TheSamba.com :: View topic

Tue Jun 05, 2012 8:29 am

Ok I need a quick 'schooling' please!

I have a 59 panel which has been SERIOUSLY bondo'd and has SERIOUS frame rust (basically the entire frame is falling apart, it has huge amounts of bondo on every panel except the upper half of the bus and even panels of sheet metal riveted all over the place.. it's totally not saveable without MAJOR work and cash).

I also have a 60 panel which has a good frame and just your normal rust in the normal places.

What I want to do is remove the upper side sheet metal from the 59 and weld them on the 60.

I have some spot weld removal 'bits' from Harbor Freight and a mig welder. Is there an easier way to do this?

Tue Jun 05, 2012 8:33 am

is the top of the 60 wasted? if not why not just repair the 60?

Tue Jun 05, 2012 8:40 am

I try not to drill through both panels if possible. Sometimes I will use a small angle grinder to remove just the back side of a spot weld, if I can sacrifice the back piece. Sometimes I just use a center punch and a regular drill bit.

Tue Jun 05, 2012 10:54 am

Eastwood & other tool suppliers has a special spot weld hole saw bit....has a live center on it.

Tue Jun 05, 2012 1:54 pm

http://www.ebay.com/itm/Spot-Weld-Cutter-Drill-Bit..._500wt_922
these are the ones i use. with a panel knife in the joint for tension the welds pop easily and have minimal drill through.

Tue Jun 05, 2012 9:50 pm

I found the HF bits too soft - they dulled VERY quickly. Bought a set from the Snap-On truck and they were awesome.

Tue Jun 05, 2012 10:00 pm

Wed Jun 06, 2012 12:20 pm

For sure get cobalt if you can as spot welds are harder than plain steel

Wed Jun 06, 2012 8:05 pm

Thanks guys, I'm going to try an angle grinder since the lower panels are absolutely shot. The only reason I'm swapping out the panels is I got a KILLER deal on the 59 and if you wanted to rebuild it you would literally have to rebuild the entire 'frame' and the floor and most of the other metal, basically just make an entire bus out of green panels and put the plate on it.. and the 60 has windows cut in it and I really want factory side panels!

Wed Jun 06, 2012 9:14 pm

Seems like you could patch it easier (and cleaner). Then swapping the belt line up?

Thu Jun 07, 2012 6:03 am

KevinAlbrecht wrote: Seems like you could patch it easier (and cleaner). Then swapping the belt line up?
I think the end result of swapping the outer shell is going to be cleaner, but yes, probably a lot easier just to patch it. So much less fun though!

Thu Jun 07, 2012 6:55 pm

Lohe wrote: KevinAlbrecht wrote: Seems like you could patch it easier (and cleaner). Then swapping the belt line up?
I think the end result of swapping the outer shell is going to be cleaner, but yes, probably a lot easier just to patch it. So much less fun though!

I would think lining up an upper sectioned half is fraught with complications a "non-professional" would not have the experience to be able to recover from completely, and and then you would be left with a hack job that you would need help fixing.

Vs.. Patching some windows that could be worked on after the fact, as time facilities and budget permits.

Now, I you may have mad skills, so more power to you.. but I would hate for you. I get yourself in a situation that no one wants to be in.

Thu Jun 07, 2012 6:56 pm

Lohe wrote: KevinAlbrecht wrote: Seems like you could patch it easier (and cleaner). Then swapping the belt line up?
I think the end result of swapping the outer shell is going to be cleaner, but yes, probably a lot easier just to patch it. So much less fun though!

I would think lining up an upper sectioned half is fraught with complications a "non-professional" would not have the experience to be able to recover from completely, and and then you would be left with a hack job that you would need help fixing.

Vs.. Patching some windows that could be worked on after the fact, as time facilities and budget permits.

Now, I you may have mad skills, so more power to you.. but I would hate for you. I get yourself in a situation that no one wants to be in.