TheSamba.com :: View topic - Bus new green body panels gap

Wed Sep 30, 2020 11:18 pm

Hello everyone, I'm in the process of restoring a 71 bay with new sheet metal. I did my best to align the rockers and quarter panel piece but it seems like I have a slightly wider gap in the lower half between the panels.

I tried closing the gap by moving the quarter panel piece closer to the rocker piece, but I would lose the adjustment on the opposite side. I also had a slight adjustment problem with the rocker / side piece. It seemed like the panel was a tad shorter than the original. Not taking away from these panels, the quality and thickness of the metal is great.

My question is, would a good seam sealer take care of the wider gap on the rear quarter/ side panel?
Thanks for the advice!

Thu Oct 01, 2020 4:19 pm

No answers, thought this belonged to the paint and body section. I will move it to the bay window general section.

Fri Oct 02, 2020 7:16 am

As there is such a long weld when installing that panel it's inevitable that it will shrink a bit. My preferred way of installing a long-side is to line up one side to where there is no gap, start your tacking process down the line and you end up with a small gap at the other side.

Once the panel is tacked, use a dull chisel and a hammer on the back-side to dress the metal over the B-pillar. In this photo you can see where I stretched the metal the last couple of millimeters. I left the gap at the bottom for the photo so that you can see the difference.

Good luck!

Fri Oct 02, 2020 6:17 pm

Bulli thank you for taking time to take these pictures for me. The trick with the chisel will definitely help me close the gap between panels! Thank you again.

Fri Oct 02, 2020 6:43 pm

I'd much prefer dealing with a slightly short gap than one that's a little too big to fit in the space provided 8)

Sat Oct 03, 2020 7:33 am

dentfreeimage wrote: Bulli thank you for taking time to take these pictures for me. The trick with the chisel will definitely help me close the gap between panels! Thank you again.

Always glad to help. Also wanted to clarify that I use a dull masonry chisel, though a standard metal chisel will work as well.

Sat Oct 03, 2020 9:14 am

So considering the propensity our vans have for seam rust, why not bed the vertical seam with panel adhesive upon installing it. That way it would be full and no way for water getting in. Any reason not to do this?

Sun Oct 04, 2020 7:31 am

alaskadan wrote: So considering the propensity our vans have for seam rust, why not bed the vertical seam with panel adhesive upon installing it. That way it would be full and no way for water getting in. Any reason not to do this?

If you're asking me, the reason I weld is because I can, that's the way it was originally made and from what I understand, panel adhesive is non-structural. I also don't know if it prevents rust in any way. It would also lead to a big mess with a the the PA catching fire and burning away as you finished the welds on the long seam.

I use a weldable primer on the ends, wipe off as much as I can with lacquer thinner once welded, then brush the seams with a thinned epoxy prime, inside and out. Wipe in a little bit of quality seam sealer then done.

Sun Oct 04, 2020 7:39 am

alaskadan wrote: So considering the propensity our vans have for seam rust, why not bed the vertical seam with panel adhesive upon installing it. That way it would be full and no way for water getting in. Any reason not to do this?

This may be a good idea? Instead of pounding the edges in, fill the gaps with panel bound and no need for seam sealer, does it make sense? Would this be a better water resistant seal, specially for a larger gap then factory with the replacement panel?

Sun Oct 04, 2020 8:00 am

I had a gap between my b pillar and new front wheel arch and it drove me crazy. I got the same advice from Bulli clinic.

I made this tool out of a steel rod. I angled it a little and smoothed the edges so it wouldn’t leave marks.

I had to cut out a piece of the triangular box section to gain access. I gently walked my hammer and chisel up and down the flange to move it towards the b pillar without distorting the metal.

Not perfect, but a lot better. I wouldn’t put panel bond in there. It wasn’t hard to do. Go gently and check your progress. Epoxy prime, seam seal, another layer of epoxy prime over the sealer. I ended up using the same tool to dress the gap in the side panel too.

Sun Oct 04, 2020 12:31 pm

You can’t argue with success. Nice work.