Panel replacement work underway !

[fmr]

Well guys for those who have read my previous posts I have still not located a good pinto engine to replace the tired one in my newly purchased first transit but I am watching a couple on Ebay

Whilst waiting I have decided to press on with the rot problems My first action has been to purchase two new rear quarter panels from Beevers, which arrived today Now I am planning the task ahead. I offered the panels up this evening and realised I will have to cut out the existing panels. Now what is the best way to separate the seams ? I assume the panel is fixed with spot welds, is it better to drill out these spot welds or simply go mental with the grinder

When affixing the new panels, are they better spot welded into place or continuously welded along all seams ? I do have the use of the neighbours Mig welder And I do own my own Arc welder I also have some college training in welding albeit a long time ago, and not on motors

Your kind advice please gentlemen.
Regards
Phil

[AndyG]

http://fordtransit.org/forum/viewtopic.php?t=7397

[Guy88]

I wouldnt use the whole panel

just use what you need to

Dont touch it withthe arc. you will most likely end up witha hole

Practice with the mig on some scrap

[fmr]

Must get the hang of that search function

The thread offered would have been more useful IF I was replacing the front wing But did contain some useful information Re: drilling spot welds out

Thank you.

Has anyone replaced the rear quarter panels on a MK4, as I am sure the replacement of these panels throw up different challenges ?

May have to buy some batteries for the camera

Phil

[fmr]

Thanks guy88, Ok I will use the neighbours Mig on the body panel work

But be warned, the Arc is coming out on the chassis plating

Phil

[Guy88]

But be warned, the Arc is coming out on the chassis plating

Phil

MIG it all

[fmr]

Got to say this:

I only did Arc at college

But it's not true !!

I did oxy/acetylene, arc, mig and tig But as I said it was a long, long time ago

Surely it's like riding a bike

Phil

[djswampy]

Hey, what is the worst that can happen? Fella in the next village welding his car in the garden managed to set light not just to his mums house but the whole row of houses in that side of the cul-de-sac. Keep an extinguisher handy when refreshing your skills.

[fmr]

Hey, what is the worst that can happen? Fella in the next village welding his car in the garden managed to set light not just to his mums house but the whole row of houses in that side of the cul-de-sac. Keep an extinguisher handy when refreshing your skills.

.............been thinking about this one, and I think the worst possible thing that could happen is I put the panels in completely the wrong place and I can't see out the windscreen

[dangeeeeerousss]

hi
im getting good at replacing bits now if your replacing a panel with an complete replacenent panel and not a repair part panel.then replace the whole panel.
but if its a repair panel like you get for the rear arches then like guy says only use what you need of it and stitch it in.
i would i mean i did drill the spot welds out i wouldnt use the grinder on it.
all the replacement parts ive had to do i pilot holed all the spot welds first then with a drill bit just bigger than the spot weld drill it out only going throught the first layer of steel you should see and hear it pop this way it makes it a damn site easier to weld back up and your not just filling holes.ive done most of my welding in the past with an arc as thats all i had but i would even attempt the chassis with an arc at the end of the day its upto you but i know if i had done what i have on the chassis it would of been a lot more pain staking and probably would still be there now filling in holes that id burned with the arc
if its a part repair panel cut out what you need and i use a 1mm thick cutting discs on the angle grinder for this sort of thing

hope this helped good luck and i dont envy you welding the chassis with the arc

[fmr]

Thanks dangeeeeerousss,
The panels I have I believe are rear quarter repair panels, one or each side which take in the complete rear arch. They fit (on the N/S) between the rear corner panel and the sliding door then into the recess almost halfway up the side of the van.
I plan to use a metal cutting disc and cut 1 inch inside the patten of the replacement panel. I will then cut the flanges off the replacement panel, drill holes all around the edges of the replacement panel and spot weld it in place with the Mig welder. I hope all this makes sense

I think the biggest headache I face is then the repair on the inner arches But will cross that bridge when I come to it

The front arches are not too bad and it is my intention to repair these with a little filler If it comes back through I will have to plan a more thorough job in the future

Looking forward to the challenge which lies ahead

Any more tips please.

Phil

[TheDrunk]

Please please please, post pics, and updates on how this work goes. I may well have to do the very same thing in the future.

[John Grove]

A Joddler (joggler?) is very handy for panels which show: It's much easier to lap weld than to butt weld, especially for overhead / vertical welding. If it's visible the welds can be dressed down with an angle grinder (Wilkinsons do a lovely little flap wheel for just this type of linishing) Just a little filler finishes ths job nicely. I did the rear wheel arches on my mk 3 like that and the repair was hardly noticeable. Smoothrite works well on hidden panels as it seems to repel the rust better than some rust treatments, but don't use it as primer because it will most likely react with the top coat paint. John G

[fmr]

Surely you all don't want to see pictures of a grown man crying in his driveway covered with cuts and burns

Ok. I'll get some batteries for the camera


Phil

[gemini]

They fit (on the N/S) between the rear corner panel and the sliding door then into the recess almost halfway up the side of the van.

dont go halfway up the van, cut out level above the rot and cut the panel to suit