any neighbours complain you could get a telling off by the council!

[pmoc_2001]

I am currently doing what you are proposing to do.

I bought a camper from by neighbour. It is rusting in exactly the same places as you describe behind the fridge and other areas too. After I got some laughable quotes from the local repair centres, I decided to go it alone with no prior experience in body repair, welding or finishing.

I figured that the fridge side panel would not be the only area that needed attention, and to be honest these vans are well past their use by date and will probably need continuous work.

I wanted to be able to use the van at the same time as carrying out the repairs so am taking the divide and conquer approach doing a bit at a time (currently repairing a step and the first bit of welding).

I also researched thoroughly and created list of things that I would need to buy before starting such as primer, rust inhibitor, grinder and pads. Another thing I did was rub/ grind down and treat all the other areas that are rusting and apply a rust inhibitor. I did this because I soon realised that bodywork takes time and by the time I get round to doing other areas of the van the rust will be worse. I have also stripped out all the furniture.

In sum I am starting in one corner and moving around the van doing the seams and other fixes as I go.

I bought a draper gas/gasless welder and a Haynes body work manual from Amazon. The book is good but does not actually teach you to weld. I have found that only practice can do that.

Good luck!

[jamesc76]

I bought a draper gas/gasless welder and a Haynes body work manual from Amazon. The book is good but does not actually teach you to weld. I have found that only practice can do that.

Good luck!

never a better statment put! pratice is the only way, plus gasless migs are pants!

[si macc]

Thanks for the post pmoc, has really encouraged me to proceed. I have wanted to take the whole interior apart and roller the exterior at some point so this will motivate me to get it done.

Looks like I'll be having to find some space to do it off the road.

My brother has a small drive way not too far away so will have to ask him. In the meantime I can get a second hand one and get practicing!

[CovKid]

https://club8090.co.uk/wiki/Ar ... outer_sill" onclick="window.open(this.href);return false;

[si macc]

Thanks covkid,

I managed to find that and have had a good look through. I've found a good location to complete the job, our office has a big courtyard out the front which is empty at the weekend. I have permission from our director to use it.

My plan is to buy a welder very soon and get down the scrapyard to find some panels to practice with. Then after our holiday in sept I should have Practiced enough to be ready to tackle the van. I can then spend the winter preping the van for a spring roller paint job next year. Well thats the plan anyway.... And all the money I save doing this can go towards a recon engine.

[dugcati]

.... all the money I save doing this can go towards a recon engine.

:roflI think we all try that trick and end up buying bling/tat or more body panels