Side window f^*k up

[hollow]

It pains me to retell this debacle but I could do with some advice here..

The story: back in january i embarked on getting some windows cut into my panel van. I didn't want the protruding rubbers common to standard panel van conversions, so I went for getting a complete cut section welded in place from a caravelle. Then first attempt was shoddy, because it was not fitted level or central to the panel!! and i regret not asking to see the window section that was going to be used prior to giving the green light as it was not a good one, as there is evidence of untreated rust on the seam between the inner and outer panels.

Obviously the process of cutting out and replacing made a fair amount of additional mess to the already rather desperate situation. And don't get me onto the rusty piece of "pooh" of a caravelle slider that was supplied to replace my panel van door!!

So what now?... I am uncomfortable living with it as it is.. I know its a 30 year old bus and I do try to subdue my instinct to be a perfectionist.. But i know the rust in the window frame underthe rubber seal will come back to bite me for sure.. Do I go for another round of making good, or do I take the plunge and get the complete window section cut out again and a decent one reset?

The worst thing is the regret I have for embarking on this in the first place and destroying a completely fine and rare panel van...

Can anyone make me feel better

[boatbuilder]

Photos of the offending windows would help

[trentjim]

Well if it makes you feel better I think you had the right idea...
Decent windows (and rhd) is why I'm still vanless - so I understand why you did what you did. Not your fault it didn't work out. But its down to you to get happy with it, it won't fix itself. You probably need to pop the window out, get busy with the dremmel and vactan and satisfy yourself that the rot is sorted. After that its cosmetics, photos would help.
Oh, and it might help you to think about it this way... At least you've got a camper...and at least it's got proper windows... Chin up
James

[jimpainter]

With the way I have read your post they didn't put in a complete panel? Did they just use the pieces from a donor and weld them into the exterior?
Pictures would be helpful. I have done window conversions into panel vans and find donor body cuts and fit them as per factory. That is that the whole panel is removed from the van and then the donor spot welded in along the 2 upright seams and across the top inside where it meets the gutters/strenthener. The bottom most join is then welded to the original panel.
jim

[hollow]

thanks for the upbeat response trentjim.. i am lucky as you say to have a decent van despite the window..

You will find images here of the first attempt..

https://dl.dropbox.com/u/25474840/2011- ... .14.07.jpg" onclick="window.open(this.href);return false;

https://dl.dropbox.com/u/25474840/2011- ... .16.52.jpg" onclick="window.open(this.href);return false;

https://dl.dropbox.com/u/25474840/2011- ... .17.06.jpg" onclick="window.open(this.href);return false;

what these images dont show well is the 5mm fall on the window frame from one side to the other which means that the lining that i wanted to install inside would not line through.. and the opening not centred in the panel, out by about 30mm.

so since this "cock"-up i had it cut out and repositioned, so it is central now, but its not pretty.

https://dl.dropbox.com/u/25474840/SAM_0290.JPG" onclick="window.open(this.href);return false;

I am an idiot for letting this happen... i clearly and naively put too much faith in others..

but in any case i am keen to know what you all make of this, and what my options are..

[Wookster]

Do you have a pic of the outside, and has it been sealed against the weather.
Inside it's messy but a few more welds, sealed against condensation, and covered with trim is probably the best you are going to get without spending loads more money.

[billy739]

if you retrim the inside it will look ok!

decide what you want from your van , whats your budget , and most of all use it!

are you putting windows in the rear? these are easier as the interior panel is already fitted!

the ideal soloution , with windows all round is a full caravelle headliner and side trim. will make it all very neat! and help with noise reduction!

[Plasticman]

pity you dont have picks of the work in progress as this would help to tell you wether its a runner or a remove and do it again, i have a mint set of frames from a velle complete with slider(later type)plus the pillars just ready for doing an erly panal to later factory glass conversion, interior is amatuerish but not a failure if your covering it,
mm

[hollow]

Thanks for the feedback everyone. Good advice Billy to 'use it! ' I am perhaps being too precious about it..

The plan is to insulate line and trim internally but I had not planned to make any more holes in the side! Is it going to be tricky without rear windows to do this?

The outside has been filled and painted so superficially it's ok.. But it needs more work in the bodyshop to get the trim lines straight.. It wasn't filled well before the paint job.

I wonder what will be revealed when I take the window out to do this..

Mm I pm'd you about your message.. I might consider redoing it.. I certainly need a decent early slider..