lose the window grooves with this advice from busy

[Lyndon]

The way to do the sides is somethign like this:
cut the grooves out using a cut of wheel (not a 4inch grinder cut off disc)
now you are left with a big hole, using a tool known as a tama-tong put a recess around the whole edge of the hole - this reduces warping and gives it strength when you weld in the panels.
measure and cut a bit of panel steel to fit in the recess area - over lap into the recess
using a mig welder, tack weld every few inchs to hold the panel (a helping hand is really needed here)
now the boring part, go round and round and round the panel placing a spot weld every 4-6 inches, do two goes around them wait for the panel to cool down (air gun can help speed this up), then around again and again letting it cool until the whole thing is welded.
You may need to hammer weld (panel hammer and dolly) as you go but is easier said than done as you need someone to help hold the dolly.
the recess has strengthened the panel and taken the weld so less grinding is required. using a large 7-9ich disc sander skim over the welds, you can use a angle grinder but do it quickly or the panel will heat and warp.
thats basically it.
if the panel does warp you'll need an extra person to help you shrink the panel with a gas set (oxy-acy) and hammer and dolly, with a wet rag.
one thing I forgot, dont cut out a square, angle the corners, stops the heat collecting in them.
http://www.munchtech.com/bedford/
Thanks Busy mate. Lyndon & the team

[ben]

yeh im gnna be doing that soon eh..

[BusyKiwi]

Also an inner brace (which I forgot to mention)

The braces can bend when they are taken off as they are stuck well with good glue, so be sure to re bend them before you put them back on, ideally bent outwards slightly to take the strain of the side panel.
Get the window panels all finished before adding the braces, then run some urethane under the brace and only weld the ends, if the bend is not enough to hold the panel you may need a support until the urethane dries

[ben]

hey busy.. did you get your panels dead flat?? or can you slightly see stuff in the light?

cheers
ben

[strez]

hey Busy any more progress on the chopped van

[arron]

busy that choped van is awsome mate

[BusyKiwi]

hey busy.. did you get your panels dead flat?? or can you slightly see stuff in the light?

cheers
ben

Yes I was lucky as I had the roof off at the time so was able to hammer and file it all myself, just needs a tiny bit of filler in the remaining of the recess.

It will either go nicely or really badly, if it goes bad (warps) it needs to be shrunk as the panel will flex when the van is mobile

It's not easy getting the panels dead flat, even when they are they need a paint scheme/mural or something to help break up the large flat panel, mines chopped so am a bit lucky as the panel is shorter. I only did two windows on mine (back two) as the side door, rear door and big panel behind drivers door were new panels I made up.

The grooves are in the sides for added strength.

Thanks guys for the kind words, sorry no more progress just yet, have been working no standard van, body all done ready for paint and then the engine side of it. I do have to get my A into G though as the engineer I am using is going to move on.

[Sundownernz]

Thats the way to do it. I took the window receses out of mine like that. The panels I put in had been through an english wheel to give them a bit of form and strength. I didn't fully weld my panels though. I spot welded them in place with the mig with about an inch between spots. Plenty strong enough and no cracking. The inner braces are a must to stop the panels flexing.

The biggest thing is to take your time and not rush the welding. Keep the heat your putting into the panel to a minimum. The side of the van is a big flattish area and you dont want it to start warping otherwise you'll be there for days trying to get it straight again.

Garry.

[ben]

its not possible to use the existing recess to weld over after the new panel is packed out to flush is it?

ben

[Warren]

its not possible to use the existing recess to weld over after the new panel is packed out to flush is it?

ben

Ummm what does that mean in English 

Warren