Front Valance Pt2

Getting back to finishing the front valance with a hope to get it wrapped up in a weekend was a bit hopeful. I should have learnt by now how long things take .

The left hand lower portion of the A pillar was as rotten as the right hand side so this was removed, keeping the original radius just below the hinge bolts to help blend the seam of the weld . Again most of my time was spent cutting and filing the two repair pieces and trying not to rush ahead and grab the welder out.

The inner valance was then trial fitted up with only a little trimming required. Using the bumper mounts as a guide I was able to line up the bumper mount holes, and then clamp the valance into position. With almost no gap between the panel and the forward chassis faces, this allowed me to drill spot welding holes at the original positions that I had grinded off keeping a good gaping and shape for the cover panel.

I secuired the clamps close to each hole trying not to weld the clamp to my van, this was to ensure a tight fit onto the front chassis supports. A few more spot welds to attach the top of the inner panel to the cab floor and this panel will not be going any where fast.

To finish the ends I kept the panels I originally cut off to use as a template, this turned into more of a guide. These panels I hope will be a little stronger that just welding a piece of angle in the corner, they also help with the profile of the outer skin, because the new valance curves in to steeply to match and support the front skin profile ill use these to weld the skin onto at the ends.

I was then able to trial fit all the other closure panels and found that the cut out for the nose, on the lower front skin does not match the correct profile! When the panel is at the correct height (by my calculations and measurments) it does not reach up to the lower portion of the nose either. Frustrated and just wanting to get this done I was tempted to just patch up the gap, but a short break from the cramped garage and a quick sugar rush I deciede to return the panel and get one made with out the cut out, Replacing this panel would also help as the original panel was too short to wrap over seam at the ends as origenally manufactured.

front window gutters

So far all the jobs I've tried to start have been held up or I've had to stop because of not having the right parts or bits need modifying. Hopefully patching up the front windows shouldn’t be such a problem.

Nope, think again.

Ordering parts on-line means you can’t see how how good the parts are untill you get them on the van. Nearly all the panels I've tried to fit need fabricating, so learning panel beating skills is becoming a necessity. I started repairing the window gutters with two corner repair panels, but trial fitting these panels and I found they didn't meet in the middle. I had a word with Schofields at a show and they made me up a pair of gutter that would stretched the whole length of the window frame and bend up enough to cover up the holes I’d already cut out.

A job that I thought would take a day, had taken that long just to get the area and parts cleaned, cut and filed to fit. This included picking away the sealant that I'd originally used under the windows, to stop rain comimg through the rust holes and filling up the van. When this repair is done I hopefully wont need a towel by my feet any more.

Before I got the gutter welded into place, a few bits of the dashboard lip needed patching up, and one of the new gutters repair panels needed cutting and splicing back together, because it was a couple of milimeters too long. With a lot of patients and a brand new light sensitive welding mask (well worth the money £80), I managed to get both gutters tacked and welded on the second day. After grinding down the worst of the welds, I used a large dreadnought file to clean up the front radius, this gave me a flat and even finish compared to rotary file or sanding disc, any remaining pits I re-welded and filed down again. A final rub down and a coat of primer and this is the vans first completed repair.