Welding land rover ali panels with portamig

[trendkill]

Hello people

Thinking of making a 3/4 roof cab for my land rover 90

I have a portamig 215 and use 0.8mm wire & coogar 5 gas.

How do i go about even starting?

Thanks in advance!!

 

[madkayaker]

different wire and gas! you need ali wire and argon gas. you need to weld a lot quicker than with steel and use a stainless wire brush to get it realy clean a few inches at a time.

 

[john224]

Cut to length drill cover with sealer pop rivit will look a lot better cheeper and easier,done a few like this,,,

 

[trendkill]

Thanks for the advice.

Do you have a few pictures of how you did yours John?

Many thanks!

 

[john224]

Ive been looking for some pics but carnt find any,
first step remove rear door,
Remove roof pannel,
Remove both sides
Drill out rivits on rear roof top back end.
Then Drill out rivits on side pannels front ends.
Deside where you want the roof to end and mark and cut.
Put in roof top back pannel seal drill pop rivit. refit roof by hand with props,
Put sides back on to meet up with roof mark sides cut and re drill /seal rivit front edges back on to match up with door seal,
put rear door in place refit top hinge,
Then you have to make up pieces to fit between tub sides and door( THIS bit is fiddley) use 1"X1" box across tub floor and up sides and across seat box/wheel arch for rear door top but up against and for the infill side pieces to fit up against touch up paint over rivits and where needed ,,,,JOB DONE
Might get a bit mixed up but you should get the gist of it,, Hardest part cutting the infill side parts in rear tub,,,

 

[trendkill]

Thinking of removing my rear bulkhead (behind seats) and the tub cappings,
Moving it all back about 16-18" then re-fitting it.

Wanted to try and make ther 3/4 cab look like a truck cab (Rounded quaters, windows etc...) Don't really want it to look like a van top thats been cut down, if you follow?

Ideally a 110 crew cab roof would be spot on but these cost a small fortune and are pretty hard to get hold of.

My main concern is the actually top piece/panel of the roof itself, figured ali welding might in the end leave me with a nicer looking finish.

Anything you could recommend if Im to go down the 'rounded roof' idea?

Thats pretty much what im after on my 90, just abit shorter.

Cheers.

 

[madkayaker]

if you could get a pick up roof you might be able to add a bit in the middle and use the rear section for the end

 

[mrcheese]

I have heard of a company called North Offroad who make a fibre glass panel.
Not used them though.