Best method to replace side windows (van) with sheet metal?

[lukeyt123]

Hi,

Looking to replace the side windows in my Mk5 Transit with sheet metal. Was looking for any advice on the best way to go about doing this?

Was thinking the easiest way to do it would be to overlap the sheet metal from the inside of the van over the window opening and then spot weld it. This way I can apply filler from outside to smooth out the joins and not have to worry so much about any difficulty / distortion that might come from butt welding.

I'm struggling to think of the best way to clamp the sheet in place though as there will be no edges to clamp it on to?

Any advice apprecated, Ta

 

[normspanners]

Some of the panel bonding 'glues' are fantastic you will get all kinds of distortion welding them also cracking problems, just glue them in,most the bonds are paintable so take your time to finish the edges and its ready to paint.
it is after all how the windscreens are held in.

 

[cumbriasteve]

I would use a tool similar to this, you cut the sheet to shape but oversize by about 5 to 10 mm depending on the tool used, put a flange all round then fit from the inside using panel adhesive.

The sheet would then at least be flush with the surrounding panel with a decent chance of filling the joint to good standard, in fairness though it would be a serious challenge to get an 'invisible' patch.

http://www.ebay.co.uk/itm/5mm-Hole-...706076?hash=item281444349c:g:cYgAAOSwpIdW7H3W

 

[MoreWellie]

above comments sound like voice of experience and sounds like a good way to get a reasonable finish

only other idea I can think of would be small bolt/rivet holes that could be filled with weld after?

 

[normspanners]

I would use a tool similar to this, you cut the sheet to shape but oversize by about 5 to 10 mm depending on the tool used, put a flange all round then fit from the inside using panel adhesive.

The sheet would then at least be flush with the surrounding panel with a decent chance of filling the joint to good standard, in fairness though it would be a serious challenge to get an 'invisible' patch.

exactly^^^ , the best would also when the panel was fitted, would be to have someone out side with duct tape to tape the joint from the outside to hold the panel in place whilst the glue cures

 

[cumbriasteve]

I did one and it was a custom van so had to be perfection I would have to think twice before doing another to the same standard, it took ages to get it 100% right.

I taped long lengths of timber along the outside panels so when the new panel was offered up from the inside it touched the timber and stopped exactly in line with the existing panels.

So once the adhesive has gone off and timbers removed you have a small groove to fill in, it's best to use a dremmel type buff and roughen (just a little) deep into the groove, this really does help the filler to bond in well.

 

[Parm]

Some of the panel bonding 'glues' are fantastic you will get all kinds of distortion welding them also cracking problems, just glue them in,most the bonds are paintable so take your time to finish the edges and its ready to paint.
it is after all how the windscreens are held in.

More than that, my car panels are mostly held together with glue

 

[Fazerruss]

I would do it as if you were doing the opposite ie fitting windows to a panel van. Get some widow seal rubber like was used on car windscreens years ago but use sheet metal rather than glass. The metal could be painted first so once fitted then job done. No welding, gluing or mess.