Club 80-90 Forums

hi looking for a few tips on welding new front panel on my bus any one done it . the panel goes from seam to seam cant see how to get to flanges on panels to weld them together bottom is spot welded so ican punch holes in panel and plug weld them, but sides of panel, cant just weld them together from front as i will loose seam and it wont look right any help out there thanks dave

I think you weld the panel through the indicator lenses, but not sure how much of the joins you can see and reach.

thank for reply didnt think of the indercators .was hoping someone had done this before cant believe i am the first to give a go thanks dave

measure 25mm or so in from the seams on the van and 25mm in on the new panel, cut along the lines youve made and weld the cutdown panel in, that way you keep the seams (if theyre not rotten of course) you can use sikalex or tigerseal instead of spotwelding along the bottom, 1 it will not rust, 2 it looks better when painted and it wont rust. thats what ive done, (but dont tell anyone! they`ll never know)

They know now! Tis possibly a better job in the long run considering most modern cars are stuck together with the stuff now.

thanks for reply sorry to say but panel rusted up to seam but like sound of sikalex or tigerseal never used them before, do you spead on panel set in place then clean up what squeezes out .it beats trying to geting grinder in there to clean up welds . thanks dave

If u look on youtube under"syncro russel eats rust" there is a short vidio someone made of me removing that panel.It is a double welded t panel at the bottom.

thanks that was a great video to watch how much of the panel did you cut of with hammer and chisel or was rest done with cutting disc cheers dave

Very seldom will i use a cutting disc.This creates far to much heat transfere onto the panels that are staying behind and is very inacurate.Use an air hacksaw.
To do this job well u will need :mig welder,air hacksaw,grinder with soft discs,drill with spot well drill bit,body chisel and large hammer,large belt sander.
Russel

Whats the belt sander used for russel?