TheSamba.com :: View topic

Wed Jun 22, 2016 2:40 pm

I know there are a lot of experienced VW restoration experts out there!

So, what are the best techniques in welding the new VW Bus metal replacement panels in?

Should the panels butt right up next to each other or should there be some overlap of the metals in your opinion/ experience?

Wed Jun 22, 2016 3:15 pm

Here are some bumpers for my 58 Bus I had to weld on and rework some...

Before and after photos

Wed Jun 22, 2016 3:25 pm

You should wander thru the paint and body forum.

Plus do some searches about metal replacement in the split bus forum.

Like this, a search for "welding in metal" results in these:

http://www.thesamba.com/vw/forum/search.php?search..._chars=200

Wed Jun 22, 2016 3:27 pm

Visitors of this forum can answer your questions... but panel welding isn't really a "Split Bus" issue... may be more appropriate for the "Body/Paint" forum.

If you poke around some build threads... or in the Body/Paint forum... you'll see some good examples of actual work & threads addressing this topic.

Samba Ironworkers Thread!

Specific bus topics (i.e. nose replacement, cargo rocker replacement) seen under -- Metalwork/Paint/Body -- section of the "Split Bus FAQ and How Tos - *Read before posting*" thread.

Wed Jun 22, 2016 4:15 pm

I would suggest that you review the restoration projects that were posted in this form so that you can judge for yourself.

I have seen very experienced welders do butt weld on panels without leaving a trace of where the two sheet metals were joined. This is achieved, of course, after grinding out the welds.

Some welders prefer to use a flange tool to achieve strength.

Will you be doing the work yourself? If you are, take your time and always check for alignment.

If you are not comfortable yet, hire an experience person to do some of the work while you watch over his/her shoulder. After getting some pointers, try doing the work yourself. Don't be afraid make mistakes. It is not rocket science. Good luck.

Wed Jun 22, 2016 4:25 pm

Ateneo,

I will be doing most of the welding myself, I worked at a body shop as a kid (18 yrs old), and have done some minimal welding over the years. I welded a front clip on my 61 VW Crew Cab back about 20 years ago. That was challenging, but a really good experience.

I did see some flanging tool type welding techniques on a video as you speak of, that is an interesting technique.

I guess the butt welding is a better technique as long as I leave a small space between the two pieces of metal for a strong enough weld to set and just spot weld in different areas (paying close attention to temperature- overheating).

I have talked to a few body shops lately and they seem to be changing out plastic parts and calling it body work.... LOL! :lol:

Fri Jun 24, 2016 4:19 pm

I just got done with a lot of the panel/rockers/dog legs and nose skin that you're likely to end up doing. Look up the youtube work done by Glideking, I got a lot out of his vids.

Get the right tools to do the job, a Decent MIG welder. I used a Hobart 140 with .025 wire. Clecos and clamps to hold everything in place beyond what you'll think you'll need. A good angle grinder with the right discs for cutting grinding and flap wheel. And when you're finishing things off I recommend a shrinking wheel for those pesky high spots.

All you need after that is time, compassionate neighbors and the right PPE.

Best of luck!

Sat Jun 25, 2016 12:10 am

This fella " a joddler" greatest a step in the new metal. And you can punch holes with this tool also. Then you could lay the new stepped sheet metal up under the old (after cutting out the crust obviously) and then "puddle weld" the holes on the old metal that reveal the new metal underneath. Then slowly grind back and cool each puddle weld as you after you've finished. Be careful not to heat up panel too much. You'll warp everything.
Then a tiny skim of filler/bondo along the 'join' line and sand back.

Or

Get a load of these butt welding clamps:

And butt the panels and slowly weld the pieces together cooling as you go. Then grinding and cooling.

Sat Jun 25, 2016 12:17 am

http://www.thesamba.com/vw/forum/viewtopic.php?t=476026

Have a look at this thread.

Sat Jun 25, 2016 5:06 am

Thanks SplitBusVanatic,

That really is a good read and very informative for what I am about to tackle!

Nice 66 Westy Bus!