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Bodywork- gauge of sheet metal?
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MarkWard
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PostPosted: Fri Aug 21, 2020 7:39 am    Post subject: Re: Bodywork- gauge size? Reply with quote

Bulli Klinik wrote:
Personally, I don't care for the style of repair panel you are attempting to fit. The rear fender panel is available with the correct flanges from Bus Depot. Be prepared to rebuild the flange area as well as the area above it.

I truly believe that those repair panels without the flanges are meant to rivet over rusty bodies on Vanagons in third world countries, not for a proper restoration.

If you look closely through this photo album: https://photos.app.goo.gl/eLZ4bvP2MSh8KN1u7
Most of your questions will be answered.

Good luck!


You are quite the "Craftsman". Very impressive.
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CelestysWesty
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PostPosted: Tue Aug 25, 2020 6:29 am    Post subject: Re: Bodywork- gauge size? Reply with quote

Bulli Klinik wrote:
Personally, I don't care for the style of repair panel you are attempting to fit. The rear fender panel is available with the correct flanges from Bus Depot. Be prepared to rebuild the flange area as well as the area above it.

I truly believe that those repair panels without the flanges are meant to rivet over rusty bodies on Vanagons in third world countries, not for a proper restoration.

If you look closely through this photo album: https://photos.app.goo.gl/eLZ4bvP2MSh8KN1u7
Most of your questions will be answered.

Good luck!


You do some awesome work- thanks for sharing!

And for the tips on the panel. I guess you gotta learn somewhere, somehow. This being my first foray into bodywork, I'm quickly learning from my mistakes as I make them.

Point in case, reconstructing the wheel well with sheet metal, adding a flange to be able to weld to, I'm now thinking that the flange should have pointed downwards so that I can actually clamp the skin in place as I tack it in!

Now I'm thinking it may be necessary for me to remove the closet and tack from the inside, something I had hoped to avoid if at all possible.

Anyway- your insight is of great value, thanks!!
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'86 Westy (Canadian model)
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Trying to remedy the rust of her past.
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CelestysWesty
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PostPosted: Thu Oct 22, 2020 4:19 am    Post subject: Re: Bodywork- gauge size? Reply with quote

Hi Samba fam-

Thought it would be good to share some progress photos of the body work I’ve been up to. Tons of knowledge acquired thus far, and still a long ways to go. But from knowing nothing to where I’m at now, feeling pretty good about the progress.
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Trying to remedy the rust of her past.
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CelestysWesty
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PostPosted: Tue Feb 09, 2021 6:27 pm    Post subject: Re: Bodywork- gauge size? Reply with quote

When my wife nearly threatened divorce, I knew my time was running out.

Here’s the last of my work- a marathon of welding and grinding before I handed the van off to someone to begin prep work for painting in January 1, 2021.

I had 5 days alone while she took a little breather out of town from me and the van. Better believe I worked like hell to get ‘er done.
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'86 Westy (Canadian model)
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Trying to remedy the rust of her past.
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CelestysWesty
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PostPosted: Tue Feb 09, 2021 6:32 pm    Post subject: Re: Bodywork- gauge size? Reply with quote

Finally received news from the random guy that my Uncle entrusted with my van to prep it for painting.

Looks like we’re going somewhere! 5 weeks in and it’s starting to get closer... baby steps!

Can’t tell you how nervous I was this guy was going to sell the van for scraps when I dropped out off.
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'86 Westy (Canadian model)
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4Gears4Tires
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PostPosted: Tue Feb 09, 2021 7:40 pm    Post subject: Re: Bodywork- gauge size? Reply with quote

That's really awesome that you managed to pull it off! After paint it's going to look great. You really breathed new life into that shell.
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CelestysWesty
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PostPosted: Thu May 27, 2021 12:35 pm    Post subject: Re: Bodywork- gauge size? Reply with quote

Hey guys- I finally did it.
Took about a year, which is what I believe someone had predicted.

Did all the panel replacement myself, grinding, bondo, windows out, rusty sills fixed, seal replacement, prep and then found a painter to shoot the 2- stage paint I had purchased from someone else.
Guy was very cool, allowed me to stay in the shop and help prep and point out all the details I wanted him to be considerate of. He also supplied beers. Paint job cost me $900. Paint another $400. My costs throughout the past year in supplies, tools, and panels, etc (excluding beer budget), about $5k. That included new tires, a used welder and tank, new tent, and a bunch of other random details.

One more small mechanical check-up and I’ll be taking her out for a short maiden voyage from Miami to North Carolina with the family for a couple weeks. Really looking forward to starting to enjoy the road in the van!

Thanks to everyone for their feedback and advice. Couldn’t have done this much without y’all. And I know this is only the beginning!
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4Gears4Tires
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PostPosted: Thu May 27, 2021 2:01 pm    Post subject: Re: Bodywork- gauge size? Reply with quote

Excellent job putting it back into road trip condition!
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[email protected]
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ahmed.aboudan@gmail.com is offline 

PostPosted: Thu May 27, 2021 2:31 pm    Post subject: Re: Bodywork- gauge size? Reply with quote

Killer job, looks real sweet, let the fun begin!
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Jaximus
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PostPosted: Sat Dec 04, 2021 4:20 pm    Post subject: Re: Bodywork- gauge of sheet metal? Reply with quote

Dude! Such a cool story right there. When I read the first posts and responses, I didn't think in a million years the next page of the thread would be this success story. Bravo!

And the Mrs. is joining on maiden voyage?
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CelestysWesty
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PostPosted: Mon Dec 06, 2021 8:33 am    Post subject: Re: Bodywork- gauge of sheet metal? Reply with quote

Jaximus wrote:
Dude! Such a cool story right there. When I read the first posts and responses, I didn't think in a million years the next page of the thread would be this success story. Bravo!

And the Mrs. is joining on maiden voyage?


Thank you friend!

The Van was made for the family- all that hard work had to pay off somehow- here are some pics from that trip last summer. Hoping to take it out for another big trip up to New England next June!
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Jaximus
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PostPosted: Wed Dec 15, 2021 5:33 am    Post subject: Re: Bodywork- gauge of sheet metal? Reply with quote

Spectacular. I sold my first weekender when I moved to the Caribbean 5 years ago. Now I'm back and have inherited another my father purchased some years ago. This one has a bit of rust, and I'm intimidated to start digging into it. Your work is an inspiration to someone in my position. Thanks for sharing.
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Boegrrl
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PostPosted: Sun Jan 23, 2022 2:22 pm    Post subject: Re: Bodywork- gauge of sheet metal? Reply with quote

This is some of the most inspiring and beautiful craftsmanship I have ever seen. Very impressive.

I am searching the files - but can anyone recommend best source for panels with flanges?

My right rear arch is done for, as is the panel above.
I need a new slider panel - the dent can’t be pulled out.

Other than that it is not terrible. Thanks for sharing the info, I am truly
Hopeful now.
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Boegrrl
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PostPosted: Sun Jan 23, 2022 2:24 pm    Post subject: Re: Bodywork- gauge of sheet metal? Reply with quote

This is some of the most inspiring and beautiful craftsmanship I have ever seen. Very impressive.

I am searching the files - but can anyone recommend best source for panels with flanges?

My right rear arch is done for, as is the panel above.
I need a new slider panel - the dent can’t be pulled out.

Other than that it is not terrible. Thanks for sharing the info, I am truly
Hopeful now.
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