Deleting middle window

Thin bits of metal and bright blue light. Including glass & trim.

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Deleting middle window

Postby mshaw1980 » 06 Feb 2018, 22:07

Hello all

So I am up to this stage with my restoration...

ImageGetting there...:-) by Mark Shaw, on Flickr

Me and my good lady wife have thought it would be a good idea to 'delete' the window above the new centre panel so we can have some storage space inside the van. The seams are rusty anyway so makes sense.

Has anyone got any advice on doing this or does anyone make the panel as my only metal working tools are a small vice, hammers and a small swaging tool (metal mickey / plasticman??)

My plan was to cut along the top swage line above the window (cant see it in this picture) and drill out the spot welds on the left and right. I would then spot the top of the new steel under the top swage line. For the bottom of the window panel I would put a step in the steel and then weld it to the new centre panel, spot the sides and then filler / seam sealer the joins. :ok

I would really prefer a ready made panel as i dont have a sheet metal folder but if anyone can assist I am all ears :-)

Thanks people
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Re: Deleting middle window

Postby tforturton » 07 Feb 2018, 11:43

CampervanCulture do an aluminium 'blank' which replaces the glass, but I think they only do the rear side windows.
Might be worth getting in touch.
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Re: Deleting middle window

Postby Oldiebut goodie » 07 Feb 2018, 12:50

A fixed curtain across the window would be a lot easier and cheaper. :D
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Re: Deleting middle window

Postby mshaw1980 » 07 Feb 2018, 13:05

Thanks Tforturton. Have seen that but want it to look like an original panel.

Thanks Oldie but like I said, I want to blank the window so I can use the 'wall' to add storage as we don't currently have any :-)
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Re: Deleting middle window

Postby Oldiebut goodie » 07 Feb 2018, 13:56

My "wardrobe" in the back is over a window with a curtain permanently covering it. You aren't going to be fixing anything to the window/replacement panel.
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Re: Deleting middle window

Postby mshaw1980 » 07 Feb 2018, 15:55

I will be adding storage if I weld in some additional steel support bars.

Thanks
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Re: Deleting middle window

Postby diabolov » 07 Feb 2018, 16:47

Is cutting a window blank from sheet material and cleaning up the seams not an option??

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Re: Deleting middle window

Postby mshaw1980 » 07 Feb 2018, 22:19

Yes seems like the route I will be taking. Just being lazy. I don't like fabricating repair pieces although I am getting better at it.
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Re: Deleting middle window

Postby Aidan » 08 Feb 2018, 15:32

shame the genuine panel van panel is no longer available that would have been the best way to do what your glw wanted and easiest to fit, because of the curve and size it is quite a difficult repair to do well I believe
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Re: Deleting middle window

Postby bigbadbob76 » 09 Feb 2018, 10:36

I made my own replacement panel for that window in 2mm steel sheet.
You could probably do the same but not cut out the hole.
I didn't cut right back to the seams so when I welded the panel in it followed the curve quite nicely.

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Re: Deleting middle window

Postby danmetallic » 09 Feb 2018, 15:24

We supply window blanks if you are interested. http://campervanculture.com/product-cat ... ain-westy/

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Re: Deleting middle window

Postby mshaw1980 » 12 Feb 2018, 21:48

Cheers guys. Would like to look more factory but the window blanks are good. My seams are rusty so I need to remove the window surrounds to clean them up.

Bob. How did you make the swage in the window panel? 2mm steel. Wow, that's partly structural, must have been a nightmare to shape that. Any more pics? :-)
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Re: Deleting middle window

Postby multisi » 13 Feb 2018, 09:08

The metal isn't 2mm for the original panel. If you are going back to the seams, make a panel with the returns each side and make small V cuts in them so it will bend to fit the curve .
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Re: Deleting middle window

Postby mshaw1980 » 13 Feb 2018, 13:22

Hi multsi

Oh I know the panel isn't 2mm steel. Just meant that it would have been tricky to shape.

May have found a solution. A metal fabricator over here has told me to bring the panel to them as they may be able to make it :-)
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Re: Deleting middle window

Postby bigbadbob76 » 15 Feb 2018, 10:40

mshaw1980 wrote:Bob. How did you make the swage in the window panel? 2mm steel. Wow, that's partly structural, must have been a nightmare to shape that. Any more pics? :-)


I clamped it in 2 vices between a couple of strips of 5mm steel and beat it with a hammer. :lol: yeah, it was a bugger to do but will last my lifetime. :D
I did the rear side window on Tuesday using 1.6mm steel, that was much easier and I was able to swage it with a joggler.
I cut along the bottom of the top swage just above the window seal and seam welded it in.
If you want to blank the rear side window I still have the piece I cut out that you could butt weld in. unfortunately the piece we cut out for the window you want to blank is not usable, we cut the corners with a big hole saw for that one.
For the 1.6mm steel we used a small disc in an air grinder and followed the corner curve with that.
I'm away from tonight until sunday but will see if I can get you more pics when I get back.
There's a couple here- http://forum.club8090.co.uk/viewtopic.php?f=50&t=159419
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