Club 80-90 Forums

Hi Guys,

So today in the lovely sun I removed the bodykit that had been on since I bought her.


Glad I did as it was hiding some rust:











I thought this might be the case as the rear window frames had a lot of rust and must have been leaking for years.
Most of this seems to be at the base of the arch panel, however an area on the mid panel has rusted through also.
Luckily the sill is perfectly in tact.

So my first question is if anyone (mm ) can advise on whether to get the tall panel or just the arch one. From what I can tell the smaller arch one has the lip to spot to the inner arch but the tall panel would need this adding. My worry is the smaller arch would be harder to align due to the curvature of the whole panel.

I also cannot see how I would weld the right side of the panel as where it would spot weld is behind a pillar inside. So not sure how that is usually done?

The inner sills look OK from what I can see but will know more when cut panel out.



Next is the snorkle box's on both sides, not in great shape but not as bad as I thought:






Will look into how best to tackle that one

Cheers guys

From the photos, I'd guess a tall panel is probably needed

I also cannot see how I would weld the right side of the panel as where it would spot weld is behind a pillar inside. So not sure how that is usually done?

Its possible to remove the remnants of the old panel and using a 1mm blade on the grinder and a thin chisel, separate the spot welds on the pillar. Then you can slip in the new panel lip and spot weld/tack it from inside the van.

For the big hole in the side of the sill, I managed to get away with just cutting out the rusted section and making up a bit from sheet metal to weld into the hole. Depends how bad yours is though.

boatbuilder wrote: Its possible to remove the remnants of the old panel and using a 1mm blade on the grinder and a thin chisel, separate the spot welds on the pillar. Then you can slip in the new panel lip and spot weld/tack it from inside the van.

Thanks BB,

I cannot see how I could spot weld from the inside as the lip seems to be on the right side of the pillar which is inaccessible, and on the other side of the pillar the middle panel is spot welded.

Both panel lips are on the front side of the pillar.
Obviously you have to remove your interior furniture and stuff to get at it.

Yea all furniture is out etc. So I would need to drill out the spot welds of both panels for that lip from inside / thin angle grind from outside. Replace panel and then spot weld again both panels from inside? If so not sure what access will be like to drill out the mid panels spot welds at that angle. If that is the case wouldn't I need a clean drilled hole for the spot? Or will the weld penetrate both if amps high enough?

Sorry still new to all this welding milarky lol

Thats about right, yes. The two panel lips protrude by slightly different amounts, so its easy to make sure that both are welded. When I was doing mine, I did some plug welds and then some more tack welds at the edges of each panel.
Its easy to get in there with a drill and a spot weld cutter.

Get yourself a decent spot weld cutter. I bought one from Just Kampers and it works well.

^^^WHS^^^ I'd go for the tall panel as it gives you less work and no seam to worry about in later years. So long as you carefully drill out the old spot welds to let the new panel in along the upright seams, it will be an easy enough job and be neat too. Just make sure your welds go through nicely, like you say, winding the power up a little more to make quite sure that the welds have penetrated so it wont fall off

Noty a bad idea to wire brush everything straight after you weld things to remove all the old paint whilst things are still very hot and give it a good dose of vactan; the risk of rust returning is much reduced if all is throughly sealed from the elements : Remember to wear a decent face mask when doing such work!