Being brave.....side panel and modification

[poshbuggers]

I'm soon to take the brave step of removing the side window panel (B pillar to C pillar) out of my converted panel van and replacing it will a good quality cut from a broken panel van and filling the hole in again. The twist is I am doing this purely to cut it out again to fit a different window.

So, a big job - most would consider unnecessary or sacrilegious at the least.

I'll be fitting a rare Polyroof window, found as a pair on Ebay.de. I've always loved the funky dayvan look the germans offered on their conversions and prefer the better viewing, light influx and sci-fi feel they offer.



I know they aren't to everyones taste but this is my 9th T3 and I know what I like and want now. Even the wife isn't sold yet but has conceded any further complaint

Earlier in the year I took the bull by the horns, sold my sliding door (with glass) and fitted a panel van door, which was then cut to suit the matching Polyroof window.











It was touch and go but careful measurement and patience have resulted in a solid, tidy fit just needing cosmetic tidying. Concerns over strength were unfounded as the glass is bonded to the panel around all 4 edges and bolted in at the top.



The door feels more solid now than before it was cut. I will be adding some stiffening ribs to double as mounts for the interior panel and window trim soon.



Now I am looking to do the same on the drivers side.



The glass is virtually the same as the slider panel and I will be using my previous work as a guide to cutting. On the inside it will look similar to this original brochure photo.



I picked up the body cut from a breakers in Leicester but it was oversized and needed a lot of trimming back. Still, better to have plenty of metal.

I've trimmed it back so the join will be along the swage line, possibly using a joggling tool to create a nice flanged edge to tuck behind the lower panel. I am left with this.



I've left the flanged returns around the panel and just need to peel back the pillar and gutter metal where it is spot welded around it to create an 'as original' panel fit. A friend who is a professional welder/fabricator will be fitting the panel.

My thinking is he should cut inside the B and C pillars into the panel and remove the main area of metal then drill out the spot welds like the panel I am working on, but in reverse almost. Then clean up the pillars and gutter, slot the joggled edge behind the lower panel and tap it into place and spot inside all around.

I'd welcome the opinion of others on here about this as I want him to make a nice job of it.

[Plasticman]

nothing wrong with doing that ,thankfully you havent got rear side windows as that would look a prat,
i think what will throw most folk is that we are conditioned to saeeing windows in the horizontal rather than vertical,
the way i see it is the biggest issue is to make the breakl in the swage look like its meant to be rather than an afterthought.
as for the fridge side , well you have a distinct advantage in so far as its the centre panel you want out, in my case i need to retain this and still extricate the rear wing
i would just chop the panel out and clean up and refit as oe. certainly add a folded rib horizontally below the window which as you say will be a twofold benefit in giving strength and also something to adhere inner panels to ,
if you can take clearer more detailed picks of the corners and swage areas etc i can maybe add more ??
mm

[poshbuggers]

Thanks MM. I am grateful of your input and will get some photos of the panel cut and inner panel tomorrow.

Here is a Polyroof in a prettier van than mine. I can't think that many have been fitted in Syncro buses though.



The problem is the fibreglass window trim obscures a lot of the upper area so I may have to warm up the inner seal and try to get it out while keeping the glass in.

The lower rib is a good idea and I think that a decent 'top hat' section just above the wooden strip shown in this photo would help as well as give me somewhere to attach a brace for the side panel.



I'll use the void below as indented storage with a net across to accommodate kids games, phones and travel nonsense. Every bit of usable space helps as I won't be fitting cupboards.

[LeeME3]

God I love that blue one at the top....any of these in the UK???

[poshbuggers]

I honestly don't know. Most people wouldn't know much about the manufacturer as they are predominantly German so anything over here is likely to be LHD.

[poshbuggers]

Here is the panel cut. There is a part of the gutter and pillars left top and sides which needs removing. I assume a spot weld drill is the most efficient method to do this?





I could probably do with another one of those ribs under the window to stiffen it as MM suggests so another call to the butchers is in order.