Club 80-90 Forums

I'm going to get my filler panel sorted out. I'm guessing the best way to do this is to cut out the rot and replace with new.


Is there a repair panel just for this bit or do I have to buy a full wheel arch panel? My wheel arch is OK.

I'm going to get a new filler surround which I've seen at justkampers, is there anything else worth changing whilst this is being done.

Where is best to get the panel from JK or Scholfields?

cheers

Gaz

You have to buy the whole panel i think but you could cut it down. Which is what we had to do with mine because it didn't fit. It was a JK panel and it was total pants it didn't fit had dents and ripples in it. Personally i would cut it where the door goes horizontal (if that makes sense) because it was the front wheel arch didn't fit.

I would cut vertically from where the doors pointy bit is and using a joggler/hole punch and puddle weld doing that you would need minimal filler to make right.

I will have a little play and post some pics showing you what i mean.

I will have to do this bit by bit as i'm not too clever.
A joggler. This one the head reverses and turns into a hole punch but you can also use a drill. Probably 5 or 6 mm.

Cut the panels so that they overlap by about 13mm. Using the joggler go along the edge of one panel

The two parts to be joined should look like this


And when offered up to each other should be flush.

Then using your hole punch/drill go along one edge making holes about 30-40mm apart.

Clamp the two parts to be welded together making sure everything is lined up.
Welding, Fill the holes with weld. Weld the holes one at the top one at the bottom as opposed to one after the other. This will help reduce heat build up and distortion of the panels. Take a breather between welds would also be a handy tip.

Thanks for the picture Tony but I'm getting somebody else to fit the panel and hopefully sort out my rusty seems at the same time.
I think I'll get my panel from Schofields!

You should now be left with a flush join. Grind down the welds, take your time here also because of heat build up.
Where i have marked with black marker is the only part that needs filling. You can fill using weld but be careful or just use filler.



Thats ok gaz i was bored any way

I plan on doing a full step by step guide with photo's when i have my windows out in March.

windysurfer wrote:I'm going to get my filler panel sorted out. I'm guessing the best way to do this is to cut out the rot and replace with new.


Is there a repair panel just for this bit or do I have to buy a full wheel arch panel? My wheel arch is OK.

I'm going to get a new filler surround which I've seen at justkampers, is there anything else worth changing whilst this is being done.

Where is best to get the panel from JK or Scholfields?

cheers

Gaz

i wouldnt cut that out at all. if its ground back correctly then you should have no worries. my first bus was far worse than your pics appear and that was ground,treated and skimmed and didn't rot back in the two yrs i kept it after.....

What is needed is a good clean inside around the fuel filler pipe regularly. There is only one way to get rid of rust.
Although cleaning up may last a few years, My originals lasted 20 years.

This was mine after 20 years

Windysurfer, That really doesn't look very bad at all. I'd just rub it back to bare metal first, if there are no holes, level it off with filler and then paint

Melvin