Filling side windows

[Blocker]

I have a donor van that I am cutting to use the side panels for my windowed HJ.

Would these be about the correct place to cut on the windowless to make use of the panels?
Marked in Red.

[mook]

Thats going to be an epic amount of work, but if you are keen i would cut wider and then unpick the seams where its all joined together. i think that if you are unsure talk to someone who is going to be doing the bodywork for you as they may be fixing any stuffups.. get as much info as you can before you cut.

[Absinth]

First tack weld a brace at the back (marked in red) to keep the roof in position. Cut your Sandman panels out where you have marked and then use a spot weld cutter to remove the remaining panel from your car.

Cut the HZ where I have marked and use a spot weld cutter to seperat the cut sections from the side panels... if you use the spot weld cutter on the cut panels you won't have 6mm holes through your side panels.

Use the cut sections to repair the rust along the top of your rear quarter panels and then fit the cleaned up side panel into position.

Hard to explain on here so if you don't understand what I'm saying let me know.

[Absinth]

rough sketch of how the panels go together.





Actually, just thinking about you van and the sunroof you may be better off replacing the entire roof and side panels as one. Cut your Sandman along the yellow lines and the HZ along the pink lines and fit the entire HZ roof and side panels to your Sandman... You will need to transplant the hoodlining strips to the HZ roof section. Probably be easier and more accurate doing it this way and you will get a better finish rather than trying to weld an infill into the roof to fill the hole.

Pretty much like what T Dog did to his in the pics on Fastlane.

[ZSANDY]

I think Absinth's second suggestion would be the way to go since you have a sun roof . It may seem like a bigger job but I think it would actually be less work and turn out a better job . A picture reference "who to" would be great addition to site as gutter rust and windows are the biggest problems with Sandman Van's Maybe t dog could post his pic's off Fastlane ?

[Blocker]

You guys don't think HZSandman's option is as good?





The end results look very good, for the windows.

[ZSANDY]

You guys don't think HZSandman's option is as good?





The end results look very good, for the windows.

This kind of job really needs to be done by someone specialized in this field even your run off the mill panel beater would struggle not to warp such a large panel while welding .

[Absinth]

Just filling in the window holes as Ian has done is a good option as long as you have an experienced welder to do the job as the large panel will warp easily.... However in your case Blocker you have severe rust along the bottom seam and the top of the rear quarters will be rusted through.... this will need to be repaired and will be much easier and a better job done if the side panels are removed.

I am in the same boat, the right side rear window was leaking and it has rusted the back section of the side panel bottom lip and the top of the quarter so to do the job properly I have to replace the entire side panel.... as I'm doing one I may as well do both the same way.

I just need to find a set of side panels.....

[colben]

You guys don't think HZSandman's option is as good?





The end results look very good, for the windows.

hey blocker
looking forward to finding the best solution to fill in the side windows
as i have the same problem on my HX sandman. welding in plates
looks like a good option as shown in pictures. Are there any welders
confident to do this type of job in S.A.

[abncraig]

once the panel warps are they stuffed for life? or can they be mended? I have a small window at the front side of my van that I want filled in but not if the risk is too high