Bodywork alteration questions

[astro_al]

Hi guys - a little car bodywork advice needed please.

I'm converting a crappy suzuki vitara into a pickup. I have cut the back off (easy bit), now I need to weld the rear doors shut and fabricate the back of the cab.

What would be the best / usual way to 'fill' the big gap between the body panels and the door panel? Do people seam weld the whole thing or just do it in places and use filler or what?

Can anyone recommend a decent filler that's easy to use for the uninitiated and won't drop out after 6 months of potholed roads? (Oh, and it needs to come in a skip-sized tub...)

Secondly, the new cab rear panel will butt against the rear doors. What is the best way to fit a panel to that? The inside panel of the doors is a right hotchpotch of holes and curves. How to approach welding the rear panel into that???

Thats about it for now. Thanks for any help, Al.

 

[Shox Dr]

I wouldn't bother filling in the door shut, Weld a bar across the inside if you must

 

[pedrobedro]

I'd put some tacks on the inside where the gap is closer and Tiger Seal the outside or use body filler. You'll be riveting or screwing some sheet in the back to line it so it will be covered anyway. Does the Vitara have a separate chassis or is it monocoque ? You'll need some reinforcement in it if it's monocoque.

 

[astro_al]

No, its separate - its very much a mini land rover, having had a crawl around it.

Ok, so just weld where possible and wodge in the filler.

What's the difference between tiger seal and filler ??? (sorry - prob dumb Q)

What about welding in the new rear wall, which falls half-way along that rear door and need to be welded / butt against it? I guess I could weld a straight vertical bar to the inside of the door, then weld the panel onto that, and fill any gaps between bar and door?

Ta, Al.

 

[stuvy]

the problem is the body will flex a little when off road so if you fill it in im guessing itl fall out from the shell flexing

 

[astro_al]

Its not going to be seriously offroaded - just bad roads / rough (farm) tracks. Is there anything flexible I can squirt in?

Al.

 

[pedrobedro]

Its not going to be seriously offroaded - just bad roads / rough (farm) tracks. Is there anything flexible I can squirt in?

Al.

Sikaflex/Tiger Seal PU mastic adhesive will fill it and probably add more strength than the weld

 

[astro_al]

Is that directly paintable? Where is a good source? Many thanks, Al.

 

[1.8T]

pu sealer is yes, local motor factors or automotive paint suppliers should stock it

 

[stuvy]

Its not going to be seriously offroaded - just bad roads / rough (farm) tracks. Is there anything flexible I can squirt in?

Al.

if youv ever been in a convertible, in particular an older car you can see the doors moving around even at slow speeds on the road. If you really want to creat a flush finish id cut an inch out of the door gap and weld some poss 18swg sheet in the use a body filler like upol etc

two things, are you sticking a roll hoop on the back of the cab?

and i know this will probably cause a debate but seeing as youv not altered the chassis or the engine box, im guessing this is perferctly legal providing you get it inspected by vosa and recieve a new log book?

 

[astro_al]

Ok, ta.

No debate necessary. I'm only altering the body on a non-monocoque chassised vehicle, therefore no inspection necessary. No new log book. Just inform the DVLA of new body type/number of seats and make sure it is insured as the correct modified vehicle.

Al.

 

[stuvy]

i thought it would be as i was only reading about ncf sahara and outback http://www.ncfblitz.co.uk/page6.html i like the idea but not the styling of these. Im sure Baloo on here has a blitz?

 

[the snooper]

for the door gaps i would just cut some strips the correct width of the gaps and weld it in slightly below the surface and skim over it

 

[astro_al]

Is there a minimum thickness of filler which will stay in place, or is anything ok?

Ta, Al.

 

[the snooper]

i would use some fibre glass first its stronger then normal bodyfiller.

and if you weld the stips often enough to limit movement it should be ok with any thickness

 

[cresad67]

Hi

We did a pick-up convertion with a toyota crown estate several years ago ( It's a 1972 car with seperate chasis ) but went with keeping the rear doors only making them narrower , so we'd got somewhere for storage

I did hear about the dvla tightening the rules as regard to conversions like this , might pay you to check first ? we've had this on the road now for almost 10 years.

Adam

 

[Windy Miller]

Hmmm interesting conversion there Adam - how do you open the rear doors? I can't see any handles!

 

[stuvy]

Hmmm interesting conversion there Adam - how do you open the rear doors? I can't see any handles!

im guessing there is a pin close to the b pillar?

I do like the super cabs so much more practical than single or double cabs.

no need to contact DVLA only for change of seats and body style

 

[stuvy]

anymore updates on this astro-al?

Im very tempted with another 4x4 to do something similar

 

[Baloo]

now l would make the opposite assumption as you havent made ( major ) modifications to the chassis then vosa wont want to see it ? and its drive on as before ??