Club 80-90 Forums

Hi,
during the next few months i was planning to replace some panels on my 81 Devon Moonraker, i will be replaceing both back arch's and bottom sill panel by the fridge and both front arches and foot wells, it sounds like the van is falling to pieces , but it has just flown through its MOT with no work required. the panels have rust so i want to replace them, i have been advised by a friend to buy a Edge setter/Joggler tool , i now that they put a small lip on to panels etc that you can then butt up to, i was thinking of buying one from Machine mart , is this a waste of £46.00.

Many thanks Devon81

There are no decent repair panels for the lower sill on the drivers (fridge) side on a RHD imo. Shcofields and JK do one but it's a LHD version that needs modifying. Best way is to tackle it like Covkid did in the wiki

https://club8090.co.uk/wiki/Ar ... outer_sill

See other articles too

https://club8090.co.uk/wiki/Ma ... .2C_etc.29

Best quality panels are from VW but I doubt they have anything you need anymore so next best is Alan Schofields in Glossop

http://www.ahschofield.co.uk/80-91-brp1.php
http://www.ahschofield.co.uk/80-91-brp2.php
http://www.ahschofield.co.uk/80-91-st.php

They work well, make sure you get the one that punches holes as well, it makes plug welding easier.

Devon81 wrote:Hi,
during the next few months i was planning to replace some panels on my 81 Devon Moonraker, i will be replaceing both back arch's and bottom sill panel by the fridge and both front arches and foot wells, it sounds like the van is falling to pieces , but it has just flown through its MOT with no work required. the panels have rust so i want to replace them, i have been advised by a friend to buy a Edge setter/Joggler tool , i now that they put a small lip on to panels etc that you can then butt up to, i was thinking of buying one from Machine mart , is this a waste of £46.00.

Many thanks Devon81

Some jogglers also punch a hole for welding, but on mine, the hole is 5mm which is too small for me to get a reliable weld. If I were doing it again, I'd get a joggler without the hole punch and just use a 7mm or 8mm drill bit to make the holes. You can sharpen a normal HSS drill in a "butterfly" pattern so it drills clean holes through sheet metal without catching.

How much of the fridge panal are you looking at doing
mike

Hi ive got to do the whole bottom of the panel as well as the complete Rear Arch panel and the Front Arch and Step, the bottom of the B Post has also got a load of filler in it as well, so i am going to try and make up a repair panel for the B Post, all of these panels have had loads of filler in them and then been blown over, any advise is greatly appretiated.

Devon81

start here , viewtopic.php?f=2&t=68856 will give you an idea of the jack point and fridge panal, also if you check out boatbuilder he has got some good pickies of the rear jp opened out.
mike

Thanks for the info Mike, my only other problem is the van's gone from being a leisure veichle, to now being my daily drive, so i'm thinking about starting from the back and then working my way forward, had a repair arch for the front off side turn up this morning from JK, good job i only need the section towards the back by the petrol cap, the form work for the front of the arch is terrable, i will probably get any panels i need for the nearside from schofields, its probably to better to pay a few quid more and not have the hassle.

Ian

yep hear what your saying, pet hate with rep' panals is ,a ;poor definition and ,b; p**s thin metal, will never ever last as long as original guage and quality of steel but ........................
good luck with it and post the picks up
mike

I have an air joddler, with hole punch, but never use the punch, as its to small, bought a proper punch of ebay to punch the holes, biggest is a 9/32 hole if i remember correctly, thats about 7mm it can do the hole further into the panel, up to 2 inches, I open out with a drill if I need it bigger hole, but saves lots of time drilling, well worth the £35

ihave 2 complete side sills cut from a van!

front arch to rear arch- full sills up about 6 inches on the side -- £100 each side.

also have a complete panel van side cut from a rhd van!

just incase you want to stick with genuine panels!

What you got down there Billy, a big band saw?