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Posted By: Bblintpicker What to do about old van windows? - April 16th 2017 11:26 am
Large side window's leak like crazy, they don't sell the same size windows on my van anymore, smaller ones need metal work, larger ones are ridiculously priced and personally 1 would rather the van didn't have windows at all.

What to do about old van windows?

I don't see where you can get upper side body panels to fill in large windows on a 77 Dodge. And I haven't seen any at the salvage yard that were in good enough shape to bother pulling. That changed yesterday when I came across this.

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It's a 2003 and not a single dent in her. I must admit that I'm a little apprehensive about doing this. I'm inexperienced and while I know the panel's should work, it didn't help that the yard was trying to talk me out of it. They thought I should just buy sheet metal and fab the piece. I wouldn't even want to try with that curve, middle flaring, and my skills. I didn't have time to pull it so the owner let me write do not crush on the side and I'm going back next Saturday.

I'll sawzall as far up and down on each side as I can & cut it down the middle to take it in two pieces. More to come (Unless I chicken out or the wife puts her foot down!)
Posted By: frscke1 Re: What to do about old van windows? - April 16th 2017 2:01 pm
I had them cut the whole side of s van off. The guy said "you want what ?" Had them cut it up & put it in a U-haul. Gave it to the collision shop to cut what they needed to repair my red van..

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Posted By: Wyteness Re: What to do about old van windows? - April 16th 2017 2:25 pm
thats really neat seeing the whole side of a van laying there. would look cool on a wall.
Posted By: Rusty Pancelode Re: What to do about old van windows? - April 16th 2017 3:52 pm
Wow!
That's crazy.


I don't know what I'd do if I needed to seal up a window hole.
I'd get after it I suppose... The hole ain't going to fix itself.

I've seen some guys cut metal and fill cargo door window holes, and they really didn't do it very well, but it came out pretty good.
I think you're only nervous because you haven't started yet. Get that metal and get to work, you'll be more comfortable once you get started.
I'm always the most apprehensive right before I start a big project, but it goes away once I get going.
Posted By: frscke1 Re: What to do about old van windows? - April 16th 2017 4:48 pm
Looked like this before ....

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You can do it ! Just get it started ... the longer you wait to start, the less you want to.
Posted By: Bblintpicker Re: What to do about old van windows? - April 16th 2017 5:05 pm
WOW FRSCKE1 THAT IS CRAZY!

OK step one - Saturday pull the panel
Posted By: frscke1 Re: What to do about old van windows? - April 16th 2017 5:12 pm
I got the 3 doors & all the hard ware for $200 & the whole side of the van + a bunch of trim goodies, bumpers, light buckets, side markers, mirrors and for $400. The ins co wanted to spend $2300 on new panels & doors, I got the whole thing for $600.

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Posted By: METZ Re: What to do about old van windows? - April 17th 2017 1:41 pm
I'm very interested in how to do this. I was always scared I would warp the panels so never tried it.
Posted By: tuner4life Re: What to do about old van windows? - April 17th 2017 5:23 pm
Go for it! It's definitely do-able to weld in that large of a panel, but you will need to do a bit of research on the proper methods. I did a ton of research and still warped the hell out of mine just doing a fender patch. I feel slightly more confident that I could do it better the second time around, but it will take a ton of practice.

Also need to make sure that you have a good Mig welder available and know how to use it. (spot welds only! to keep the temp low)

Be sure to keep a bucket of cold water to cool the welds immediately after each spot

Lastly buy these to help hold the panel and keep the correct gap: Eastwood panel holders


Or my preferred way for the future would be to deliver the van and patch panel to someone who knows what they are doing and pay whatever the want because it's a pain in the backside!

Posted By: frscke1 Re: What to do about old van windows? - April 17th 2017 5:45 pm
Originally Posted by tuner4life
Or my preferred way for the future would be to deliver the van and patch panel to someone who knows what they are doing and pay whatever the want because it's a pain in the backside!


Thats what I did ... let the pro's do it !
Posted By: Bblintpicker Re: What to do about old van windows? - April 22nd 2017 10:54 pm
Well I was there as soon as they opened. They had me right up front while I was doing it.

I think most people coming into the yard found the job pretty amusing. Plus I kept doing stupid stuff like leaving the hammer on the top and it vibrating off the side right onto me. <SMILE>
I took both sides just in case and 14 inches from the roof to patch the old venturi vent too. I don't think I ever want to do that again but I am excited about the project.

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Posted By: frscke1 Re: What to do about old van windows? - April 22nd 2017 11:05 pm
NICE !

You can rebuild it .. bigger stronger better .. we have the technology
Posted By: Rusty Pancelode Re: What to do about old van windows? - April 23rd 2017 12:37 am
Awesome!

Someone was pretty lazy to send that van to the junkyard with the shelving still inside it.
They could have probably doubled their money if they'd pulled them and sold them separately.

Posted By: Dyno_Dave Re: What to do about old van windows? - April 23rd 2017 2:18 am
Nice work Bblintpicker!
Posted By: Bblintpicker Re: What to do about old van windows? - April 23rd 2017 9:47 am
Originally Posted by Rusty_Pancelode
Awesome!
Someone was pretty lazy to send that van to the junkyard with the shelving still inside it.
They could have probably doubled their money if they'd pulled them and sold them separately.


Yeah Rusty they really looked brand new - I almost pulled them.

Thanks All - I'll likely roughly cut them to size today. I don't need them sitting out front. It's my intent to weld these panels as opposed to adhesive.
Posted By: Bblintpicker Re: What to do about old van windows? - May 07th 2017 12:00 am
I have the patches all cut to about an inch larger than the openings - got everything cleared out from inside and removed windows. Getting that sealer off is no fun.
Never noticed but one window was about 1.5 inches lower than the other. One is right on the body line the other is lower.

I really like this picture. . .

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Posted By: Ram4ever Re: What to do about old van windows? - May 09th 2017 7:32 pm
Now that's some serious demolition and construction you've got on your hands! You did a much neater job of taking the side off the white van than I did, LOL! I still remember the guys at the yard rolling their eyes; "oh, it's *him* again"... LOL!

Dropping the hammer off the roof onto your head? Way to pound the novelty of your yard experience home with a vengeance, LOL! smile

I can't get over those nice shelves being left inside either. I'd have been sorely tempted to pull them and use them in my lawn mower shed if nothing else!

Are you going to flange the lips around the areas to be filled? I had really good results by doing that, even across the body lines. I held it all together with Clecos and bonded the pieces with 3M body panel adhesive, installing self tapping screws as I pulled out the Clecos. Finished by grinding off the screw heads once the adhesive had fully cured. Made for a nice job, and the flanges help make the entire panel far more rigid.
Posted By: Bblintpicker Re: What to do about old van windows? - May 10th 2017 10:59 pm
Ram, I know that's the common way of doing it - I just can't get my head around doing it with adhesive.

It's going to take a good bit of time but I'm going to cut and trim the patched to fit like a glove.

Then I'm going to duct tape it in place and slowly weld it in or at least that is the plan! <SMILE>

Posted By: Ram4ever Re: What to do about old van windows? - May 12th 2017 11:15 am
Ah, now you've revealed your secret; with duct tape involved, there's no possibility of failure! smile

You must have the patience of a Saint to do that much precision welding and tapping out any warpage. I'll be pulling for you from the side lines!
Posted By: Bblintpicker Re: What to do about old van windows? - May 12th 2017 10:39 pm
Originally Posted by Ram4ever
Ah, now you've revealed your secret; with duct tape involved, there's no possibility of failure! smile


Duct tape fixes everything! but seriously Ram I follow your technical posts - now I'm worried. I'm all in so there is no turning back.
Posted By: frscke1 Re: What to do about old van windows? - August 12th 2017 5:03 am
So how did you do ?
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