HZ panelvan resto

[DuncanM]

Hi guys

Lots of progress on the van, with lots of pics to follow over the next few days. Ok, so firstly, I was looking at how to fill the rear windows. I decided to make up some metal sheets that were the same size as the window holes, with a lip formed by a bead roller. The thinking was I could use panelbond (you know the really strong metal glue that lots of manufacturers use to glue some body parts like roofs onto modern cars). That way I could avoid the amount of heat distortion I knew I'd get over such a large open area of 1mm steel if I welded them in. A mate of mine did it with a Valiant van about 10 years ago and the results were excellent...

So I made the sheets up, got the bead roller out and put a 1mm lip into the panels. The front windows on the side:

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and the rear. I made them all up from the window hole individually as I couldn't swear each respective hole (front side or rear side) would be identical:

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As there is a slight curve on the holden van sides I massaged the panel until the curve was spot on. This didn't need an English wheel (thank god as I don't have one!) and it was pretty spot on.

However... this is where the problems started. The person who pulled the side windows out prior to me getting the car must have been pretty rough, as the metal, particularly on one side, was distorted and bent out beyond all proportion. These are the areas I've noted in the red:

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You can see the difference in the LH side ones.

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So.... My wonderful plan was stuffed and I realised I needed to cut the whole side out and replace and weld the side in if I wanted it to work properly. At that point I admitted it was beyond my confidence to do it without stuffing it up, as I don't have a TIG among other things. So I decided to leave this one to the professionals... Sometimes you have to know your own limitations. Booked it in to a guy (Darren) in Smithfield and he cut out and welded in the panels. So he cut out the entire side panel as I expected.

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Welded in bracing panels

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Then tacked and welded in the side panels, taking a lot of time and spacing of welds.

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Then ground back, filled and in primer.

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A bit annoyed I didn't do it myself, but for the time, cost and hassle (since I'd need to get steel that size as well get it curved correctly for the car) I decided this time I'd outsouce. Very happy with his work too....

[maxsandman]

Great work & excellent info
Don't blame you at all for outsourcing the side panels, seen a few vans that should've got a professional

[Innuendo]

Nice one, good move all around.

[DuncanM]

Thanks guys. Yeah I'd still love to have tried the panel bond to see if it worked. It looked good on some sides:

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But you can see on the drivers side (even from this angle and distance), that it just wasn't going to fit (the panel is already shaped to the shape it was MEANT to be, I should add..

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You can clearly see the gap at the rear of the front window sheet and the body...

[DuncanM]

Anyway, onto other things... So once I got the car back I stripped the rear quarters - the worst part of the car... Some previous repairs that will need a bit of work, and one lower quarter that needs replacing - not due to rust but about 6 inches of bog hiding some notable panel damage. Luckily the lower rear quarter replacement sections cover all the area of the damage so I've decided I'll just cut it out and weld a new section in. However, firstly, let's strip it back to bare metal and get it in etch primer...

So, lower rear quarters stripped. As usual I started with paint stripper and then moved on to the strip discs and wire wheel

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I do like it once it is stripped to bare metal... something very "clean" about it...

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Then it was just preparing the panel sides again and getting it in primer both sides:

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So, first stage completed. Now onto the welding, bodywork and hi fill. As well as looking at getting together bits for the interior...

[Robbo]

Good work.

[Blue victor]

Amazing work so far mate

As I look at the incredible level of effort I keep thinking of what you said in your initial post "My background is in Chryslers - restored about 9 Chargers and decided I wanted to travel around Australia with my pup and so wanted a van"

So when finished, you and a dishlicker (someone who doesn't wipe his feet or his arse) are going stonechip collecting in between dodging wildlife.........wow!

Enjoying both the pace and detail of your updates. Thanks for sharing

[DuncanM]

Ha!! Yeah... she won't wipe her feet, she'll drool over the upholstery, she will get food everywhere, wipe her arse on the seats and shed all the time and cover everything in her hair...

Wouldn't change it

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[hdt134]

Great thread well done

[DuncanM]

Hi guys

Sorry for the delay (almost a year since my last post!! However, absence doesn't mean no movement. So LOTS has been done and Ill be putting up a series of updates to bring me up to date over the next few days. Firstly, I decided on the interior colour to be black - couldn't think of another logical choice given I was spraying the car in papaya. Worried about the back looking a bit like a coal mine but think I'll be able to get around that.

So got the full length headlining kit and bows from Jason (this was a couple of years ago now) and purchased the black headlining in sandpaper.

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Also decided on getting the seats with houndstooth inserts as I felt it may break up the blackness of the cabin a bit.

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Also got reproduction door trims made up by Elias. Perfect match to the seats.

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