A familiar story Hectors refurb

[Plasticman]

pray which make of grinder would this be? if you dont allready then get some 0.6 mm cutting discs,be carefull not to force or bend them but they cut very well and give grinders an easier time . she has suffered a bit hasnt it
mm

[Doogs]

This one

http://www.machinemart.co.uk/shop/produ ... 22-grinder" onclick="window.open(this.href);return false;

to be fair they replaced it and the new one has been going all today no problems so i think i was just unlucky,

[Plasticman]

Ah, that will do light work ok , but do get some 0.6mm cutting discs, 1mm are handy for some jobs like using edge on to dress welds delicately, but go to a proper store for the discs
mm

[Dazco]

Keep an eye on Aldi they do have some from time to time cheap and chearful , think mine was £17 . i use 2 (not at the same time) 1 set up with a slitting disc the other either a grinding disc or wire brush, i got bored of changing the discs over every 2 minutes

[Doogs]

Got some of the rusty bits cut out and new metal welded back in ready for the new arch over the last couple of days, when i get the final fit im going to vactan thoroughly and give it a coat of combi colour which will hopefully stop it happening again

[Doogs]

Had a few hours on the van this week and a decent shift today, vactaned the arch then a coat of rustoleum and probably a bit over the top but tigersealed the new welds above and below



then wing tacked on after a good bit of tweaking



and finally the small panel at the rear



the schofields panels seem to fit very well im finding with a bit of tweaking, im also finding it very satisfying cutting out all the rotted stuff as after its out the job somehow doesnt seem nearly as intimidating

[boatbuilder]

Yep its nice to work with fresh rust-free metal isn't it?
Be really careful when you're welding the inner arch to the new panel..... it can warp really easily, ask me how I know!

[bmouthboyo]

Think this job is on the cards for me...

Can i ask what thickness / weight steel you used for the inner srch you fabricated? Also how did you bend it around the arch? Any useful guides you followed?

Thanks

[Doogs]

Hi,

I used 1 mm mild steel, although i think most would probably use about 1.2 mm, but just mark out and cut the rotted part out. i made the section in 2 parts it clamps up and bends around the contour reasonably easily, i personally put a wee bit in to reinforce the joint between the sections but it could easily be fabricated as one section i think i just didnt have a long enough sheet of steel it was easier than i expected but do make sure that you have everything clean and shiny before you start welding

[Doogs]

Work is a bit quiet this week so had more time at the van, started on the 2nd arch repairs, had always noticed the rust worse on that side and the wing a bit bulgy discovered under the short arch section another short arch in much worse nick

so back to the grinder and more cutting




Had less metal left after the rot was out and a longer piece to form than the other side, so tried it in 3 parts this time thinking it may follow the angle of curve more closely if it was a shorter section





last piece needs more work but at least the rot's gone and reckon the old boy feels a bit better for it

[bmouthboyo]

looking good

I have a feeling this is what I will need to do on one of my arches after a leaking rear window for many years. Hope you dont mind me asking but can I check I have understood the process:

I will have to buy a tall rear side panel AHSchofields
Cut my existing panel a few inches below the swag line
Grind of the remnants by drilling spot welds out
Repair inner arch as in previous pics
Cut top of panel to fit up to previous panels cut

This is where I am less sure:
Does the replacement panel come with a lip just above the arch part to weld onto the inner arch? If so is this welded with the panel lip above or below the inner arch? I have seen metal mickey adding this "lip" to a tall panel so am pretty sure it isn't on them, in which case why not? / best way to secure inner arch?
Spot weld along the seems of the panel from the inside?
Seem weld the top of the panel from the outside, grind back etc.

I have scoured the threads but most seem to show the panel and inner arch before but not the welding to secure it after.

Thanks guys

[Plasticman]

looking good



I have scoured the threads but most seem to show the panel and inner arch before but not the welding to secure it after.

Thanks guys

you need to look closer as the welding you speak of is in great detail, and I take it you are speaking figuratively when you say seam weld as in continouse seam welding? tacks are all you need for most except as in this thread where the inner arch is being made up, yse you can get away with tacking but butt weelding all along is the correct way
good work here fella
mm

[bmouthboyo]

That's right MM I meant but weld continuously along the area that was cut, I thought someone said it's OK to tack where VW would have but when chopping panels you have to fully weld, hence the upper outside part? I will read up again on this.

Reason I wanted to double check about the lip is I read on your thread you said you prefer to weld the lower panel and chop the tall panel for the top part due to the lip.

bmb

[Plasticman]

dont want to hijack doogs thread so pick one of yours and we can carry on there
mm

[pmoc_2001]

Glad you are posting your progress in the rear wings. I am tackling the exact same areas now. However, my inner arch is completely rotten up to where it starts to bend down. I’m thinking of removing the inner part of the arch which is spot welded to the boot floor as the new arch will push all the way through the slot.

Just one question are you worried about welding and grinding with the wheels on?